EAS00000 XJR1300(L) ’99 SERVICE MANUAL 1998 by Yamaha Motor Co., Ltd. 1st Edition, August 1998 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
EAS00002 NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycle has a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
EAS00009 1 2 GEN INFO SPEC 3 4 CHK ADJ ENG 5 6 CARB CHAS 7 8 TRBL SHTG ELEC 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.
EAS00013 INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE OVERHAUL CARBURETORS CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 CHK ADJ 3 ENG 4 CARB 5 CHAS 6 ELEC 7 TRBL SHTG 8
GEN INFO 1
GEN INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . REPLACEMENT PARTS . . . . . . . . . .
GEN INFO
MOTORCYCLE IDENTIFICATION GEN INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER (For E) The vehicle identification number 1 is stamped into the right side of the steering head. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust, and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling, always 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.
IMPORTANT INFORMATION GEN INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock washer tabs and the cotter pin ends along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible.
CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times. 3. Check: all connections Loose connection Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. 4.
SPECIAL TOOLS GEN INFO EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool No.
SPECIAL TOOLS Tool No. 90890-03113 Tool name/Function Engine tachometer This tool is used to check engine speed. 90890-03141 Timing light This tool is used to check the ignition timing. 90890-03158 Carburetor angle driver This tool is used to turn the pilot screw when adjusting the engine idling speed. 90890-04016 Valve guide reamer, remover and installer (5.5 mm) These tools are used to rebore, remove and install the valve guide.
SPECIAL TOOLS Tool No. 90890-06754 Tool name/Function Ignition checker This tool is used to check the ignition system components. 90890-85505 Yamaha bond No. 1215 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
GEN INFO
SPEC 2
SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius XJR1300(L) 5EA2/5EA3/5EA4 2175 mm (GB) (D) (NL) (B) (F) (E) (P) (I) (GR) (SF) (AUS) 2250 mm (N) (SF) (G) (A) 775 mm 1115 mm 775 mm 1500 mm 120 mm 2800 mm Basic weight: With oil and full fuel tank 253 kg Engine: Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Compre
SPEC GENERAL SPECIFICATIONS Model XJR1300(L) Carburetor: Type/quantity Manufacturer BS36/4 MIKUNI Spark plug: Type quantity Manufacturer Spark plug gap DPR8EA-9/X24EPR-U9 NGK/DENSO 0.8 X 0.9 mm Clutch type: Wet, multiple-disc Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th Spur gear 98/56 (1.750) Chain drive 38/17 (2.235) Constant mesh 5-speed Left foot operation 40/14 (2.
GENERAL SPECIFICATIONS Model Brake: Front brake Rear brake type operation type operation SPEC XJR1300(L) Dual disc brake Right hand operation Single disc brake Right foot operation Suspension: Front suspension Rear suspension Telescopic fork Swingarm Shock absorber: Front shock absorber Rear shock absorber Coil spring/Oil Damper Coil spring/Gas-oil damper Wheel travel: Front wheel travel Rear wheel travel 130 mm 110 mm Electrical: Ignition system Generator system Battery type Battery capacity T.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model Standard Limit Cylinder head: Warp limit 0.1 mm Cylinder: Bore size Taper limit Out of round limit Wear limit 79.00 79.01 mm 0.05 mm 0.05 mm 79.1 mm Chain drive (Center) 25.000 25.021 mm 24.967 24.980 mm 0.020 0.054 mm 35.95 36.05 mm 28.248 28.348 mm 7.95 8.05 mm 35.95 36.05 mm 28.248 28.348 mm 7.95 8.05 mm 35.85 mm 28.15 mm 35.85 mm 28.15 mm 0.
MAINTENANCE SPECIFICATIONS Model Standard Cam chain: Cam chain type/No. of links Cam chain adjustment method Valve, valve seat, valve guide: Valve clearance (cold) IN EX Valve dimensions: Head Dia. “A” head diameter “B” face width “C” seat width “D” margin thickness Stem outside diameter Guide inside diameter Stem-to-guide clearance Limit 79RH2015/156 Automatic 0.11 0.15 mm 0.16 0.20 mm Face Width Seat Width Margin Thickness IN EX IN EX IN EX IN EX IN EX IN EX IN EX 28.
MAINTENANCE SPECIFICATIONS Model Valve spring: Inner spring Free length Set length (valve closed) Compressed pressure (installed) Tilt limit Direction of winding (top view) Outer spring Free length Set length (valve closed) Compressed pressure (installed) Tilt limit Direction of winding (top view) Piston: Piston to cylinder clearance Piston size “D” Measuring point “H” Piston off-set Piston off-set direction Piston pin bore inside diameter Piston pin outside diameter SPEC Standard Limit IN EX IN EX IN
MAINTENANCE SPECIFICATIONS Model SPEC Standard Limit Piston rings: Top ring: Type Dimensions (B T) End gap (installed) Side clearance (installed) 2nd ring: Barrel 1.00 3.05 mm 0.20 0.35 mm 0.045 0.080 mm 0.6 mm 0.1 mm Type Dimensions (B T) End gap (installed) Side clearance (installed) Oil ring: Taper 1.2 3.0 mm 0.35 0.50 mm 0.03 0.07 mm 0.75 mm 0.1 mm 2.5 2.9 mm 0.2 0.5 mm 0.050 0.155 mm 0.017 0.040 mm 0.08 mm 62.25 63.85 mm 382.0 383.
MAINTENANCE SPECIFICATIONS Model Clutch: Friction plate thickness Quantity Clutch plate thickness SPEC Standard 2.9 3.1 mm 8 pcs 1.9 2.1 mm Limit 7 pcs 6 mm 1 pc 0 0.2 mm 0.004 0.048 mm Hydraulic inner push 2.8 mm 0.1 mm 0.1 mm 0.3 mm Transmission: Main axle deflection limit Drive axle deflection limit 0.06 mm 0.06 mm Shifter: Shifter type Guide bar bending limit Guide bar 0.1 mm Carburetor: I.D. mark Main jet (M.
MAINTENANCE SPECIFICATIONS Model Lubrication system: Oil filter type Oil pump type Tip clearance Housing and rotor clearance Side clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure (hot) Pressure check location SPEC Standard Paper type Trochoid type 0.12 0.17 mm 0.03 0.08 mm 0.03 0.08 mm 180 220 kPa (1.8 2.2 kg/cm2, 1.8 2.2 bar) 480 580 kPa (4.8 5.8 kg/cm2, 4.8 5.8 bar) 80 kPa (0.8 kg/cm2, 0.8 bar) at 1000 r/min MAIN GALLERY 2-9 Limit 0.2 mm 0.
SPEC MAINTENANCE SPECIFICATIONS Tightening torques Part to be tightened g Camshaft cap Oil gallery bolt Spark plug Cylinder head Cylinder head cover Cylinder Cylinder Cylinder Connecting rod Cam sprocket Timing chain tensioner Timing chain tensioner cap bolt Chain guide (upper) Chain guide (intake) Oil pump Oil pump Oil strainer housing Oil filter case Oil pan Drain bolt (engine oil) Oil gallery blind plug Drain filter Oil delivery pipe (oil pan) Oil delivery pipe (oil cooler) Oil cooler Oil cooler cover O
SPEC MAINTENANCE SPECIFICATIONS Part to be tightened g Crankcase Crankcase Main gallery Oil buffle plate Stopper plate Bearing housing HY-VO chain guide Clutch boss Clutch pressure plate Push lever comp. Drive sprocket Shift shaft stopper Stopper plate (Starter clutch idle gear shaft) Stopper lever Side plate Shift arm Shift lod A.C. generator Oil level sensor Rotor Thread size Q’ty y Bolt Bolt Plug Bolt Bolt Screw Bolt Nut Bolt Bolt Nut Screw Screw M8 1.25 M10 1.25 M20 1.5 M5 0.8 M6 1.
MAINTENANCE SPECIFICATIONS Tightening sequence Cylinder head Crankcase 2-12 SPEC
MAINTENANCE SPECIFICATIONS Model SPEC XJR1300(L) Lubrication chart: Pressure feed Splashed Generator shaft Ex. camshaft Lifter IN.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Model Standard Limit Steering system: Steering bearing type Angular bearing Front suspension: Front fork travel Fork spring free length Fitting length Collar length Spring rate (K1) (K2) Stroke (K1) (K2) Optional spring Oil capacity Oil level Oil grade 130 mm 407.3 mm 363.3 mm 150 mm 4.9 N/mm (0.5 kg/mm) 8.8 N/mm (0.
MAINTENANCE SPECIFICATIONS Model Front disc brake: Type Disc outside diameter thickness Disc deflection limit Pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear disc brake: Type Disc outside diameter thickness Disc deflection limit Pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Brake lever & brake pedal: Brake pedal position Throttle grip free play SPEC Standard Limit Dual 298 5 mm 5.
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened g Part name Thread size Q’ty y Tightening torque Remarks Nm m kg Handle crown and inner tube Handle crown and steering stem Handle crown and handlebar holder (lower) Upper handlebar holder Lower bracket and inner tube Steering stem and ring nut Front master cylinder and holder Front brake hose union bolt Meter Headlight stay (lower) Grip end Front turn signal lights Front fender and front fork Headlight stay and upper cover Engin
MAINTENANCE SPECIFICATIONS Part to be tightened g Part name Hook Screw Helmet holder Bolt Tail light bracket Bolt Side stand Bolt Side stand Nut Side stand switch Screw Footrest bracket Bolt Rear footrest bracket Bolt Footrest and footrest bracket Bolt Rear brake reservoir tank Screw Rear master cylinder and bracket Bolt Center stand Nut and Bolt Front wheel axle – Front wheel axle pinch bolt Bolt Front brake caliper and front fork Bolt Front brake disk and hub Bolt Front brake caliper and bleed screw – F
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Model Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advancer type 5 /1050 r/min 50 /5000 r/min TPS & Electrical type T.C.I.: Pickup coil resistance/color T.C.I. unit model/manufacturer 248 372 Ω/W/R-W/G 5EA20/YAMAHA Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance 83R/YAMAHA 6 mm 1.9 2.9 Ω 9.5 14.
MAINTENANCE SPECIFICATIONS Model SPEC Standard Limit 0.7 mm MS5E-491/JIDECO 100 A 4.2 4.
CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS SPEC EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUES 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. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE Lubrication Point Symbol Oil seal lips O-ring Bearing Piston surface Piston pin Crankshaft pin Crankshaft journal/big end Connecting rod bolt/nut Camshaft cam lobe/journal Valve stem (IN, EX) Valve stem end (IN, EX) Valve lifter Oil pump rotor (inner/outer), housing Oil strainer assembly Starter idle gear inner surface Starter wheel gear inner surface Starter clutch (outer/roller) Crankcase cover (push rod hole
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC CHASSIS Lubrication Point Symbol Steering bearing (upper/lower) and bearing cover lip Front wheel oil seal (left/right) Rear wheel oil seal (left/right) Clutch hub fitting area Rear brake pedal shaft Shift pedal Centerstand sliding surface Sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever bolt, sliding surface Clutch lever bolt, sliding surface Rear footrest pivot Swingarm pivot bearing Swingarm pivot shaft outer surface Swingarm
LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 2 3 4 5 6 7 Camshaft (intake) Camshaft (exhaust) Main gallery Oil strainer Oil pump Main axle Crankshaft 2-23 SPEC
LUBRICATION DIAGRAMS 1 2 3 4 5 6 7 8 Oil cooler Starter clutch Main axle Drive axle Oil pump Oil pan Relief valve Main gallery 2-24 SPEC
LUBRICATION DIAGRAMS 1 2 3 4 Camshaft Crankshaft Oil pump Oil filter 2-25 SPEC
CABLE ROUTING SPEC CABLE ROUTING 1 Starter motor cable 9 Throttle position sensor 2 Battery negative (–) lead 10 Ignition coil lead (#2, 3) 3 Battery negative (–) lead con- 11 Throttle cable nector 12 Engine ground lead 4 AC generator connector 13 Air ventilation hose 5 Rear brake switch lead connec- 14 Rear brake switch tor 15 Starting circuit cutoff relay 6 Neutral lead 7 Pickup lead 8 Sidestand switch lead 2-26 A Fasten the wireharness to the seat rail with a plastic band.
CABLE ROUTING D Route the wireharness and start- F Fasten the wireharness to the er motor cable in front of the resframe with a plastic band. Make ervoir tank bracket and the batsure that the end of band down tery negative (–) lead behind the ward. reservoir tank bracket. And fas- G Insert the plastic band through ten them with a plastic band. the hole of plastic panel and then E Fasten the wireharness, neutral fasten the throttle cables with it.
CABLE ROUTING L Route the wireharness and starter motor cable behind the side cover bracket and fasten them with a plastic band at front of the bracket. M Align the white paint marks of the fuel tank drain hose, fuel tank breather hose and air filter case drain hose. N Touch the brake pipe to the brake caliper stopper.
CABLE ROUTING 1 Clutch hose 2 Starter cable 3 Air filter case drain hose 4 Frame ground 5 Flasher relay connector 6 Oil light relay connector 7 Igniter unit connectors 8 Starter motor 9 AC generator 10 Sidestand switch 11 Sidestand switch lead 12 Ignition coil lead (#1, 4) SPEC A Insert the plastic band through E Fasten the high tension cables (#1, 2) with a plastic clamp. Posithe hole of plastic panel and then tion the clamp at 50 – 80 mm fasten the clutch hose with it.
CABLE ROUTING H Fasten the seat lock cable to the K seat real with a plastic band. Make sure that the end of band down ward. I Route the air filter case drain hose over the starter motor to right side of motorcycle. L J Position the clutch pipe parallel with the oil filter cover. M SPEC Fasten the sidestand switch lead N Route the speedometer cable with steel clamp on the frame through the guide.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 Throttle cables Ignition coil (#2, 3) Throttle position sensor Neutral switch connector Pickup coil connector Sidestand switch connector Battery Reservoir tank Battery negative (–) lead Starting circuit cutoff relay Battery positive (+) lead connector 12 13 14 15 16 17 18 19 20 21 22 23 Starter relay Seat lock cable Seat lock Battery positive (+) lead Fuse box Starter relay connector Flasher relay Oil light relay Igniter unit Fuel sender connector Starter cable Ignit
CABLE ROUTING SPEC E Connect the fuel sender connec- G Fasten the battery positive (+) J Position the seat lock cable intor, neutral switch connector, lead and battery positive (+) lead side under the seat lock bracket. pickup coil connector and sideconnector on the groove of the K Fasten the wireharness to the stand switch connector above battery with the battery rubber frame with a plastic band. Make the air filter case. band.
CABLE ROUTING N Fasten the wireharness, taillight lead and rear turn signal light leads (left and right) with steel clamp on the frame make sure that the end of clamp forward. O Route the rear turn signal light leads (left and right) through the each holes of the rear fender. P Touch the starter cable to the stopper and position it vertical of the motorcyle.
CABLE ROUTING 1 2 3 4 5 6 7 Meter leads Main switch lead Starter cable Handlebar switch lead (left) Clutch hose Brake hose Handlebar switch lead (right) A Route the throttle cables through the guide on the headlight stay. B Route the meter leads, main switch lead into the upper hole of the headlight body. C Route the handlebar switch lead (left) inside of the clutch hose. Fasten the handlebar switch lead (left), clutch hose and starter cable with a plastic band.
CABLE ROUTING H Touch the brake pipe to the stopper. I Route the handlebar switch lead (right) and front turn signal light lead (right) into the right under hole of the headlight stay. J Fasten the handlebar switch lead (right) and front brake hose with a plastic band.
SPEC
CHK ADJ 3
CHK ADJ CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 3-1 SEAT SIDE COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . .
CHK ADJ LUBRICATING THE SIDE STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 LUBRICATING THE CENTERSTAND . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 3-40 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ PERIODIC INSPECTION AND ADJUSTMENT 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 a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ *: It is recommended that these items be serviced by a Yamaha dealer. **: Molybdenum disulfide grease. ***: Lithium soap base grease. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder, caliper cylinder or clutch release cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required. 2.
SEAT, SIDE COVER AND FUEL TANK CHK ADJ SEAT, SIDE COVER AND FUEL TANK 30 Nm (3.0 mSkg) 19 Nm (1.9 mSkg) Order Job/Part 1 2 3 4 Removing the seat, side cover and fuel tank Seat Side cover (left) Side cover (right) Fuel hose 5 6 7 8 9 Fuel tank Fuel sender lead Drain hose Grab bar Rear fender cover Q’ty Remarks Remove the parts in the order listed. 1 1 1 1/1 NOTE: Disconnect the fuel pipe, set the fuel cock lever “ON” or “RES” position. 1 1 2 1 1 For installation, reverse the removal procedure.
ADJUSTING THE VALVE CLEARANCE CHK ADJ ENGINE ADJUSTING THE VALVE CLEARANCE the following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: S seat S side covers S fuel tank Refer to “SEAT, SIDE COVER AND FUEL TANK”. 2. Remove: S oil cooler 1 S air ducts 2 3.
ADJUSTING THE VALVE CLEARANCE CHK ADJ a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the timing plate with the mark b on the pickup coil base plate. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c. Measure the valve clearance with a thickness gauge 1 . NOTE: S If the valve clearance is incorrect, record the measured reading.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 5. Adjust: S Valve clearance a. Align the intake and exhaust valve lifter slots with each other. b. Slowly turn the crankshaft until the cam lifted at maximum. c. Install the tappet adjusting tool 1 as shown. Tappet adjusting tool: P/N 90890-04110 NOTE: Make sure that the tappet adjusting tool touches only the valve lifter 2 , not the valve pad 3 . d. Slowly turn the crankshaft so that the valve pad can be removed. e.
ADJUSTING THE VALVE CLEARANCE CHK ADJ INTAKE MEASURED CLEARANCE 0.00 0.05 0.06 0.10 0.11 0.15 0.16 0.20 0.21 0.25 0.26 0.30 0.31 0.35 0.36 0.40 0.41 0.45 0.46 0.50 0.51 0.55 0.56 0.60 0.61 0.65 0.66 0.70 0.71 0.75 0.76 0.80 0.81 0.85 0.86 0.90 0.91 0.95 0.96 1.00 1.01 1.05 1.06 1.10 1.11 1.15 1.16 1.20 1.21 1.25 1.26 1.30 1.31 1.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EXAMPLE: Original valve pad number = 248 (thickness = 2.48 mm (0.098 in)) Rounded value = 250 h. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. i.
SYNCHRONIZING THE CARBURETORS CHK ADJ EAS00050 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Remove: S side covers S seat S fuel tank Refer to “SEAT, SIDE COVER AND FUEL TANK”. 3. Install: S vacuum gauge 1 S engine tachometer 2 (to the spark plug lead of cyl.
SYNCHRONIZING THE CARBURETORS ADJUSTING THE ENGINE IDLING SPEED CHK ADJ b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same. c. Synchronize carburetor #2 to carburetor #3 by turning the synchronizing screw 3 in either direction until both gauges read the same. Vacuum pressure at engine idling speed: 31.3 kPa (235 mm Hg) NOTE: The difference in vacuum pressure between two carburetors should not exceed 1.33 kPa (10 mm Hg, 0.
ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ Engine tachometer 90890-03113 3. Measure: S engine idling speed Out of specification Adjust. Engine idling speed 1,000 1,100 r/min 4. Adjust: S engine idling speed a. Turn the pilot screw 1 in or out until it is lightly seated. b. Turn the pilot screw out the specified number of turns. Carburetor angle driver 2 90890-03158 Pilot screw 1–1/2 turns out c.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 2. Remove: S seat S fuel tank Refer to “SEAT, SIDE COVER AND FUEL TANK”. 3. Adjust: S throttle cable free play NOTE: When the motorcycle is accelerating, the accelerator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 3 on the decelerator cable. b. Turn the adjusting nut 4 in direction a or b to take up any slack on the decelerator cable. c. Loosen the locknut 5 on the accelerator cable. d.
CHECKING THE SPARK PLUGS CHECKING THE IGNITION TIMING CHK ADJ EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Disconnect: spark plug cap 2. Remove: spark plug CAUTION: Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 3. Check: spark plug type Incorrect Change. Spark plug type (manufacturer) DPR8EA-9 (NGK) X24EPR-U9 (DENSO) 4.
CHECKING THE IGNITION TIMING MEASURING THE COMPRESSION PRESSURE CHK ADJ 2. Install: timing light 1 engine tachometer 2 (to the spark plug lead of cyl. #1) Timing light 90890-03141 Engine tachometer 90890-03113 3. Check: ignition timing a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 1,000 1,100 r/min b. Check that the pickup coil a is within the firing range b on th timing plate.
MEASURING THE COMPRESSION PRESSURE CHK ADJ 3. Disconnect: S spark plug cap 4. Remove: S spark plug CAUTION: Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: S compression gauge 1 S adapter 2 Compression gauge 90890-03081 Adapter 90890-04082 6. Measure: S compression pressure Above the maximum pressure Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits.
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ a. Turn the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm2, 1 bar). 7. Install: S spark plug Spark plug 18 Nm (1.8 mSkg) 8.
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ CAUTION: S Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled “ENERGY CONSERVING II” b or higher. S Do not allow foreign materials to enter the crankcase. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again.
CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE CHK ADJ Quantity Total amount 4.2 L Without oil filter element replacement 3L With oil filter element replacement 3.35 L 9. Install: S engine oil filler cap 10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check; S engine (for engine oil leaks) 12. Check: S engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. EAS00077 MEASURING THE ENGINE OIL PRESSURE 1.
MEASURING THE ENGINE OIL PRESSURE/ ADJUSTING THE CLUTCH LEVER CHK ADJ Engine oil pressure 80 kPa (0.8 kg/cm2, 0.8 bar) Engine speed Approx. 1000 r/min Engine oil temperature 70 80_C (158 176_F) Out of specification Adjust. Engine oil pressure Possible causes Below specification Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Leaking oil passage Above specification Faulty oil filter Oil viscosity too high 6.
CHECKING THE CLUTCH FLUID LEVEL/ BLEEDING THE HYDRAULIC CLUTCH SYSTEM CHK ADJ EAS00083 CHECKING THE CLUTCH FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Check: S clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level. Recommended clutch fluid Brake fluid DOT 4 WARNING S Use only the designated clutch fluid.
BLEEDING THE HYDRAULIC CLUTCH SYSTEM CHK ADJ NOTE: S Be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to overflow. S When bleeding the hydraulic clutch system, make sure that there is always enough clutch fluid before applying the clutch lever. Ignoring this precaution could allow air to enter the hydraulic clutch system, considerably lengthening the bleeding procedure. S If bleeding is difficult, it may be necessary to let the clutch fluid settle for a few hours.
CLEANING THE AIR FILTER ELEMENT CHK ADJ EAS00087 CLEANING THE AIR FILTER ELEMENT 1. Remove: S side cover (right) Refer to “SEAT, SIDE COVER AND FUEL TANK”. S air filter case cover 1 2. Remove: S air filter element 2 3. Clean: S air filter element 1 Apply compressed air to the inner surface of the air filter element. 4. Check: S air filter element Damage Replace. 5.
CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS/ CHECKING THE FUEL AND VACUUM HOSES CHK ADJ EAS00095 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS The following procedure applies to all of the carburetor joints and intake manifolds. 1. Remove: S seat S side cover S fuel tank Refer to “SEAT, SIDE COVER AND FUEL TANK”. 2. Check: S carburetor joint 1 S intake manifold 2 Cracks/damage Replace. Refer to “CARBURETOR” in chapter 6. 3.
CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM CHK ADJ EAS00098 CHECKING THE CRANKCASE BREATHER HOSE EAS00100 1. Check: S crankcase breather hose 1 Cracks/damage Replace. Loose connection Connect properly. CAUTION: Make sure that the crankcase breather hose is routed correctly. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes, mufflers and gaskets. 1. Check: S exhaust pipe 1 S muffler 2 Cracks/damage Replace.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE CHK ADJ EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. NOTE: Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever holder. Position #1 b Position #4 c Distance a is the largest. Distance a is the smallest.
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ EAS00110 c. Tighten the locknut 1 to specification. Locknut 18 Nm (1.8 mSkg) WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident.
CHECKING THE BRAKE FLUID LEVEL / CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ S 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.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenever: S the system was disassembled, S a brake hose was loosened or removed, S the brake fluid level is very low, S brake operation is faulty. NOTE: S Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.
BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ Bleed screw 6 Nm (0.6 mSkg) k. Fill the reservoir to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. WARNING After bleeding the hydraulic brake system, check the brake operation. EAS00136 ADJUSTING THE SHIFT PEDAL 1. Check: S shift pedal position The end 1 of the shift pedal is above the shift rod. (The angle a should be approximately 90_.) Incorrect Adjust. 2.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Check: S drive chain slack a Out of specification Adjust. Drive chain slack 20 30 mm 4. Adjust: S drive chain slack a. b. c. d.
ADJUSTING THE DRIVE CHAIN SLACK/ LUBRICATING THE DRIVE CHAIN CHK ADJ CAUTION: Do not loosen the wheel axle nut after tightening it to the specified torque. If the groove in the wheel axle nut is not aligned with the cotter pin hole in the wheel axle, tighten the nut further until they are aligned. i. Tighten the tensionbar bolt to specification. Tensionbar bolt 23 Nm (2.3 mSkg) EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Check: S steering head Grasp the bottom of the front fork legs and gently rock the front fork. Looseness or binding Adjust the steering head. 3.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ 8. Remove: S upper handleber holder 1 S handleber 2 –0.2po 9. Remove: S handle crown 1 10. Adjust: S steering head 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. Ring nut wrench 90890-01403 Lower ring nut (initial tightening torque) 52 Nm (5.2 mSkg) c.
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 . 11. Install: S handle crown Steering stem nut 110 Nm (11.
ADJUSTING THE FRONT FORK LEGS CHK ADJ ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. S Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: S Grooves are provided to indicate the adjustment position. S Never go beyond the maximum or minimum adjustment positions. 1.
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES CHK ADJ EAS00161 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the rear shock absorber assemblies. WARNING S Securely support the motorcycle so that there is no danger of it falling over. S Always adjust both rear shock absorber assemblies evenly. Uneven adjustment can result in poor handling and loss of stability. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1.
CHECKING THE TIRES CHK ADJ EAS00162 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: S tire pressure Out of specification Regulate. WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. S 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.
CHECKING THE TIRES CHK ADJ WARNING It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: S tire surfaces Damage/wear Replace the tire. Minimum tire tread depth 1.6 mm 1 Tire tread depth 2 Side wall 3 Wear indicator WARNING A 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. S When using a tube tire, be sure to install the correct tube.
CHECKING THE TIRES/CHECKING THE WHEELS CHK ADJ Front tire Manufacturer Size Type MICHELIN 120 / 70ZR17 MACADAM 90X DUNLOP 120 / 70ZR17 D207F BRIDGESTONE 120 / 70ZR17 BT57F Size Type MICHELIN 180/ 55ZR17 MACADAM 90X DUNLOP 180 / 55ZR17 D207 BRIDGESTONE 180 / 55ZR17 BT57R Rear tire Manufacturer WARNING New tires have a relatively low grip on the road surface until they have been slightly worn.
CHECKING ANDLUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS LUBRICATING THE SIDE STAND/LUBRICATING THE CENTERSTAND 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 cause the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible. 1. Check: S cable sheath Damage Replace. 2.
CHECKING AND CHARGING THE BATTERY CHK ADJ EAS00178 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: S Wear protective eye gear when handling or working near batteries. S Charge batteries in a well-ventilated area. S Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: S seat 2. Disconnect: S battery leads (from the battery terminals) CAUTION: First, disconnect the negative lead 1 , then the positive lead 2 . 3. Remove: S battery 4. Check: S battery charge a.
CHECKING AND CHARGING THE BATTERY CHK ADJ WARNING Do not quick charge a battery. CAUTION: S Make sure that the battery vent is 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.
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a variable-voltage charger Charger Ammeter Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? NOTE: Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. NOTE: Set the charging voltage to 16 17 V.
CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage charger Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? Charge the battery until the charging voltage reaches 15 V.
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES CHK ADJ 6. Check: S battery vent Obstruction Clean. Damage Replace. 7. Install: S battery 8. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 9. Check: S battery terminals Dirt Clean with a wire brush. Loose connection Connect properly. 10. Lubricate: S battery terminals Recommended lubricant Dielectric grease 11.
CHK ADJ CHECKING THE FUSES Pocket tester 90890-03112 b. If the pocket tester indicates “∞”, replace the fuse. 3. Replace: S blown fuse a. Turn off the ignition. b. Install a new fuse of the correct amperage rating. c. Turn on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. Fuses Amperage rating Quantity Main fuse 30 A 1 Headlight fuse 15 A 1 Signaling system fuse 15 A 1 Ignition fuse 7.
REPLACING THE HEADLIGHT BULB CHK ADJ EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: S headlight unit 1 2. Disconnect: S headlight lead 1 S auxiliary light lead 2 3. Remove: S cover 3 4. Remove: S headlight bulb holder 1 5. Remove: S headlight bulb 2 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 6. Install: S headlight bulb (New) Secure the new headlight bulb with the headlight bulb holder.
REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM CHK ADJ 7. Install: S headlight bulb holder 8. Install: S cover 9. Connect: S auxiliary light lead S headlight lead 10. Install: S headlight unit EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b. Direction a Direction b Headlight beam is raised. Headlight beam is lowered. 2. Adjust: S headlight beam (horizontally) a. Turn the adjusting knob 2 in direction a or b.
CHK ADJ
ENG 4
ENG CHAPTER 4. ENGINE OVERHAUL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS, HOSES AND EXHAUST PIPES . . . . . . . . . . . . . . . . . . . . . . . LEADS AND DRIVE SPROCET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENG CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . ASSEMBLING THE CLUTCH MASTER CYLINDER . . . . . . . . . . . . . INSTALLING THE CLUTCH MASTER CYLINDER . . . . . .
ENG CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . CHECKING THE CIRCLIPS AND WASHERS . . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79 4-79 4-79 4-81 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT CAM AND SHIFT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENG
ENGINE ENG EAS0018 ENGINE OVERHAULE ENGINE LEADS, HOSES AND EXHAUST PIPES 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) 20 Nm (2.0 m kg) 10 Nm (1.0 m kg) New New 20 Nm (2.0 m kg) 25 Nm (2.5 m kg) 25 Nm (2.5 m kg) Order 20 Nm (2.0 m kg) Job/Part Q’ty Remove the parts in the order listed. Removing the leads, hoses and exhaust pipes Seat, side cover, fuel tank 1 2 3 4 5 6 7 8 Remarks Refer to “SEAT, SIDE COVER AND FUEL TANK” in Chapter 3. Refer to “CARBURETOR” in Chapter 5.
ENGINE ENG 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) 20 Nm (2.0 m kg) 10 Nm (1.0 m kg) New New 20 Nm (2.0 m kg) 25 Nm (2.5 m kg) 25 Nm (2.5 m kg) Order Job/Part 20 Nm (2.0 m kg) Q’ty 9 10 O-ring Ground lead 2 1 11 Crankcase breather hose 1 Remarks NOTE: Disconnect ground lead. For installation, reverse the removal procedure.
ENG ENGINE EAS00190 LEADS AND DRIVE SPROCKET 10 Nm (1.0 m kg) New 85 Nm (8.5 m kg) New 10 Nm (1.0 m kg) 25 Nm (2.5 m kg) 10.Nm (1.0 m kg) Order Job/Part Q’ty Remarks Remove the parts in the order listed. 1 Removing the leads and drive sprocket Starter motor lead 1 2 3 4 5 6 7 8 9 10 11 Starter motor Pickup/neutral switch lead A.C. generator lead A.C. generator Clutch release cylinder comp.
ENG ENGINE 10 Nm (1.0 m kg) New 85 Nm (8.5 m kg) New 10 Nm (1.0 m kg) 25 Nm (2.5 m kg) 10.Nm (1.0 m kg) Order 12 13 14 Job/Part Q’ty Lock washer Drive sprocket Drive chain Remarks 1 1 1 For installation, reverse the removal procedure.
ENGINE ENG ENGINE 48 Nm (4.8 m kg) 88 Nm (8.8 m kg) 64 Nm (6.4 m kg) 28 Nm (2.8 m kg) 30 Nm (3.0 m kg) 55 Nm (5.5 m kg) 64 Nm (6.4 m kg) 26 Nm (2.6 m kg) Order Job/Part Q’ty Remarks Remove the parts in the order listed. 1 2 Removing the engine Footrest Down tube 1 1 3 4 5 6 7 Engine bracket (front) Spacer Engine bracket (rear upper) left, right Engine bracket (rear lower) Engine 2 1 2 1 1 NOTE: Place a suitable stand under the frame and engine. Refer to “INSTALLING THE ENGINE”.
ENGINE ENG EAS00192 INSTALLING THE ENGINE 1. Tighten the bolts in the following order. Bolt 1 : 88 Nm (8.8 m kg) Bolt 2 : 48 Nm (4.8 m kg) Bolt 3 : 55 Nm (5.5 m kg) Bolt 4 : 30 Nm (3.0 m kg) Bolt 5 : 64 Nm (6.4 m kg) Nut 6 : 64 Nm (6.4 m kg) 2. Install: shift arm 1 NOTE: Align the punch mark b in the shift shaft with the punched mark a on the shift arm. Align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket. Shift arm bolt 10 Nm (1.
CAMSHAFT ENG CAMSHAFT CYLINDER HEAD COVER 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “SEAT, SIDE COVER AND FUEL TANK”. Removing the cylinder head covers Seat, fuel tank 1 2 3 4 5 Remarks 2 1/1 4 1 1 Bolts Air duct (left/right) Plug cap Cylinder head cover Gasket For installation, reverse the removal procedure.
CAMSHAFTS ENG EAS00196 CAMSHAFTS 12 Nm (1.2 m kg) 20 Nm (2.0 m kg) 18 Nm (1.8 m kg) 10 Nm (1.0 m kg) New 20 Nm (2.0 m kg) Order 1 2 3 4 5 6 7 8 9 10 Job/Part Q’ty Remarks Remove the parts in the order listed.
CAMSHAFTS ENG EAS00199 REMOVING THE CAMSHAFTS 1. Align: “T” mark on the timing plate (with the stationary pointer on the pickup coil base plate) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the “T” mark a with the pickup coil mark b . NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. 2. Remove: timing chain guide (top side) 1 3. Loosen: camshaft sprocket bolts 4. Loosen: cap bolt 2 5.
CAMSHAFTS ENG EAS000204 CHECKING THE CAMSHAFTS 1. Check: camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft. 2. Measure: camshaft lobe dimensions a and b Out of specification Replace the camshaft. Camshaft lobe dimension limit Intake/exhaust a Wear limit <28.15 mm> b Wear limit <35.85 mm> 3. Measure: camshaft runout Out of specification Replace. Camshaft runout Less than 0.03 mm 4.
CAMSHAFTS ENG 5. Measure: camshaft journal diameter a Out of specification Replace the camshaft. Within specification Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.967 24.980 mm EAS00208 CHECKING THE CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshafts sprockets and timing chain guides. 1. Check: camshaft sprocket Damage/wear Replace the camshaft sprockets and the timing chain as a set. 2.
CAMSHAFTS A ENG INSTALLING THE CAMSHAFTS 1. Install: camshaft sprockets B NOTE: Be sure to set the sprockets in the specified position as shown in the figure. Temporarily tighten the bolts in this stage. A Exhaust side B Intake side 2. Install: camshaft (exhaust) camshaft (intake) a. Turn the crankshaft counterclockwise until the TDC mark a is aligned with the pickup coil mark b . CAUTION: Do not turn the crankshaft during the camshafts installation.
CAMSHAFTS ENG d. Check if the punched marks c on both camshafts are inside the holes of camshaft caps d . If they are not in the position, repeat the above steps. e. Tighten the bolts (camshaft cap) in a crisscross pattern from the inside outwards. CAUTION: The bolts (camshaft caps) must be tightened evenly or damage to the cylinder head, camshaft caps and camshaft will result. Bolt (camshaft cap): 12 Nm (1.2 m kg) f. Remove the safety wire from the timing chain. 3.
CAMSHAFTS ENG a. Turn the crankshaft counterclockwise several times until the TDC mark on the timing plate is aligned with the stationary pointer. b. Check if both the camshaft timing punch marks a are aligning with the camshaft cap hole b . 5. Tighten: Bolts (cam sprockets) CAUTION: Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. Bolts (cam sprockets): 20 Nm (2.
CYLINDER HEAD ENG EAS00221 CYLINDER HEAD 35 Nm (3.5 m kg) New 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) New 10 Nm (1.0 m kg) Order Job/Part Q’ty Remarks Remove the parts in the order listed. NOTE: Removing the cylinder head Remove the engine mount (front) and move the engine to front side. 1 2 3 4 5 Refer to “CAMSHAFTS”. Camshafts Cylinder head Gasket Dowel pins O-rings Intake manifold 1 1 2 2 4 Refer to “REMOVING/INSTALLING THE CYLINDER HEAD”. For installation, reverse the removal procedure.
CYLINDER HEAD ENG EAS00223 REMOVING THE CYLINDER HEAD 1. Remove: cylinder head nuts 1 16 NOTE: Loosen the nuts in the proper sequence as shown. Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. EAS00228 CHECKING THE CYLINDER HEAD The following procedure applies to all of the cylinder heads. 1.
CYLINDER HEAD ENG NOTE: To ensure an even surface, rotate the cylinder head several times. EAS00232 INSTALLING THE CYLINDER HEAD 1. Install: gasket (New) 1 dowel pins 2 2. Install: cylinder head washers copper washers cylinder head nuts NOTE: Apply engine oil onto the threads of the cylinder head nuts. Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages. Cylinder head Cap nut 35 Nm (3.5 m kg) Cylinder head nut 10 Nm (1.0 m kg) 3.
VALVES AND VALVE SPRINGS ENG EAS00236 VALVES AND VALVE SPRINGS Order 1 2 3 4 5 6 7 8 9 10 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the valves and valve springs Camshaft Cylinder head Valve pads Valve lifters Valve cotters Upper springs seats Valve springs (outer) Valve springs (inner) Intake valves Exhaust valves Lower spring seats Oil seals Refer to “CAMSHAFTS”. Refer to “CYLINDER HEAD”. 16 16 32 16 16 16 8 8 16 16 Refer to “REMOVING/INSTALLING THE VALVES”.
VALVES AND VALVE SPRINGS ENG EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Remove: valve lifter 1 valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2.
VALVES AND VALVE SPRINGS ENG 4. Remove: S upper spring seat 1 S valve springs 2 S oil seal 3 S lower spring seat 4 S valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1.
VALVES AND VALVE SPRINGS ENG a. Remove the valve guide with a valve guide remover 1 . b. Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . c. After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem to valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover, reamer & installer (5.5 mm): 90890-04016 3.
VALVES AND VALVE SPRINGS ENG EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: carbon deposits (from the valve face and valve seat) 2. Check: valve seat Pitting/wear Replace the cylinder head. 3. Measure: valve seat width a Out of specification Replace the cylinder head. Valve seat width Intake: 0.9 1.1 mm Exhaust: 0.9 1.1 mm a. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. b.
VALVES AND VALVE SPRINGS ENG d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hand. e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g.
VALVES AND VALVE SPRINGS ENG Valve spring free length (intake and exhaust) Inner spring 39.65 mm <37.5 mm> Outer spring 41.1 mm <39 mm> 2. Measure: S compressed spring force a Out of specification Replace the valve spring. b Installed length Compressed spring force Intake and exhaust inner spring 61.7 72.5 N (6.29 7.39 kg) at 32.8 mm Intake and exhaust outer spring 130.4 154.0 N (13.3 15.7 kg) at 34.8 mm 3.
VALVES AND VALVE SPRINGS ENG Recommended lubricant Molybdenum disulfide oil 2. Install: valve 1 lower spring seat 2 oil seal 3 valve springs 4 upper spring seat 5 (into the cylinder head) NOTE: Install the valve spring with the larger pitch a facing up. b Smaller pitch 3. Install: valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2. Valve spring compressor 90890-04019 4.
CYLINDERS AND PISTONS ENG EAS00252 CYLINDERS AND PISTONS New New 20 Nm (2.0 m kg) New Order Job/Part Q’ty 1 2 3 4 5 6 7 Removing the cylinders and pistons Cylinder head Cylinder block Dowel pins Gasket Piston pin clips Piston pins Pistons Oil ring sets Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. 1 2 1 8 4 4 4 Refer to “REMOVING/INSTALLING THE CYLINDERS AND PISTONS”. For installation, removal procedure.
CYLINDERS AND PISTONS ENG EAS00254 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Remove: piston pin clip 1 piston pin 2 piston 3 CAUTION: 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.
CYLINDERS AND PISTONS ENG a. Measure cylinder bore “C” with the cylinder bore gauge. 1 20 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 gauge Standard 79.00 79.01 mm Wear limit 79.1 mm Cylinder bore “C” “C” = X + Y/2 b. If out of specification, replace the cylinder, and replace the piston and piston rings as a set. c.
CYLINDERS AND PISTONS ENG EAS00263 CHECKING THE PISTON RINGS 1. Measure: piston ring side clearance Out of specification Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.045 0.080 mm : 0.1 mm 2nd ring 0.03 0.07 mm : 0.1 mm 2.
CYLINDERS AND PISTONS ENG EAS00270 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pistons and cylinders. 1. Install: top ring 1 2nd ring 2 lower oil ring rail 3 upper oil ring rail 4 oil ring expander 5 1 2 4 5 3 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers a are located on the upper side of the rings. The piston rings that have an “R” mark must be installed into the 2nd ring groove. 2.
CYLINDERS AND PISTONS ENG 3. Install: gasket (New) 1 dowel pins 2 4. Lubricate: piston piston rings cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A forward 6. Install: cylinder block NOTE: Install pistons #2 and #3 before installing pistons #1 and #4. Pass the timing chain and timing chain guide (intake side) through the timing chain cavity.
CLUTCH ENG EAS00273 CLUTCH CLUTCH COVER New 10 Nm (1.0 m kg) Order 1 2 3 Job/Part Q’ty Remarks Remove the parts in the order listed. Drain Removing the clutch cover. Engine oil Clutch cover Gasket Dowel pins 1 1 2 For installation, reverse the removal procedure.
CLUTCH ENG EAS00274 CLUTCH 70 Nm (7.0 m kg) New New 8 Nm (0.8 m kg) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the clutch Pressure plate Clutch spring Spring housing Pressure plate Clutch push rod (short) Ball Clutch push rod (long) O-ring Friction plates Clutch plates Friction plates Clutch boss nut Lock washer 1 1 1 1 1 1 1 1 1 6 6 1 1 4-33 Refer to “INSTALLING THE CLUTCH”. Refer to “REMOVING/INSTALLING THE CLUTCH”.
CLUTCH ENG 70 Nm (7.0 m kg) New New 8 Nm (0.8 m kg) Order 14 15 16 17 18 19 20 21 22 23 Job/Part Q’ty 1 1 1 1 1 1 1 1 1 1 Clutch boss Stopper ring Clutch plate Clutch spring plate Clutch spring plate seat Friction plates (narrow) Thrust washer Spacer Bearing Clutch housing Remarks Refer to “REMOVING/INSTALLING THE CLUTCH”. For installation, reverse the removal procedure.
CLUTCH ENG EAS00275 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: clutch boss nut 1 NOTE: While holding the clutch boss 2 with the universal clutch holder, loosen the clutch boss nut. Universal clutch holder 3 90890-04086 3. Remove: clutch boss nut 1 lock washer 2 clutch boss 3 thrust washer 4 spacer 5 bearing 6 clutch housing 7 NOTE: Insert two 6 mm bolts 8 into the spacer and then remove the spacer by pulling on the bolts.
CLUTCH ENG EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: clutch plate Damage Replace the clutch plates as a set. 2. Measure: clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification Replace the clutch plates as a set. Clutch plate warpage limit Less than 0.1 mm CHECKING THE CLUTCH SPRING 1. Check: Clutch spring Damage Replace as a set. 2.
CLUTCH ENG EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: Clutch housing dogs Damage/pitting/wear Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. 2. Check: bearing Damage/wear Replace the clutch housing. EAS00285 CHECKING THE CLUTCH BOSS 1. Check: clutch boss splines Damage/pitting/wear Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation.
CLUTCH ENG EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check: O-ring 1 short clutch push rod 2 long clutch push rod 3 ball 4 bearing 5 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. Long clutch push rod bending limit 0.3 mm INSTALLING THE CLUTCH 1. Install: clutch housing 1 NOTE: Engage the notch of clutch housing and the projection on the oil pump drive gear. 2.
CLUTCH ENG 3. Tighten: clutch boss nut 1 NOTE: While holding the clutch boss with the universal clutch holder 2 , tighten the clutch boss nut. Universal clutch holder 90890-04086 Clutch boss nut 70 Nm (7.0 m kg) 4. Bend the lock washer tab along a flat side of the nut. 5. Lubricate: long clutch push rod 1 ball 2 short clutch push rod 3 (with the recommended lubricant) Recommended lubricant Lithium soap base grease 6.
CLUTCH ENG 7. Install: Friction plates (narrow type) 1 Clutch plates 2 Stopper ring 3 Friction plates (wide type) 4 a. Install the friction plate of narrow contact face 1 and one of the clutch plate to the clutch boss. b. Install the stopper ring 3 . NOTE: Install the stopper ring onto the groove around the clutch boss with both ends of the ring fitted in the hole a on the boss. c. Install the other 6 clutch plates and the 6 friction plates of wide contact face alternately. d.
CLUTCH ENG EAS00305 CLUTCH MASTER CYLINDER 10 Nm (1.0 m kg) New 30 Nm (3.0 m kg) Order Job/Part Q’ty Remarks Remove the parts in the order listed. 1 2 3 Removing the clutch master cylinder Clutch lever Clutch switch lead Clutch switch 1 1 1 NOTE: Before removing the clutch master cylinder, drain the clutch fluid from the entire clutch system. 4 5 6 7 Union bolt Copper washers/Clutch hose Clutch lever holder Clutch master cylinder 1 2/1 1 1 Refer to “INSTALLING THE CLUTCH MASTER CYLINDER”.
CLUTCH ENG New Order 1 2 3 4 Job/Part Q’ty Remarks Disassembly the parts in the order listed. Disassembling the clutch master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 For assembly, reverse the disassembly procedure.
CLUTCH ENG EAS00307 CAUTION: Clutch components rarely require disassembly. Therefore, always follow these preventive measures: Never disassemble clutch components unless absolutely necessary. If any connection on the hydraulic clutch system is disconnected, the entire clutch system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Never use solvents on internal clutch components. Use only clean or new clutch fluid for cleaning clutch components.
CLUTCH ENG 2. Check: clutch master cylinder 1 clutch master cylinder kit 2 Rust/scratches/wear Replace the clutch master cylinder and clutch master cylinder kit as a set. clutch hose 3 Cracks/damage/wear Replace. EAS00309 ASSEMBLING THE CLUTCH MASTER CYLINDER WARNING Before installation, all internal clutch components must be cleaned and lubricated with clean or new clutch fluid. Never use solvents on internal clutch components as they will cause the piston seals to swell and distort.
CLUTCH ENG Union bolt 30 Nm (3.0 m kg) 3. Install: clutch lever 1 NOTE: Lubricate the clutch lever pivot bolt with lithium soap base grease. 4. Fill: clutch master cylinder reservoir (with the specified amount of the recommended clutch fluid) Recommended clutch fluid Brake fluid DOT 4 WARNING Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance.
CLUTCH ENG 6. Check: clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level. Refer to “CHECKING THE CLUTCH FLUID LEVEL” in chapter 3. 7. Check: clutch lever operation Soft or spongy feeling Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3.
CLUTCH ENG EAS00311 CLUTCH RELEASE CYLINDER 30 Nm (3.0 m kg) 10 Nm (1.0 m kg) Order Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the clutch release cylinder 1 Bolt 3 2 3 4 5 6 Union bolt Copper washer Spacer Clutch hose Clutch release cylinder 1 3 1 1 1 Refer to “INSTALLING THE CLUTCH RELEASE CYLINDER”. NOTE: Before removing the clutch releace cylinder, drain the clutch fluid from the entire clutch system. Refer to “INSTALLING THE CLUTCH RELEASE CYLINDER”.
CLUTCH Order 1 2 3 4 5 Job/Part Q’ty ENG Remarks Disassembly the parts in the order listed. Disassembling the clutch release cylinder Clutch release cylinder Piston seal Clutch release cylinder piston Piston seal Spring 1 1 1 1 1 Refer to “DISASSEMBLING THE CLUTCH RELEASE CYLINDER”. For assembly, reverse the disassembly procedure.
CLUTCH ENG EAS00313 DISASSEMBLING THE CLUTCH RELEASE CYLINDER 1. Remove: piston seal 1 clutch release cylinder piston 2 spring 3 piston seal 4 a. Blow compressed air into the clutch hose joint opening a to force out the piston from the clutch release cylinder. WARNING Cover the clutch release cylinder with a rag. Be careful not to get injured when the piston is expelled from the clutch release cylinder. Never try to pry out the clutch release cylinder piston. b.
CLUTCH ENG EAS00315 INSTALLING THE CLUTCH RELEASE CYLINDER 1. Check: copper washers (New) clutch hose 1 union bolt 2 WARNING Proper clutch hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”. Union bolt 30 Nm (3.0 m kg) 2. Fill: clutch master cylinder reservoir (with the specified amount of the recommended clutch fluid) Recommended clutch fluid Brake fluid DOT 4 WARNING Use only the designated clutch fluid.
CLUTCH ENG NOTE: In order to ensure a correct reading of the clutch fluid level, make sure that the top of the reservoir is horizontal. 3. Bleed: clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3. 4. Check: clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level. Refer to “CHECKING THE CLUTCH FLUID LEVEL” in chapter 3. 5. Check: clutch lever operation Soft or spongy feeling Bleed the clutch system.
OIL PUMP ENG OIL PUMP 4 Nm (0.4 m kg) New 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to “INSTALLING THE CLUTCH”. Removing the oil pump. Clutch Oil pump drive gear Collar Washer Oil buffer plate Circlip Oil pump driven gear Washer Oil pump Dowel pin Collar O-ring 1 1 1 1 1 1 1 1 1 1 3 Refer to “INSTALLING THE OIL PUMP”. For installation, reverse the removal procedure.
OIL PUMP Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Q’ty ENG Remarks Disassembly the parts in the order listed. Disassembling the oil pump Oil pump housing Inner rotor Outer rotor Pin Dowel pin Oil pump housing Inner rotor Outer rotor Pin Oil pump shaft Oil pump cover 1 1 1 1 1 1 1 1 1 1 1 Refer to “ASSEMBLING THE OIL PUMP”. For assembly, reverse the disassembly procedure.
OIL PUMP ENG EAS00364 CHECKING THE OIL PUMP 1. Check: oil pump drive gear 1 oil pump driven gear 2 oil pump housing 3 oil pump housing cover 4 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 Outer of specification Replace the oil pump. 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner-rotor to outer-rotor tip clearance 0.
OIL PUMP ENG EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: inner rotor outer rotor oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: oil pump shaft 1 (to the oil pump cover 2 ) pin 3 inner rotor 4 outer rotor 5 pin 6 oil pump housing 7 screw Oil pump housing screw 10 Nm (1.0 m kg) NOTE: When installing the inner rotor, align the pin 3 in the oil pump shaft with the groove on the inner rotor 4 . 3.
SHIFT SHAFT ENG EAS00327 SHIFT SHAFT New 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the shift shaft and stopper lever Oil pump Drive sprocket cover Circlip Washer Shift shaft Washer Shift lever spring Bolt Stopper lever Stopper lever spring Refer to “OIL PUMP”. Refer to “ENGINE”. 1 1 1 1 1 1 1 1 Refer to “INSTALLING THE SHIFT SHAFT”. For installation, reverse the removal procedure.
SHIFT SHAFT ENG EAS00328 CHECKING THE SHIFT SHAFT 1. Check: shift shaft 1 Bends/damage/wear Replace. shift lever spring Damage/wear Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: stopper lever 1 Bends/damage Replace. Roller turns roughly Replace the stopper lever. EAS00331 INSTALLING THE SHIFT SHAFT 1. Install: stopper lever 1 stopper lever spring 2 shift shaft lever 3 NOTE: Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss.
SHIFT SHAFT ENG NOTE: Lubricate the oil seal lips with lithium soap base grease. Hook the end of the shift lever spring onto the shift lever spring stopper 4 .
TIMING PLATE AND PICKUP COIL ENG TIMING PLATE AND PICKUP COIL 45 Nm (4.5 m kg) 4 Nm (0.4 m kg) 7 Nm (0.7 m kg) Order 1 2 3 4 5 6 7 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the timing plate and pickup coil Seat, side cover, fuel tank Pickup coil read Timing plate cover Gasket Pickup coil Timing plate Dowel pin Pickup base 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
OIL PAN ENG OIL PAN New 10 Nm(1.0 m kg) 10 Nm(1.0 m kg) New New New New Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the oil pan Engine Oil level switch/O-ring Oil pan Dowel pin Gasket Relief valve/O-ring Relief valve/O-ring Oil strainer Oil strainer housing Gasket Q’ty Remarks Remove the parts in the order listed. Refer to “ENGINE”. 1/1 1 2 1 1/1 1/1 1 1 1 Refer to “REMOVING / INSTALLING THE OIL PAN”. Refer to “INSTALLING THE OIL STRAINER”. For installation, reverse the removal procedure.
OIL PAN ENG EAS00362 REMOVING THE OIL PAN 1. Remove: oil level switch 1 oil pan 2 gasket dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS00365 CHECKING THE RELIEF VALVE 1. Check: relief valve body 1 relief valve 2 spring 3 Cover 4 Damage/wear Replace the defective part(-s).
OIL PAN ENG EAS00378 INSTALLING THE OIL STRAINER 1. Install: oil strainer housing 1 Oil strainer housing bolt 10 Nm (1.0 m kg) LOCTITE NOTE: The arrow a on the oil strainer housing must point towards the front of the engine. 2. Install: oil strainer cover 1 relief valve 2 NOTE: The arrow a on the oil strainer cover must point towards the front of the engine. EAS00380 INSTALLING THE OIL PAN 1.
CRANKCASE ENG CRANKCASE 35 Nm (3.5 m kg) 12Nm (1.2 m kg) 24 Nm (2.4 m kg) 10 Nm (1.0 m kg) 35 Nm (3.5 m kg) 12Nm (1.2 m kg) 10Nm (1.0 m kg) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “ENGINE”. Refer to “CAMSHAFTS”. Refer to “CYLINDER HEAD”. Refer to “CYLINDERS AND PISTONS”. Refer to “CLUTCH”. Refer to “OIL PUMP”. Refer to “SHIFT SHAFT”. Refer to “TIMING PLATE AND PICKUP COIL”. Refer to “OIL PAN”.
CRANKCASE ENG 35 Nm (3.5 m kg) 12 Nm (1.2 m kg) 24 Nm (2.4 m kg) 10 Nm (1.0 m kg) 35 Nm (3.5 m kg) 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) Order Job/Part Q’ty 4 5 Bearing cover Crankcase (lower) 1 1 6 Dowel pin 2 Remarks Refer to “DISASSEMBLING/ASSEMBLING THE CRANKCASE”. For installation, reverse the removal procedure.
CRANKCASE ENG EAS00384 DISASSEMBLING THE CRANKCASE 1. Remove: S crankcase bolts NOTE: S 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. S Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). S The numbers embossed on the crankcase indicate the crankcase tightening sequence. 2. Place the engine upside down. 3.
CRANKCASE ENG EAS00399 CHECKING THE CRANKCASE 1. Throughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: crankcase Cracks/damage Replace. oil delivery passages Obstruction Blow out with compressed air. EAS00412 ASSEMBLING THE CRANKCASE 1. Lubricate: crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2.
CRANKCASE ENG 5. Set the shift drum assembly and transmission gears in the neutral position. 6. Install: S lower crankcase 1 (onto the upper crankcase 2 ) CAUTION: Before tightening the crankcase bolts, make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand. NOTE: S Carefully position the shift forks so that they mesh smoothly with the transmission gears. S Mesh shift fork center with the 2nd pinion gear 3 on the main axle. 7.
STARTER CLUTCH ENG EAS00342 STARTER CLUTCH 7 Nm (0.7 m kg) 10 Nm (1.0 m kg) Order Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to “CRANKCASE”. 1 2 3 4 5 6 7 Removing the starter clutch Crankcase Bearing housing O-ring Oil seal Nozzle Generator shaft Bearing Starter clutch drive gear 1 1 1 1 1 1 1 8 9 10 11 12 Starter clutch gear Collar Circlip Starter clutch roller Stopper plate 1 1 1 1 1 4-68 Refer to “INSTALLING THE STARTER CLUTCH”.
STARTER CLUTCH ENG 7 Nm (0.7 m kg) 10 Nm (1.0 m kg) New Order 13 14 15 Job/Part Q’ty Idle gear shaft Starter clutch idle gear Bearing Remarks 1 1 1 For installation, reverse the removal procedure.
STARTER CLUTCH ENG EAS00350 CHECKINHG THE STARTER CLUTCH 1. Check: starter clutch rollers 1 Damage/wear Replace. 2. Check: starter clutch idle gear 2 starter clutch drive gear 3 starter clutch gear 4 Burrs/chips/roughness/wear Replace the defective part(-s). 3. Check: starter clutch gear’s contacting surfaces Damage/pitting/wear Replace the starter clutch gear. 4. Check: starter clutch operation a. Install the starter clutch gear 4 onto the starter clutch and hold the starter clutch. b.
STARTER CLUTCH ENG EAS00352 CHECKING THE GENERATOR SHAFT 1. Check: generator shaft 1 generator shaft splines 2 Damage/wear Replace the generator shaft. oil passages 3 Dirt/obstruction Wash the generator shaft and then blow out the oil passages with compressed air. bearing 4 Rough movement Replace. INSTALLING THE STARTER CLUTCH ROLLER 1.
CRANKSHAFT ENG EAS00381 CRANKSHAFT CRANKSHAFT Order Job/Part Q’ty 1 2 3 4 5 6 Removing the crankshaft assembly Crankcase Starter clutch Crankshaft Oil seal Cover Timing chain HY-VO chain Crankshaft journal bearings 1 1 1 1 1 10 7 HY-VO chain guide 1 Remarks Remove the parts in the order listed. Refer to “CRANKCASE”. Refer to “STARTER CLUTCH”. Refer to “INSTALLING THE CRANKSHAFT ASSEMBLY”. Refer to “REMOVING/INSTALLING THE CRANKSHAFT ASSEMBLY”. For installation, reverse the removal procedure.
CRANKSHAFT ENG CONNECTING ROD 36 Nm (3.6 m kg) Order 1 2 3 4 5 Job/Part Q’ty Removing the connecting rod. Nut Connecting rod bolt Coonecting rod Connecting rod cap Connecting rod bearing 8 8 4 4 8 Remarks Remove the parts in the order listed Refer to ”INSTALLING THE CONNEECTING RODS.” Refer to ”REMOVING/INSTALLING THE CONNECTING RODS.” For installation, reverse the removal procedur.
CRANKSHAFT ENG EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: crankshaft assembly 1 crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EAS00391 REMOVING THE CONNECTING RODS 1. Remove: connecting rods 1 big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
CRANKSHAFT ENG a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. b. Place the upper crankcase upside down on a bench. c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a of the crankshaft journal upper bearings with the notches b in the crankcase. d. Put a piece of Plastigauge 2 on each crankshaft journal.
CRANKSHAFT ENG g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure the compressed Plastigauge width 1 on each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings. 4.
CRANKSHAFT ENG CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions. a. Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods. b. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap.
CRANKSHAFT ENG Refer to “INSTALLING THE CONNECTING RODS”. Connecting rod nut 36 Nm (3.6 m kg) f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS”. g. Measure the compressed Plastigauge width 1 on the crankshaft pin. If the clearance is out of specification, select replacement big end bearings. 6.
CRANKSHAFT ENG CHECKING THE TIMING CHAIN 1. Check: timing chain 1 Damage/stiffness Replace the timing chain and camshaft sprockets as a set. 2. Check timing chain guide (intake side) Damage/wear Replace. EAS00400 CHECKING THE HY-VO CHAIN 1. Check: HY-VO chain 1 Damage/stiffness Replace the HY-VO chain and sprockets as a set. 2. Check: HY-VO chain guide Damage/wear Replace. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1.
CRANKSHAFT ENG Recommended lubricant Engine oil 3. Install: big end bearings 1 connecting rods 2 connecting rod caps 3 (onto the crankshaft pins) NOTE: Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. Be sure to reinstall each big end bearing in its original place. Make sure that the “Y” marks a on the connecting rods face towards the left side of the crankshaft.
CRANKSHAFT ENG EAS00407 INSTALLING THE CRANKSHAFT 1. Install: crankshaft journal upper bearings (into the upper crankcase) NOTE: Align the projections a on the crankshaft journal upper bearings with the notches b in the crankcase. Be sure to install each crankshaft journal upper bearing in its original place. 2. Install: HY-VO chain 1 timing chain 2 (onto the crankshaft sprocket) crankshaft assembly 3 NOTE: Pass the timing chain through the timing chain cavity.
TRANSMISSION ENG EAS00419 TRANSMISSION Order 1 2 3 4 5 6 7 8 9 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the transmission, shift drum assembly, and shift forks. Crankcase Main axle assembly Oil seal Bearing Drive axle assembly Collar O-ring Oil seal Circlip Bearing Refer to “CRANKCASE”. 1 1 1 1 1 1 1 1 1 Refer to “INSTALLING THE TRANSMISSION”. For installation, reverse the removal procedure.
TRANSMISSION ENG New New New Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Part Disassembling the transmission Washer 1st wheel gear/Collar Washer 4th wheel gear Circlip Washer 3rd wheel gear/collar Washer 5th wheel gear Circlip Washer 2nd wheel gear/collar Drive axle Q’ty Remarks Disassembly the parts in the order listed.
TRANSMISSION ENG New New New Order 14 15 16 17 18 19 20 21 Job/Part 2nd pinion gear 5th pinion gear/collar Washer 3rd pinion gear Circlip Washer 4th pinion gear Main axle (1st pinion gear) Q’ty Remarks 1 1/1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
TRANSMISSION ENG SHIFT CAM AND SHIFT FORK Order 1 2 3 4 5 6 Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to ”CRANKCASE” Removing the shift cam and shift fork. Crankcase Shif fork quide bar Shift fork (L) Shift fork (C) Shift fork (R) Stopper plate Shift drum 1 1 1 1 1 1 4-85 Refer to ”INSTALLING THE TRANSMISSION For installation, reverse the removal produre.
TRANSMISSION ENG EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1. Check: shift fork cam follower 1 shift fork pawl 2 Bends/damage/scoring/wear Replace the shift fork. 2. Check: shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends Replace. WARNING Do not attempt to straighten a bent shift fork guide bar. 3.
TRANSMISSION ENG 2. Measure: drive axle runout (with a centering device and dial gauge 1 ) Out of specification Replace the drive axle. Drive axle runout limit 0.06 mm 3. Check: transmission gears Blue discoloration/pitting/wear Replace the defective gear(-s). transmission gear dogs Cracks/damage/rounded edges Replace the defective gear(-s). 4. Check: transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect Reassemble the transmission axle assemblies.
TRANSMISSION ENG EAS00429 INSTALLING THE TRANSMISSION 1. Install: main axle assembly 1 drive axle assembly 2 NOTE: Make sure that the drive axle bearing circlips 3 are inserted into the grooves 4 in the upper crankcase. The drive axle bearing pin 5 must face towards the rear of the crankcase and the main axle bearing pin 6 must face towards the front of the crankcase. 2. Check: transmission Rough movement Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.
CARB 5
CARB CHAPTER 5. CARBURETORS CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR . . . . . . . . . . .
CARB
CARBURETORS CARB EAS00481 CARBURETORS CARBURETORS Order Job/Part Q’ty Remove the parts in the order listed. Refer to “SEAT, SIDE COVER AND FUEL TANK” in Chapter 3.
CARBURETORS CARB New Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Part Q’ty Remarks Disassembly the parts in the order listed. Disassembling the carburetor Starter shaft/Starter levers Upper bracket 1/4 NOTE: 1 The following procedure applies to all of the carburetors.
CARBURETORS CARB EAS00484 New Order 14 15 16 17 18 19 20 Job/Part Q’ty Remarks 1/1 Float chamber Float chamber gasket Float pin Float Needle valve ass’y Pilot jet Main jet Needle jet 1 1 1 1 1 1 Refer to “ASSEMBLING THE CARBURETORS”. For assembly, reverse the disassembly procedure.
CARBURETORS CARB EAS00486 CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 1. Check: carburetor body float chamber jet housing Cracks/damage Replace. 2. Check: fuel passages Obstruction Clean. a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic-carburetorcleaning solution. b. Blow out all of the passages and jets with compressed air. 3. Check: float chamber body Dirt Clean. 4.
CARBURETORS CARB 10. Check: jet needle kit 1 needle jet 2 main jet 3 pilot jet 4 pilot screw 5 Bends/damage/wear Replace. Obstruction Clean. Blow out the jets with compressed air. 11. Check: piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness Replace the piston valve. 12. Check: fuel feed pipes hose joint Cracks/damage Replace. Obstruction Clean. Blow out the pipes with compressed air. 13.
CARBURETORS CARB EAS00489 2. Measure: float height a Out of specification Adjust. Float height 21.3 23.3 mm a. Hold the carburetor upside down. b. Measure the distance from the mating surface of the float chamber (with the gasket removed) to the top of the float. NOTE: The float arm should rest on the needle valve without depressing it. c. If the float height is not within specification, inspect the needle valve seat and needle valve. d.
CARBURETORS CARB EAS00493 INSTALLING THE CARBURETORS 1. Adjust: carburetor synchronization Refer to “SYNCHRONIZING THE CARBURETORS” in chapter 3. 2. Adjust: engine idling speed Engine idling speed 1,000 1,100 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 3. Adjust: throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3 5 mm Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. EAS00497 MEASURING AND ADJUSTING THE FUEL LEVEL 1.
CARBURETORS CARB 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.
CARBURETORS CARB Out of specification Replace the throttle position sensor. Throttle position sensor resistance 0 to 4 6 kΩ at 20_C (68_F) (Yellow – Black/Blue) 2. Adjust: S throttle position sensor angle a. Turn the main switch to “ON”. b. Disconnect the throttle position sensor coupler. c. Reconnect the throttle position sensor coupler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjustment mode. d.
CARBURETORS CARB EAS00505 CHECKING THE FUEL COCK 1. Check: fuel cock Cracks/damage/wear Replace. EAS00506 CHECKING THE FUEL COCK OPERATION NOTE: After installing the fuel cock, check its operation. 1. Check that the fuel cock lever is positioned to “ON” or “R”. 2. Place a container under the end of the fuel hose. 3. Check: fuel cock operation a. Suck on the end of the vacuum hose. Fuel flows Fuel cock is OK Fuel does not flows Replace the fuel cock.
CHAS 6
CHAS CHAPTER 6. CHASSIS FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . .
CHAS FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL AND BRAKE DISCS CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 73 Nm (7.3 m kg) 19 Nm (1.9 m kg) 40 Nm (4.0 m kg) 20 Nm (2.0 m kg) Order Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the front wheel and brake discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00518 Order 1 2 3 4 Job/Part Q’ty Remarks Disassembly the parts in the order listed. Disassembling the front wheel. Oil seal Bearing Spacer Bearing 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. disconnect: speedometer cable 1 3. Remove: brake calipers 2 (left and right) NOTE: Do not squeeze the brake lever when removing the brake calipers. 4. Loosen: pinch bolt (front wheel axle) 1 front wheel axle 2 5.
FRONT WHEEL AND BRAKE DISCS CHAS Front wheel radial runout limit 1.0 mm Front wheel lateral runout limit 0.5 mm 4. Check: wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings. oil seals Damage/wear Replace. 5. Replace: wheel bearings (New) oil seals (New) a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. c.
FRONT WHEEL AND BRAKE DISCS CHAS Brake disc deflection limit (maximum) Front: 0.2 mm Rear: 0.15 mm a. Place the motorcycle on a suitable stand so that the wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary. c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the deflection 2 3 mm below the edge of the brake disc. 3.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00544 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs. 1. Lubricate: wheel axle oil seal lips Recommended lubricant Lithium soap base grease 2. Install: brake disc 1 NOTE: Apply LOCTITE 648 to the threads of the brake disc bolts. Tighten the brake disc bolts in stages and in a crisscross pattern. 3.
FRONT WHEEL AND BRAKE DISCS CHAS 6. Install: brake caliper Brake caliper bolt 40 Nm (4.0 m kg) WARNING Make sure that the brake hose is routed properly. EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: After replacing the tire, wheel or both, the front wheel static balance should be adjusted. Adjust the front wheel static balance with the brake discs installed. 1. Remove: balancing weight(-s) NOTE: Place the front wheel on a suitable balancing stand. 2.
FRONT WHEEL AND BRAKE DISCS CHAS 3. Adjust: S front wheel static balance a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b. Turn the front wheel 90_ so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. 4. Check: S front wheel static balance a.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00550 REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET REAR WHEEL 150 Nm (15.0 m kg) Order Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the rear wheel NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 1 2 3 4 5 6 7 2 1 1 1 1 1 1 Chain adjusters Rear wheel axle nut Plate washer Chain puller (left) Wheel axle Chain Puller (right) Rear wheel Refer to “REMOVING/INSTALLING THE REAR WHEEL”.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS BRAKE DISC AND REAR WHEEL SPROCKET 20 Nm (2.0 m kg) 60 Nm (6.0 m kg) Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the brake disc and rear wheel sprocket Collar Brake disc Clutch hub Collar Rear wheel sprocket Clutch dampers Oil seal Bearing 1 1 1 1 1 5 1 1 For installation, the removal procedure.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Loosen: adjusting bolt 1 locknut 2 3. Remove: wheel axle nut 3 wheel axle 4 rear wheel right collar 5 NOTE: Push the rear wheel forward and remove the drive chain from the rear wheel sprocket.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: rear wheel drive hub Cracks/damage Replace. rear wheel dive hub dampers Damage/wear Replace. EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: rear wheel sprocket More than 1/4 tooth a wear Replace the rear wheel sprocket. Bent teeth Replace the rear wheel sprocket. b Correct 1 Drive chain roller 2 Rear wheel sprocket 2. Replace: rear wheel sprocket a.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: wheel axle wheel bearings oil seal lips Recommended lubricant Lithium soap base grease 2. Tighten: wheel axle nut Wheel axle nut 150 Nm (15.0 m kg) EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1.
FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS Order 1 2 3 4 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the front brake pads Clip Pad pin Pad support Brake pad 4 2 2 4 Refer to “REPLACING THE FRONT BRAKE PADS”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00578 REAR BRAKE PADS 40 Nm (4.0 m kg) Order 1 2 3 4 5 6 7 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the rear brake pads Caliper Cover Clip Pad pin Pad spring Brake pad Caliper shim 1 1 2 2 1 2 2 Refer to “REPLACING THE REAR BRAKE PADS”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES 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.
FRONT AND REAR BRAKES CHAS 3. Remove: brake pads 7 4. Measure: brake pad wear limit a Out of specification Replace the brake pads as a set. Brake pad wear limit 0.5 mm 5. Install: brake pads brake pad spring NOTE: Always install new brake pads, and a brake pad spring as a set. a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b.
FRONT AND REAR BRAKES CHAS 6. Install: brake pad pins brake pad clips brake caliper Brake caliper bolt 40 Nm (4.0 m kg) 7. Check: brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 8. Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES CHAS 5. Install: brake pad shims (onto the brake pads) brake pads brake pad spring NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set. a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 m kg) d.
FRONT AND REAR BRAKES CHAS EAS00586 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 m kg) New 30 Nm (3.0 m kg) Order Job/Part Q’ty Removing the front brake master cylinder Brake fluid 1 2 3 4 5 6 7 Brake lever Brake switch lead Front brake switch Union bolt Copper washers/Brake hose Master cylinder bracket Master cylinder Remarks Remove the parts in the order listed. Drain 1 2 1 1 2 /1 1 1 Refer to “DISASSEMBLING/ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER”.
FRONT AND REAR BRAKES CHAS New Order 1 2 3 4 Job/Part Q’ty Remarks Disassembly the parts in the order listed. Disassembling the front brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 m kg) 28 Nm (2.8 m kg) 23 Nm (2.3 m kg) Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the rear brake master cylinder Brake fluid Bolts Brake pedal Brake switch Union bolt Copper washers/brake hose Clip/reservoir hose Cotter pin/copper washer Pin Master cylinder ass’y Reservoir tank Q’ty Remarks Remove the parts in the order listed.
FRONT AND REAR BRAKES CHAS New Order 1 2 3 4 Job/Part Q’ty Remarks Disassembly the parts in the order listed. Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: rear view mirror (right) brake lever 1 2. Disconnect: brake switch coupler 2 (from the brake switch) 3. Remove: union bolt 3 copper washers 4 brake hose 5 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.
FRONT AND REAR BRAKES CHAS EAS00592 A B C D 2. Check: brake master cylinder kit 1 Damage/scratches/wear Replace. C Front D Rear E F 3. Check: front brake master cylinder reservoir 1 Cracks/damage Replace. front brake mater cylinder reservoir diaphragm 2 Damage/wear Replace. rear brake fluid reservoir 1 Cracks/damage Replace. rear brake fluid reservoir diaphragm 2 Cracks/damage Replace. E Front F Rear 4. Check: brake hoses 1 Cracks/damage/wear Replace.
FRONT AND REAR BRAKES CHAS EAS00598 ASSEMBLING AND INSTALLING FRONT BRAKE MASTER CYLINDER THE WARNING 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 NOTE: Install the brake master cylinder holder with the “UP” mark facing up.
FRONT AND REAR BRAKES CHAS 3. Fill: brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT AND REAR BRAKES CHAS EAS00610 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: copper washers (New) 1 brake hose 2 Union bolt 3 30 Nm (3.0 m kg) WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”. CAUTION: When installing the brake hose onto the brake master cylinder make sure that the brake pipe touches the projection a as shown. 2.
FRONT AND REAR BRAKES CHAS 3. Bleed: brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 5. Adjust: brake pedal position a Refer to “ADJUSTING THE REAR BRAKE” in chapter 3. Brake pedal position (below the top of the rider footrest) a 45 mm 6.
FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPER 7 Nm (0.7 m kg) 40 Nm (4.0 m kg) 30 Nm (3.0 m kg) Order 1 2 3 4 Job/Part Q’ty Remarks Remove the parts in the order listed. Drain Removing the front brake calipers Brake fluid Union bolts Copper washers Brake hoses Caliper ass’y 2 4 2 2 Refer to “DISASSEMBLING/ ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS 6 Nm (0.6 m kg) 6 Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Disassembling the front brake calipers. The following procedure applies to both of the front brake calipers. 2 Clips 1 Pad pin 1 Pad spring 2/2 Brake pads/shims 4 Caliper pistons 1 Bleed screw 4 Dust seals 4 Piston seals Remarks Disassembly the parts in the order listed. Refer to “DISASSEMBLING THE FRONT BRAKE CALIPERS”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS ESA00616 REAR BRAKE CALIPER 40 Nm (4.0 m kg) New 30 Nm (3.0 m kg) Order 1 2 3 4 Job/Part Q’ty Remarks Remove the parts in the order listed. Drain Removing the rear brake caliper Brake fluid Union bolt Copper washers Brake hose Caliper ass’y 1 2 1 1 Refer to “DISASSEMBLING/ ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS New New New New 6 Nm (0.6 m kg) Order 1 2 3 4 5 6 7 8 9 Job/Part Q’ty Disassembling the rear brake caliper 1 Cover 2 Clips 2 Pad pins 1 Pad support 2/2 Brake pads/shims 2 Caliper pistons 2 Dust seals 2 Piston seals 2 Bleed screws Remarks Disassembly the parts in the order listed. Refer to “DISASSEMBLING THE REAR BRAKE CALIPER.” For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2 brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: brake caliper pistons 1 brake caliper piston seals 2 a.
FRONT AND REAR BRAKES CHAS EAS00629 DISASSEMBLING THE REAR 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 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: brake caliper pistons 1 brake caliper piston seals 2 a. Secure the right side brake caliper pistons with a piece of wood a . b.
FRONT AND REAR BRAKES CHAS EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Every two years and Brake fluid whenever the brake is disassembled. 1. Check: brake caliper pistons 1 Rust/scratches/wear Replace the brake caliper. brake caliper cylinders 2 Scratches/wear Replace the brake caliper. brake calipers 3 Cracks/damage Replace.
FRONT AND REAR BRAKES CHAS Never use solvents on internal brake components as they will cause the piston seals to swell and distort. Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1. Install: brake caliper 1 (temporarily) copper washers (New) brake hose 2 union bolt 3 Union bolt 30 Nm (3.0 m kg) WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”.
FRONT AND REAR BRAKES CHAS Recommended brake fluid DOT 4 WARNING Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the reservoir.
FRONT AND REAR BRAKES CHAS EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING 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.
FRONT AND REAR BRAKES CHAS 4. Fill: brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT FORK CHAS EAS00647 FRONT FORK 30 Nm (3.0 m kg) 23 Nm (2.3 m kg) 23 Nm (2.3 m kg) 7 Nm (0.7 m kg) Order 1 2 3 4 5 6 Job/Part Removing the front fork Front wheel Brake calipers Brackets Front fender Bolts (upper bracket) Cap bolts Bolts (lower bracket) Front fork (left/right) Q’ty Remarks Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISCS”. 2 1 2 2 4 1/1 Refer to “REMOVING/INSTALLING THE FRONT FORK LEGS”. For installation, reverse the removal procedure.
FRONT FORK CHAS 23 Nm (2.3 m kg) 23 Nm (2.3 m kg) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Part Q’ty Remarks Disassembly the parts in the order listed. Disassembling the front fork Cap bolts O-rings Plates Spacers Spring seats Fork springs Dust seals Oil seal clips Oil seals Seal spacers Outer tube bushings Bolts (damper rod) Gaskets 2 2 2 2 2 2 2 2 2 2 2 2 2 6-42 Refer to “DISASSEMBLING/ ASSEMBLING THE FRONT FORK LEGS”.
FRONT FORK CHAS 23 Nm (2.3 m kg) 23 Nm (2.3 m kg) Order 14 15 16 17 18 19 Job/Part Q’ty 2 2 2 2 2 2 Inner tubes Inner tube bushings Oil flow stoppers Damper rods Damper rod springs Outer tubes Remarks Refer to “DISASSEMBLING/ ASSEMBLING THE FRONT FORK LEGS”. For assembly, reverse the disassembly procedure.
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.
FRONT FORK CHAS 4. Remove: dust seal 1 oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 5. Remove: damper rod bolt 1 NOTE: While holding the damper rod with the damper rod holder 2 and T-handle 3 , loosen the damper rod bolt. Damper rod holder (30 mm) 90890-01327 T-Handle 90890-01326 6. Remove: inner tube a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c.
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. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: spring free length a Over the specified limit Replace. Spring free length limit 395 mm 3. Check: damper rod 1 Damage/wear Replace. Obstruction Blow out all of the oil passages with compressed air.
FRONT FORK CHAS EB703703 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING Make sure that the oil levels in both front fork legs are equal. Uneven oil levels can result in poor handling and a loss of stability. NOTE: When assembling the front fork leg, be sure to replace the following parts: -inner tube bushing -outer tube bushing -oil seal -dust seal Before assembling the front fork leg, make sure that all of the components are clean. 1.
FRONT FORK CHAS 4. Install: outer tube bushing 1 seal spacer 2 oil seal 3 (with the fork seal driver weight 4 and adapter 5 ) Fork seal driver weight 90890-01367 Adapter 90890-01374 CAUTION: Make sure that the numbered side of the oil seal faces up. NOTE: Before installing the oil seal, apply lithium soap base grease onto its lips. Apply fork oil onto the outer surface of the inner tube. 5. Install: oil seal clip 1 NOTE: Adjust the oil seal clip so that it fits into the outer tube groove. 6.
FRONT FORK CHAS 7. Fully compress the front fork leg. 8. Fill: front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 538 cm3 Recommended oil Fork oil 10w or equivalent CAUTION: Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 9.
FRONT FORK CHAS NOTE: Install the fork spring with its smaller pitch upward. Before installing the cap bolt, apply grease to the O-ring. Temporarily tighten the cap bolt. EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure that the inner fork tube is flush with the top of the upper bracket. 2.
HANDLEBAR CHAS EAS00664 HANDLEBAR 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 26 Nm (2.6 m kg) 26 Nm (2.6 m kg) 23 Nm (2.
HANDLEBAR 10 Nm (1.0 m kg) CHAS 10 Nm (1.0 m kg) 26 Nm (2.6 m kg) 26 Nm (2.6 m kg) 23 Nm (2.3 m kg) Order 14 15 16 17 Job/Part Q’ty Remarks 1 1 2 1 Refer to “REMOVING THE HANDLEBAR”. Handlebar grip Collar Upper handlebar holders Handlebar 6-52 Refer to “INSTALLING THE HANDLEBAR”. For installation, reverse the removal procedure.
HANDLEBAR CHAS EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: throttle cable housing 1 NOTE: While removing the throttle cable housing, pull back the rubber cover 2 . 3. Remove: handlebar grip (left) 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. EAS00668 CHECKING THE HANDLEBAR 1.
HANDLEBAR CHAS 3. Install: handlebar grip a. Apply a light coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag. WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried. EAS00671 INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2.
THE HANDLEBAR CHAS 3. Install: handlebar grip 1 left grip end 2 NOTE: There should be 1 3 mm of clearance a between the handlebar grip and the left grip end. 4. Install: left handlebar switch 1 NOTE: Align the pin on the left handlebar switch with the hole a in the handlebar. 5. Install: master cylinder (clutch) 1 master cylinder bracket 2 NOTE: Align the mating surfaces of the master cylinder with the punch mark a on the handlebar. 6.
THE HANDLEBAR CHAS NOTE: Align the pin on the right handlebar switch with the hole a in the handlebar. There should be 1 3 mm of clearance b between the throttle grip and the right grip end. 8. Install: master cylinder ass’y (front brake) 9. Adjust: throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.
STEERING HEAD CHAS EAS00676 STEERING HEAD LOWER BRACKET 110 Nm (11.0 m kg) 1st 52 Nm (5.2 m kg) 2nd 18 Nm (1.8 m kg) 40 Nm (4.0 m kg) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISCS”. Refer to “FRONT FORK”. Refer to “HANDLEBAR”.
STEERING HEAD CHAS 110 Nm (11.0 m kg) 1st 52 Nm (5.2 m kg) 2nd 18 Nm (1.8 m kg) 40 Nm (4.0 m kg) Order 11 12 13 Job/Part Q’ty Bearing Dust seal Lower handlebar holders Remarks 1 1 2 For installation, reverse the removal procedure.
STEERING HEAD CHAS EAS00679 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 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, then remove the upper ring nut with the ring nut wrench.
STEERING HEAD CHAS a. Remove the bearing races 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 dust seal and new bearing races. CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Always replace the bearing balls and bearing races as a set. Whenever the steering head is disassembled, replace the dust seal. 4.
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN 23 Nm (2.3 m kg) 7 Nm (0.7 m kg) 23 Nm (2.3 m kg) 125 Nm (12.5 m kg) 30 Nm (3.0 m kg) 7 Nm (0.7 m kg) Order Job/Part Q’ty Remove the parts in the order listed. Removing the rear shock absorber, swingarm and drive chain.
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS 23 Nm (2.3 m kg) 7 Nm (0.7 m kg) 23 Nm (2.3 m kg) 125 Nm (12.5 m kg) 30 Nm (3.0 m kg) 7 Nm (0.7 m kg) Order 11 12 Job/Part Q’ty Bearings Drive chain Remarks 2 1 For installation, reverse the removal procedure.
REAR SHOCK ABSORBER, SWINGARMAND DRIVE CHAIN CHAS EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you 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 and gas cylinder.
REAR SHOCK ABSORBER, SWINGARMAND 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 lower bolt 1 NOTE: When removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down. 3.
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1. Check: rear shock absorber rod 1 Bends/damage Replace the rear shock absorber assembly. rear shock absorber Gas leaks/oil leaks Replace the rear shock absorber assembly. spring 2 Damage/wear Replace the rear shock absorber assembly. gas cylinder 3 Damage/gas leaks Replace. bushings Damage/wear Replace. dust seals Damage/wear Replace.
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS 4. Check: dust covers 1 washers 2 Damage/Wear Replace. bearings 3 Damage/Pitting Replace. bush 4 Damage/Scratches Replace. EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: ten-link section a of the drive chain Out of specification Replace the drive chain. Ten-link drive chain section limit (maximum) 150 mm NOTE: While measuring the ten-link section, push down on the drive chain to increase its tension.
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS 4. Check: O-rings 1 Damage Replace the drive chain. drive chain rollers 2 Damage/wear Replace the drive chain. drive chain side plates 3 Damage/wear Replace the drive chain. Cracks Replace the drive chain and make sure that the battery breather hose is properly routed away from the drive chain and below the swingarm. 5. Lubricate: drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6.
CHAS
– ELEC + 7
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 BULB SOCKETS . . . . . . . . . . . . . . . . . . TYPES OF BULBS . . .
ELEC
ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 10 Main switch Fuel sender Starter relay Starting circuit cutoff relay Battery Oil level relay Flasher relay Ignitior unit Neutral switch Sidestand switch 11 12 13 14 Rear brake switch Oil level switch Horns Ignition coils 7-1 ELEC
SWITCHES ELEC 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.
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 Horn switch Clutch switch Dimmer switch Pass switch Turn signal switch Main switch Front brake switch Engine stop switch Start switch Lights switch (for Europe) Rear brake switch Fuse Side stand switch Neutral switch Oil level switch *1: for Europe *2: for AUS 9 10 11 12 13 14 15 7-4 ELEC
CHECKING THE BULBS AND BULB SOCKETS ELEC 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 The bulbs used on this motorcycle are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS ELEC WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: bulb socket (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. a. Install a good bulb into the bulb socket. b.
2 3 5 6 9 10 11 12 14 15 18 Main fuse Battery Main switch Ignition fuse Ignitor unit Ignition coils Spark plugs Pickup coil Neutral switch Sidestand switch Engine stop switch IGNITION SYSTEM 7-8 ELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM
IGNITION SYSTEM ELEC EAS00739 EAS00737 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. 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.
ELEC 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.
IGNITION SYSTEM ELEC EAS00749 8. Main switch S Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the main switch OK? YES NO Replace the main switch. Secondary coil resistance 9.5 X 14.3 kΩ at 20_C S Is the ignition coil OK? EAS00750 YES 9. Engine stop switch NO S Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? Replace the ignition coil. YES EAS00748 NO 7.
IGNITION SYSTEM ELEC EAS00754 13. Wiring Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the ignition system’s wiring properly connected and without defects? NO Properly connect or repair the ignition system’s wiring. 7-12 YES Replace the ignitor unit.
2 3 4 5 6 7 8 14 15 17 18 38 Main fuse Battery Starter relay Main switch Ignition fuse Starter motor Starting circuit cutoff relay Neutral switch Sidestand switch Start switch Engine stop switch Clutch switch ELECTRIC STARTING SYSTEM 7-13 ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM ELEC EAS00739 EAS00757 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The starter motor fails to turn. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. starting circuit cutoff relay 5. 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) Open-circuit voltage 12.
ELECTRIC STARTING SYSTEM EAS00759 ELEC EAS00760 4. Starting circuit cutoff relay 5. Diode Disconnect the relay unit from the coupler. Connect the pocket tester (Ω 1) and battery (12 V) to the relay unit terminals as shown. Disconnect the starting circuit cutoff relay from the coupler. Connect the pocket tester (Ω 1) to the starting circuit cutoff relay terminals as shown. Measure the starting circuit cutoff relay for continuity as follows.
ELECTRIC STARTING SYSTEM EAS00761 ELEC EAS00750 6. Starter relay 8. Engine stop switch Disconnect the starter relay from the coupler. Connect the pocket tester (Ω 1) and battery (12 V) to the starter relay coupler as shown. 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/white 2 NO Replace the right handlebar switch.
ELECTRIC STARTING SYSTEM EAS00764 12. Start switch Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the start switch OK? YES NO Replace the right handlebar switch. EAS00766 13. Wiring 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 repair the starting system’s wiring. YES The starting system circuit is OK.
ELECTRIC STARTING SYSTEM ELEC STARTER MOTOR 10 Nm (1.0 m kg) Order 1 2 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the starter motor Starter motor lead Starter motor assembly 1 1 For installation, reverse the removal procedure. 1 2 3 4 5 6 7 Disassembling the starter motor Starter motor front cover Washer set Starter motor rear cover washer set Brush holder/brush Armature assembly Starter motor yoke Disassembly the pats in the order listed.
ELECTRIC STARTING SYSTEM ELEC EAS00769 Checking The Starter Motor 1. Check: S commutator Dirt Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification Replace the starter motor. Min. commutator diameter 27 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 0.7 mm NOTE: The mica must be undercut to ensure proper operation of the commutator. 4.
ELECTRIC STARTING SYSTEM ELEC 5. Measure: brush length a Out of specification Replace the brushes as a set. Min. brush length 5 mm 6. Measure: brush spring force Out of specification Replace the brush springs as a set. Brush spring force 7.65 X 10.01 N (0.780 X 1.021 kg) 7. Check: gear teeth Damage/wear Replace the gear. 8. Check: oil seal Damage/wear Replace the defective part(-s). EAS00772 Assembling The Starter Motor 1.
CHARGING SYSTEM ELEC EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 1 2 3 5 7-22 Generator Main fuse Battery Main switch
CHARGING SYSTEM ELEC EAS00739 EAS00774 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The battery is not being charged. Check: 1. main fuse 2. battery 3. charging voltage 4. startor coil assembly resistance 5. brush check 6. field coil resistance 7. main switch 8. wiring (of the entire charging system) Open-circuit voltage 12.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals.
CHARGING SYSTEM ELEC EAS00777 5. Brush check NOTE: Make sure that the battery is fully charged. S Remove the brush holder 1 . S Is the charging voltage within specification? NO YES The charging circuit is OK. EAS00776 4. Stator coil assembly resistances S Check the brush spring. S Measure the overall length of brushes. S Remove the generator cover. S Connect the pocket tester (Ω 1) to the stator coil assembly coupler as shown. Brush spring force 5.10 X 5.69 N (0.52 X 0.
CHARGING SYSTEM EAS00778 6. Field coil resistance S Connect the pocket tester (Ω as shown. 1) to the rotor S Measure the field coil resistance. Field coil resistance 2.8 X 3.0 Ω at 20_C S Is the field coil OK? YES NO Replace the field coil. EAS00749 7. Main switch S Check the mian switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the main switch OK? YES NO Replace the main switch. EAS00779 8. Wiring S Check the wiring connections of the entire charging system.
CHARGING SYSTEM ELEC A.C. GENERATOR 7 Nm (0.7 m kg) 25 Nm (2.5 m kg) Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Q’ty Remarks Disassembly the parts in the order list. Disassembling the A.C. Generator Cover Brush holder Regulator Rectifier cover Rectifier Rear cover Rotor assembly Bearing cover Bearing Bearing Stator assembly 1 1 1 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
Main fuse 3 Battery 5 Main switch 21 Lights switch 32 Meter light 37 High beam indicator light 41 Pass switch 42 Dimmer switch 44 Headlight fuse 45 Auxiliary light 46 Tail / brake light 47 Headlight 2 LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 7-27 ELEC
LIGHTING SYSTEM ELEC EAS00739 EAS00781 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light (for Europe) or meter light. Open-circuit voltage 12.8 V or more at 20_C Check: 1. main, and headlight fuses 2. battery 3. main switch 4. lights switch (for Europe) 5. dimmer switch 6. pass switch 7.
LIGHTING SYSTEM EAS00784 ELEC EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 5. Dimmer switch Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the dimmer switch OK? YES 1. Headlight bulb and socket Check the headlight bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the headlight bulb and socket OK? NO The dimmer switch is faulty. Replace the left handlebar switch.
LIGHTING SYSTEM Headlight Tester positive probe yellow 1 or green 2 Tester negative probe black 3 High beam indicator light Tester positive probe yellow 4 Tester negative probe black 5 2. Voltage 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 Set the main switch to “ON”. Set the light switch to “ ” or “ ”.
ELEC LIGHTING SYSTEM 2. Voltage 2. Voltage Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. 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 Tester positive probe blue/red 1 Tester negative probe black 2 L/R Set the main switch to “ON”. Set the light switch to “ ” or “ ”.
Main fuse Battery Main switch 5 7-32 49 48 46 40 39 36 light (right) Oil level warning light Turn signal switch Horn switch Tail/brake light Front turn signal light Rear turn signal light 35 Turn signal indicator light (left 34 Turn signal indicator 33 Neutral indicator light 31 Fuel sender 30 Fuel gauge 26 Oil level switch 25 Flasher relay 24 Horn 23 Rear brake light switch 22 Signaling system fuse 19 Front brake light switch 16 Oil level relay 14 Neutral switch 3 2 SIGNALING SYS
SIGNALING SYSTEM EB806010 ELEC EAS00739 TROUBLESHOOTING 2. Battery S Any of the following fail to light: turn signal light, brake light or an indicator light. S The horn fails to sound. S Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. Check: 1. main and signaling system fuses 2. battery 3. main switch 4. wiring (of the entire signaling system) Open-circuit voltage 12.
SIGNALING SYSTEM ELEC EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. Disconnect the black 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? 1. Horn switch Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the horn switch OK? YES NO Br Replace the left handlebar switch. 2.
SIGNALING SYSTEM EAS00797 Set the main switch to “ON”. Pull in the brake lever or push down on the brake pedal. Measure the voltage (12 V) of yellow at the tail/brake light coupler (wire harness side). Is the voltage within specification? 2. A tail/brake light fails to come on. 1. Tail/brake light bulb and socket Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
SIGNALING SYSTEM Tester positive probe brown/white 1 Tester negative probe ground 2. Turn signal switch Check the turn signal for continuity. Refer to “CHECKING THE SWITCHES”. Is the turn signal switch OK? YES ELEC NO Replace the left handlebar switch. 3. Voltage Connect the pocket tester (DC 20 V) to the flasher relay coupler (wire harness side) as shown. Set the main switch to “ON”. Set the turn signal switch to “ ” or “ ”.
SIGNALING SYSTEM EAS00760 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. ELEC 3. Diode Disconnect the starting circuit cutoff relay from the coupler. Connect the pocket tester (Ω 1) to the starting circuit cutoff relay terminals as shown.
ELEC SIGNALING SYSTEM 4. Voltage 2. Oil level switch Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Drain the engine oil and remove the oil level switch from the oil pan. Check the oil level switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the oil level switch OK? Tester positive probe brown 1 Tester negative probe sky blue 2 YES NO Replace the oil level switch. 3.
SIGNALING SYSTEM ELEC S Set the main switch to “ON”. S Measure the voltage (12 V) of brown 1 and black/red at the meter assembly coupler. S Is the voltage within specification? 4. Starting circuit cutoff relay S Disconnect the relay unit from the coupler. S Connect the pocket tester (Ω 1) to the relay unit terminals as shown. Tester positive probe red/blue 1 Tester negative probe brack/red 2 YES This circuit is OK.
SIGNALING SYSTEM Check that the fuel level gauge needle move to “F” to “E”. NOTE: Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes. 2. Voltage 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 black 2 Does the fuel level gauge needle move appropriately? YES This circuit is OK. Set the main switch to “ON”.
SELF-DIAGNOSIS ELEC EAS00834 SELF-DIAGNOSIS The XJR1300 (L) features a self-diagnosing system for the following circuit(-s): throttle position sensor ignition circuit If any of these circuits are defective, their respective condition codes will be displayed on the tachometer when the main switch is set to “ON” (irrespective of whether the engine is running or not). The engine is not operated condition code at 2,000 r/min.
ELEC SELF-DIAGNOSIS EAS00835 1. Wire harness TROUBLESHOOTING Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? The tachometer starts to display the self-diagnosis sequence. Check: 1. throttle position sensor 2. ignition circuit YES NOTE: Before troubleshooting, remove the following part(-s): 1) rider seat 2) fuel tank 3) air filter case Troubleshoot with the following special tool(-s). NO Repair or replace the wire harness. EB812401 2.
SELF-DIAGNOSIS ELEC EAS00749 2. Ignition circuit CIRCUIT DIAGRAM 3. Main switch Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the main switch OK? YES NO Replace the main switch. EB812400 4. Wire harness Check the ire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? YES NO Repair or replace the wire harness. EAS00760 5. Starting circuit cutoff relay Disconnect the starting circuit cutoff relay from the coupler.
SELF-DIAGNOSIS NOTE: When you switch the “–” and “+” leads of the digital pocket tester the readings in the above chart will be reversed. Are the tester readings correct? YES NO Replace the ignitor unit. Replace the relay unit.
TRBL SHTG 8
TRBL SHTG CHAPTER 8. TROUBLESHOOTING STARTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1 8-1 8-1 INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . .
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.
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 FUEL SYSTEM Carburetors Faulty starter plunger Loose or clogged pilot jet Loose or clogged pilot air jet Damaged or loose carburetor joint Incorrectly synchronized carburetors Incorrectly adjusted engine idling speed (throt
FAULTY CLUTCH/OVERHEATING TRBL SHTG EAS00852 FAULTY CLUTCH CLUTCH SLIPS Clutch Improperly assembled clutch Improperly assembled clutch master cylinder Improperly assembled clutch release cylinder Loose or fatigued clutch spring Loose union bolt Worn friction plate Worn clutch plate Damaged clutch release cylinder Engine oil Incorrect oil level Incorrect oil viscosity (low) Deteriorated oil CLUTCH DRAGS Clutch Unevenly tensioned clutch springs Warped pressure plate Bent clutch
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING TRBL SHTG EAS00857 POOR BRAKING PERFORMANCE 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 EAS00860 FAULTY FRONT FORK LEGS LEAKING OIL Bent, damaged or rusty inner tube Damaged outer tube Incorrectly installed oil seal
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 TURN SIGNAL BLINKS SLOWLY Faulty turn signal relay Faulty main switch Faulty turn signal switch Wrong turn signal bulb TURN SIGNAL REMAINS LIT Faulty turn signal relay Burnt-out-turn
TRBL SHTG
XJR1300’99 WIRING DIAGRAM for EUR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 COLOR CODE B ..... Br . . . . Ch . . . Dg . . . G .... Gy . . . L ..... Lg . . . . Black Brown Chocolate Dark green Green Gray Blue Light green O .... Sb . . . . P ..... R..... Y ..... B/ L . . . B/ R . . . B/ Y . . . Orange Sky blue Pink Red Yellow Black/ Blue Black/ Red Black/ Yellow Br/ L . . Br/ W . G/Y . . L/B . . . L/R . . .
XJR1300L WIRING DIAGRAM for AUS COLOR CODE B . . . . . Black Br . . . . Brown Ch . . . Chocolate Dg . . . Dark green G . . . . Green Gy . . . Gray L . . . . . Blue Lg . . . . Light green O .... Sb . . . . P ..... R..... Y ..... B/L . . . B/R . . . B/Y . . . Orange Sky blue Pink Red Yellow Black/Blue Black/Red Black/Yellow 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 46 47 48 49 Br/L . . Br/W . G/Y . . L/B . . . L/R . . . L/W . .
