Yamaha XVS 125 00 Service Manual

EB000000
XVS125
SERVICE MANUAL
2000 by Yamaha Motor Co.,Ltd.
First edition, January 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-
torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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” on the following page.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“Periodic checks and Adjustments”), where the sub-section title(-s) appears.
(In Chapter 3, “Periodic checks and Adjustments”, the sub-section title appears at the top of each page,
instead of the section title.)
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
6
1
2
7
EAS00009
1 2 SYMBOLS
GEN The following symbols are not relevant to every
SPEC vehicle.
INFO Symbols 1 to 8 indicate the subject of each
chapter.
3 4
1 General information
CHK 2 Specifications
ADJ ENG 3 Periodic checks and adjustments
4 Engine
5 6 5 Carburetor(-s)
6 Chassis
7 Electrical system
CARB CHAS 8 Troubleshooting
7 8
TRBL
ELEC
SHTG
Symbols 9 to 16 indicate the following.
9 10
9 Serviceable with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
11 12
13 Tightening torque
14 Wear limit, clearance
15 Engine speed
16 Electrical data
13 14
15 16
Symbols 17 to 22 in the exploded diagrams indi-

17 18 19
cate the types of lubricants and lubrication
points.
17 Engine oil
18 Gear oil
20 21 22 19 Molybdenum disulfide oil
20 Wheel bearing grease
21 Lithium soap base grease
22 Molybdenum disulfide grease
Symbols 23 to 24 in the exploded diagrams indi-
23 24
cate the following:
23 Apply locking agent (LOCTITE)
24 Replace the part
EAS00011
INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG
4
CARBURETOR CARB
5
CHASSIS CHAS
6
ELECTRICAL SYSTEM ELEC
7
TROUBLESHOOTING TRBL
SHTG 8
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

GEN
INFO
GEN
MOTORCYCLE IDENTIFICATION INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB10010
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped
into the right side of the steering head.
MODEL CODE
The model code label 1 is affixed to the frame.
This information will be needed to order spare
parts.
1-1
GEN
IMPORTANT INFORMATION INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCE-
DURES
1. Remove all dirt, mud, dust and foreign mate-
rial before removal and disassembly.
2. Use proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS” section.
3. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts that
have been ”mated” through normal wear.
Mated parts must always be reused or re-
placed as an assembly.
4. During machine disassembly, clean all of the
parts and place them in trays in the order of
disassembly. This will speed up assembly
and allow for the correct installation of all
parts.
5. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
1-2
GEN
IMPORTANT INFORMATION INFO
EB101030
LOCK WASHERS/PLATES AND COTTER

PINS
1. Replace all lock washers/plates 1 and cot-
ter pins after removal. Bend lock tabs along
OR
the bolt or nut flats after the bolt or nut has
been tightened to specification.
EB101040
BEARINGS AND OIL SEALS

1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible. When installing oil seals, apply a light
coating of lightweight lithium base grease to
the seal lips. Oil bearings liberally when
installing, if appropriate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassemb-
ly. Always replace piston pin clips after one
use. Replace distorted circlips. When instal-
ling a circlip 1 , make sure that the sharp-
edged corner 2 is positioned opposite the
thrust 3 it receives See sectional view.
4 Shaft
1-3
GEN
CHECKING THE CONNECTIONS INFO
EB103000
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 sev-
eral times.
3. Check:
all connections
Loose connection Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
NOTE:
Make sure that all connections are tight.
5. Check:
continuity
(with the pocket tester)
Pocket tester
90890-03112
NOTE:
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer
available at most part stores.
1-4
GEN
SPECIAL TOOLS INFO
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques. Special tools may differ by shape and part number from country to country. In
such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name / How to use Illustration

Bolt Slide hammer bolt/Weight
90890-01083
Weight These tools are used to remove the rocker

90890-01084 arm shaft.
Valve adjusting Tappet adjusting tool
tool
This tool is used to adjust the valve

90890-01311 CLEARANCE.
Damper rod T-handle/Damper rod holder
holder
90890-01365
T-handle These tools are needed to loosen and
90890-01326 tighten the damper rod holding bolt.
Piston pin puller
90890-01304
This tool is used to remove the piston pin.

Fuel level gauge
90890-01312
This gauge is used to measure the fuel level in
the float chamber.
Flywheel puller
Flywheel puller
90890-01362
These tools are needed to remove the rotor.
Ring nut wrench
90890-01403
This tool is used to loosen and tighten the
steering stem ring nut.
Weight Front fork seal driver weight/
90890-01367 Adapter (33 mm)
Adapter These tools are needed when installing the

90890-01369 slide metal, oil seal and dust seal into the fork.
1-5
GEN
SPECIAL TOOLS INFO
Sheave holder
90890-01701
This tool is needed to hold the rotor, when
removing or installing the rotor bolt.
Clutch holder
90890-04086
This tool is heed to hold the clutch when
removing or installing the clutch boss nut.
Valve spring compressor
90890-04019
This tool is needed to remove and install the
valve assemblies.
Valve guide remover (5.0 mm)
90890-04097
This tool is needed to remove the valve guide.

Valve guide installer (5.0 mm)
90890-04098
This tool is needed to install the valve guides
properly.
Valve guide reamer (5.0 mm)
90890-04099
This tool is needed to rebore the new valve
guide.
Timing light
90890-03141
This tool is necessary for checloing ignition
timing.
Pocket toster
90890-03112
This instrument is needed for checking the
electrical system.
Engine tachometer
90890-03113
This tool is needed for observing engine r/min.
1-6
GEN
SPECIAL TOOLS INFO
Ignition checker
90890-06754
This instrument is necessary for checking the
ignition system components.
Compression gauge set
90890-03081
These tools are needed to measure engine
compression.
Yamaha bond No.1215
90890-85505
This sealant (bond) is used for crankcase mat-
ing surfaces, etc.
1-7
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
ELECTRICAL SPECIFICATONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
LUBRICATIONS POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . 2-20

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
ENGINE OIL LUBRICATION CHART SPECIFICATIONS . . . . . . . . . . . . 2-22
ENGINE OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

SPEC
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5JX1/5JX2
Dimensions
Overall length 2,320 mm
Overall width 910 mm
Overall height 1,075 mm
Seat height 670 mm
Wheelbase 1,530 mm
Minimum ground clearance 150 mm
Minimum turning radius 2,900 mm
Weight
Wet (with oil and a full fuel tank) 156 kg
Dry (with out oil and fuel) 144 kg
Maximum load 183 kg
(total of cargo, rider, passenger, and
accessaries)
2-1
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Air-cooled, 4-stroke, SOHC SSS
Displacement 124 cm3 SSS
Cylinder arrangement V-2 cylinder SSS
Bore stroke 41 47 mm SSS
Compression ratio 11.0 : 1 SSS
Engine idling speed 1,250 1,450 r/min SSS
Vacuum pressure at engine idling 24 kPa (0.24 kg/cm2) SSS
speed
Standard compression pressure 1,200 kPa (12 kg/cm2) at 400 r/min SSS
(at sea level)
Fuel
Recommended fuel Regular unleaded gasoline SSS
Fuel tank capacity
Total (including reserve) 11 L SSS
Reserve only 3.4 L SSS
Engine oil
Lubrication system Wet sump SSS
Recommended oil SSS
Temp. _C
SAE20W40SE or SAE10W30SE
Quantity
Total amount 1.75 L SSS
Without oil filter cartridge 1.4 L SSS
replacement
With oil filter cartridge replacement 1.6 L SSS
Oil pressure (hot) 50 kPa at 1,300 r/min SSS
(0.5 kgf/cm2 at 1,300 r/min)
Relief valve opening pressure 450 550 kPa (4.5 5.5 kgf/cm2) SSS
Oil filter
Oil filter type paper SSS
Bypass valve opening pressure 450 550 kPa (4.5 5.5 kgf/cm2) SSS
Oil pump
Oil pump type Trochoidal SSS
Inner-rotor-to-outer-rotor-tip 0.15 mm 0.2 mm
clearance
Outer-rotor-to-oil-pump-housing 0.03 0.09 mm 0.15 mm
clearance
Housing and rotor clearance 0.03 0.09 mm 0.15 mm
2-2
Item Standard Limit

Starting system type Electric starter
Spark plugs
Model (manufacturer) quantity CR7HSA (NGK), U22FSR-U 1
(DENSO)
Spark plug gap 0.6 0.7 mm
Cylinder head
Max. warpage 0.05 mm
Camshafts
Drive system Chain drive (left and right)
Camshaft cap inside diameter 22.000 22.021 mm
Camshaft journal diameter 21.96 21.98 mm
Camshaft-journal-to-camshaftcap 0.020 0.061 mm
clearance
Camshaft lobe dimensions
Intake
Measurement A 26.190 mm 26.15 mm
Measurement B #1 : 21.045 mm 21.005 mm
#2 : 21.087 mm 21.047 mm
Measurement C 5.19 mm
Exhaust
Measurement A 26.190 mm 26.15 mm
Measurement B #1 : 21.087 mm 21.047 mm
#2 : 21.045 mm 21.005 mm
Measurement C 5.19 mm
Max. camshaft runout 0.015 mm
2-3
Item Standard Limit

Timing chain
Model/number of links SILENT CHAIN/110
Tensioning system Automatic
Rocker arm/rocker arm shaft
Bearing inside diameter 10.000 10.015 mm 10.035 mm
Shaft outside diameter 9.981 9.991 mm 9.961 mm
Arm-to-shaft clearance 0.009 0.034 mm 0.08 mm
Valves, valve seats, valve guides
Valve clearance (cold)
Intake 0.08 0.12 mm
Exhaust 0.10 0.14 mm
Valve dimensions
Head diameter Face width Seat width Margin thickness

Valve head diameter A
Intake 19.9 20.1 mm
Valve face width B
Intake 1.2 2.5 mm
Exhaust 1.5 3.0 mm
Valve seat width C
Intake 0.9 1.1 mm 1.6 mm
Exhaust 0.9 1.1 mm 1.6 mm
Valve margin thickness D
Intake 0.5 0.9 mm
Exhaust 0.7 1.3 mm
Valve stem diameter
Intake 4.975 4.990 mm 4.950 mm
Exhaust 4.960 4.975 mm 4.953 mm
Valve guide inside diameter
Intake 5.000 5.012 mm 5.03 mm
Exhaust 5.000 5.012 mm 5.03 mm
Valve-stem-to-valve-guide clearance
Intake 0.010 0.037 mm 0.08 mm
Exhaust 0.025 0.052 mm 0.10 mm
Valve stem runout 0.02 mm
Valve seat width

Intake 0.9 1.1 mm 1.6 mm
Exhaust 0.9 1.1 mm 1.6 mm
2-4
Item Standard Limit

Valve springs
Free length
Intake 29.71 mm 27.81 mm
Exhaust 29.71 mm 27.81 mm
Installed length (valve closed)
Intake 25.6 mm SSS
Exhaust 25.6 mm SSS
Compressed spring force
(installed)
Intake 120.6 138.3 N (12.06 13.83 kg) SSS
Exhaust 120.6 138.3 N (12.06 13.83 kg) SSS
Spring tilt
Intake SSS 2.5_/1.3 mm

Exhaust SSS 2.5_/1.3 mm
Winding direction (top view)
Intake Clockwise SSS
Exhaust Clockwise SSS
Cylinders
Cylinder arrangement Air coded 4-stroke SSS
Bore stroke 41 47 mm SSS
Compression ratio 11.0 : 1 SSS
Bore 40.99 41.03 mm 41.1 mm
2-5
Item Standard Limit

Pistons
Piston-to-cylinder clearance 0.02 0.04 mm 0.15 mm
Diameter D 40.96 41.00 mm
Height H 3 mm
Piston pin bore (in the piston)
Diameter 13.002 13.013 mm 13.045 mm
Offset 0 mm
Offset direction Intake side
Piston pins
Outside diameter 12.996 13.000 mm 12.976 mm
Piston-pin-to-piston-pin-bore 0.002 0.017 mm
clearance
Piston rings
Top ring
Ring type Barrel

Dimensions (B T) 0.8 1.7 mm
End gap (installed) 0.15 0.30 mm 0.4 mm
Ring side clearance 0.02 0.08 mm 0.12 mm
2nd ring
Ring type Taper

End gap (installed) 0.15 0.30 mm 0.4 mm
Ring side clearance 0.02 0.06 mm 0.12 mm
Oil ring

End gap (installed) 0.2 0.7 mm
2-6
Item Standard Limit

Connecting rods
Crankshaft-pin-to-big-end-bearing 0.020 0.048 mm
clearance
Crankshaft
Width A 67.95 68.00 mm

Max. runout C 0.03 mm
Big end side clearance D 0.40 1.05 mm
Crankshaft-journal-to-crankshaft- 0.020 0.048 mm
journal-bearing clearance
Clutch
Clutch type Wet, multiple disc
Clutch release method Inner push, cam push
Clutch release method operation Cable operation
Operation Left hand operation
Clutch cable free play (at the end 5 10 mm
of the clutch lever)
Friction plates
Thickness 2.9 3.1 mm 2.5 mm
Plate quantity 5 pcs
Clutch plates
Thickness 1.9 2.1 mm
Plate quantity 4 pcs
Max. warpage 0.05 mm
Clutch springs
Free length 34.6 mm 33.6 mm
Spring quantity 4 pcs
2-7
Item Standard Limit

Transmission
Transmission type Constant mesh, 5-speed
Primary reduction system Spur gear
Primary reduction ratio 85/25 (3.400)
Secondary reduction system Chain drive
Secondary reduction ratio 59/16 (3.688)
Operation Left-foot operation
Gear ratios
1st gear 37/14 (2.643)
2nd gear 32/19 (1.684)
3rd gear 29/23 (1.261)
4th gear 26/26 (1.000)
5th gear 23/27 (0.852)
Max. main axle runout 0.08 mm
Max. drive axle runout 0.08 mm
Shifting mechanism
Shift mechanism type Cam drum
Max. shift fork guide bar bending 0.025 mm
installed shift rod length 267.8 mm
Air filter type Dry element
Carburetors
Model (manufacturer) quantity BDS26 1 (MIKUNI)
Throttle cable free play (at the 3 5 mm
flange of the throttle grip)
ID mark 5JX1 00
Main jet #90
Main air jet #120

Jet needle 4DHM20-2/3
Needle jet N-8
Pilot air jet #135
Pilot outlet 0.85
Pilot jet #15
Bypass 1 0.8
Bypass 2 0.8
Bypass 3 0.8
Pilot screw turns out 2
Valve seat size 1.0
Starter jet 1 #22.5
Starter jet 2 0.7
Butterfly valve size #140
Fuel level (above the line on the 9.5 10.5 mm
float chamber)
2-8
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Double cradle SSS
Caster angle 35_ 0’ SSS
Trail 135 mm SSS
Front wheel
Wheel type Spoke wheel SSS
Rim
Size 18 1.60 SSS
Material Steel SSS
Wheel travel 140 mm SSS
Wheel runout
Max. radial wheel runout SSS 2.0 mm
Max. lateral wheel runout SSS 2.0 mm
Rear wheel
Wheel type Spoke wheel SSS
Rim
Size 15 M/C MT 3.00 SSS
Material Steel SSS
Wheel travel 100 mm SSS
Wheel runout
Max. radial wheel runout SSS 2.0 mm
Max. lateral wheel runout SSS 2.0 mm
Front tire
Tire type Tube SSS
Size 80/100 – 18 47P SSS
Model (manufacturer) CHENG SHIN, C-916 SSS
IRC MARBELLA, NF27
Tire pressure (cold)

0 90 kg 175 kPa (1.75 kg/cm2, 1.75 bar) SSS
High-speed riding 175 kPa (1.75 kg/cm2, 1.75 bar) SSS
Min. tire tread depth SSS 0.8 mm
Rear tire
Tire type Tube SSS
Size 130/90 – 15 M/C 66P SSS
Model (manufacturer) CHENG SHIN, C-915 SSS
IRC MARBELLA, NR31
Tire pressure (cold)
High-speed riding 200 kPa (2.0 kg/cm2, 2.0 bar) SSS
Min. tire tread depth 0.8 mm
2-9
Item Standard Limit

Front brakes
Brake type Single-disc brake
Operation Right-hand operation
Brake lever free play (at lever end) 5 8 mm
Recommended fluid DOT 4
Brake discs
Diameter thickness 282 5 mm
Min. thickness 4.5 mm
Max. deflection 0.15 mm
Brake pad lining thickness 6.2 mm 0.8 mm
Master cylinder inside diameter 12.7 mm

Caliper cylinder inside diameter 25.4 mm and 30.1 mm
Rear brake
Brake type Leading, trading brake
Operation Right-foot operation
Drum inside diameter 130 mm 131 mm
Shoe thickness 4 mm 2 mm
Shoe spring free length 50.5 mm
Front suspension
Suspension type Telescopic fork
Front fork type Coil spring/oil damper
Front fork travel 140 mm
Spring
Free length 304.4 mm 299.4 mm
Spacer length 180 mm
Installed length 290.3 mm
Spring rate (K1) 5.2 N/mm (0.53 kgf/mm)
Spring stroke (K1) 0 80 mm
Optional spring available NO
Fork oil
Recommended oil Suspension oil 10W or equivalent
Quantity (each front fork leg) 311 cm3
Level (from the top of the innertube, 112 mm
with the inner tube fullycompressed,
and without the fork spring)
Steering
Steering bearing type Angular ball bearings
Rear suspension
Suspension type Swingarm
Rear shock absorber assembly type Coil spring/gas-oil damper
Rear shock absorber assembly travel 70 mm
Spring
Free length 228.5 mm
Installed length 207.5 mm
Spring rate (K1) 17.7 N/mm (1.8 kgf/mm)
Spring stroke (K1) 0 40 mm
Optional spring available No
2-10
Item Standard Limit

Swingarm
Free play (at the end of the swingarm)
Radial 1.0 mm
Axial 1.0 mm
Drive chain
Model (manufacturer) 428 V (DID)
Link quantity 146
Drive chain slack 30 40 mm
Maximum ten-link section 129.5 mm
2-11
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V SSS
Ignition system
Ignition system type TCI SSS
Ignition timing 15_ BTDC at 1,350 r/min SSS
Advancer type Throttle position sensor and electrical SSS
Pickup coil resistance/color 192 288 Ω/L/Y G/W SSS
Transistorized coil ignition unit model TNDF60 (DENSO) SSS
(manufacturer)
Ignition coils
Model (manufacturer) J0226, J0227 (DENSO) SSS
Minimum ignition spark gap 6 mm SSS
Primary coil resistance 3.4 4.6 Ω SSS
Secondary coil resistance 10.4 15.6 kΩ SSS
Throttle position sensor standard 4.0 6.0 kΩ SSS
resistance
Charging system
System type AC magneto SSS
Model (manufacturer) TLMX20 (DENSO) SSS
Nominal output 14 V/23 W at 5000 r/min SSS
Stater coil resistance 0.224 0.336 Ω at 20_C W-W SSS
Voltage regulator
Regulator type Semiconductor, short circuit type SSS
Model (manufacturer) SH650D-11 (SHINDENGEN) SSS
No-load regulated voltage 14.1 14.9 V SSS
Rectifier
Model SH650D-11/SHINDENGEN SSS
Rectifier capacity 18 A SSS
Withstand voltage 200 V SSS
Battery
Battery type GT6B-3 SSS
Battery voltage/capacity 12 V 6 Ah SSS
Headlight type Halogen bulb
Indicator light type quantity LED 2
Bulbs (voltage/wattage quantity)
Headlight 12 V 60 W/55 W 1 SSS
Auxiliary light 12 V 4 W 1 SSS
Tail/brake light 12 V 21 W/5 W 1 SSS
Turn signal light 12 V 21 W 4 SSS
2-12
ELECTRICAL SPECIFICATIONS SPEC
Item Standard Limit

Indicator light 12 V 1.7 W 4
Meter light 12 V 1.7 W 1
Electric starting system
System type Constant mesh
Starter motor
Model 5JX
Power output 0.4 kW
Brushes
Overall length 10 mm 3.5 mm
Spring force 5.52 8.28 N (563 844 gf)
Commutator resistance 0.0171 0.0209 Ω
Commutator diameter 22 mm 21 mm
Mica undercut 1.5 mm
Starter relay
Model (manufacturer) MS5F-561 (JIDENCO)
Amperage 180 A
Coil resistance 4.18 4.62 Ω
Horn
Horn type Plain
Model (manufacturer) quantity YF-12 (NIKKO) 1
Max. amperage 3A
Flasher relay
Relay type Full-transistor
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency 75 95 cycles/min.
Wattage 21 W 2 + 3.4 W
Fuses (amperage quantity)
Main fuse 30 A 1
Headlight fuse 15 A 1
Signaling system fuse 10 A 1
Ignition fuse 10 A 1
Carburetor heater fuse 10 A 1
Thermo switch 4TR (NIPPON TEXAS INSTRUMENT)
Model (manufacturer)
2-13
GENERAL TORQUE SPECIFICATIONS/
CONVERSION TABLE SPEC
EB202001 EAS00028
GENERAL TORQUE CONVERSION TABLE

SPECIFICATIONS All specification data in this manual are listed
This chart specifies torque for standard fasten- in SI and METRIC UNITS.
ers with standard I.S.O. pitch threads. Torque Use this table to convert METRIC unit data to
specifications for special components or as- IMPERIAL unit data.
semblies are provided for each chapter of this
Ex.
manual. To avoid warpage, tighten multi-fasten-
er assemblies in a crisscross fashion, in pro- METRIC MULTIPLIER IMP
gressive stages, until the specified torque is
reached. Unless otherwise specified, torque ** mm x 0.03937 = ** in
specifications require clean, dry threads. Com- 2 mm x 0.03937 = 0.08 in
ponents should be at room temperature.
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
mSkg 7.233 ftSlb
mSkg 86.794 inSlb
Torque
cmSkg 0.0723 ftSlb
cmSkg 0.8679 inSlb
kg 2.205 lb
Weight
g 0.03527 oz
km / hr 0.6214 mph
km 0.6214 mi
A: Distance between flats m 3.281 ft
Distance
m 1.094 yd
B: Outside thread diameter
cm 0.3937 in
mm 0.03937 in
General torque
cc (cm3) 0.03527 oz (IMP liq.)
A B specifications Volume / cc (cm3) 0.06102 cuSin
(Nut) (Bolt) Capacity lt (liter) 0.8799 qt (IMP liq.)
Nm mSkg It (liter) 0.2199 gal (IMP liq.)
10 mm 6 mm 6 0,6 kg / mm 55.997 lb / in
Miscella-
kg / cm2 14.2234 psi (lb / in2)
12 mm 8 mm 15 1,5 neous
Centigrade 9/5 (_C) + 32 Fahrenheit (_F)
14 mm 10 mm 30 3,0
17 mm 12 mm 55 5,5
19 mm 14 mm 85 8,5
22 mm 16 mm 130 13,0
2-14
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Tightening torques
Tightening
Thread torque
Part to be tightened
g Part name Q’ty
y Remarks
size
Nm mkg
Cylinder head and cylinder Bolt M8 8 22 2.2
Cylinder head (timing chain side, long) Bolt M6 4 12 1.2
Cylinder head (timing chain side, short) Bolt M6 4 12 1.2
Cam sprocket cover (hexagon) Bolt M6 4 10 1.0
Cam sprocket cover Bolt M6 2 10 1.0
Cylinder head (exhaust pipe) Stud bolt M6 4 7 0.7
Cylinder head cover bracket Bolt M6 2 7 0.7
Cylinder head cover Screw M6 4 0.7 0.07
Spark plug M10 2 13 1.3
Tappet cover M45 4 18 1.8
Valve clearance adjusting lock nut Nut M5 4 7 0.7
Stopper plate Bolt M6 2 12 1.2
Camshaft sprocket Bolt M8 2 26 2.6
Timing chain guide stopper Bolt M6 4 10 1.0
Plate Bolt M6 2 10 1.0
Timing chain tensioner Bolt M6 4 10 1.0
Timing chain tensioner cap Bolt M6 2 8 0.8
A.C. magneto Nut M12 1 80 8.0
Oil pump cover and rotor housing Screw M6 1 7 0.7
Cover Screw M6 1 7 0.7
Oil pump assembly Screw M6 3 7 0.7
Oil filter cover Bolt M6 3 10 1.0
Engine oil drain bolt Bolt M35 1 32 3.2
Carburetor joint and cylinder head Bolt M6 4 10 1.0
Air filter assembly and silencer Bolt M6 2 7 0.7
Air filter stay and cylinder Bolt M6 2 10 1.0
Silencer assembly Bolt M6 2 10 1.0
Fuel pump Bolt M6 2 10 1.0
Air filter stay and stay Bolt M6 2 7 0.7
Exhaust pipe joint Nut M6 4 10 1.0
Rear exhaust pipe Bolt M6 2 10 1.0
Front exhaust pipe and muffler Bolt M8 1 12 1.2
Exhaust pipe cover Bolt M6 2 7 0.7
Muffler mount Bolt M10 2 25 2.5
Crankcase Screw M6 14 7 0.7
Generator cover Bolt M6 8 10 1.0
Crankcase cover Bolt M6 3 10 1.0
Clutch cover Bolt M6 9 10 1.0
Clutch cable holder and clutch cover Bolt M6 2 10 1.0
Left crankcase straight plug Bolt M14 1 23 2.3
Oil check plug Screw M6 1 7 0.7
Nozzle M8 2 5 0.5
One-way clutch Bolt M8 3 30 3.0
Primary drive gear Nut M16 1 80 8.0
Clutch boss Nut M16 1 75 7.5
Clutch spring Screw M6 4 8 0.8
Push lever adjusting screw lock nut Nut M6 1 8 0.8
2-15
Tightening
Thread torque
Part to be tightened
g Part name Q’ty
y Remarks
size
Nm mkg
Push lever axle Screw M8 1 12 1.2
Drive sprocket Nut M16 1 60 6.0
Shift drum segment Screw M5 1 3.8 0.38
Shift arm Bolt M6 1 8 0.8
Shift pedal adjuster Nut M8 2 10 1.0 1 of 2 has
LH thread
Neutral switch M10 1 20 2.0
Stater coil Screw M6 3 7 0.7
Pickup coil Screw M5 2 5 0.5
Starter motor Bolt M6 2 10 1.0
2-16
Cylinder head tightening sequence:
Crankcase tightening sequence:
2-17
CHASSIS
Tightening torques
Thread Tightening torque

Part to be tightened Remarks
size Nm mkg
Upper bracket and inner tube M8 20 2.0
Upper bracket and steering shaft M22 110 11.0
Ring nut (steering shaft) M25 18 1.8 See NOTE
Under bracket and inner tube M12 30 3.0
Main switch and frame M8 23 2.3
Front wheel axle shaft pinch bolt M8 20 2.0
Front brake master cylinder and bracket M6 7 0.7
Upper bracket and handle holder (under) M10 32 3.2
Handlebar holder (upper and lower) M8 23 2.3
Brake hose union bolt M10 30 3.0
Brake hose holder and under bracket M6 9 0.9
Front fender and front fork M6 7 0.7
Headlight stay and under bracket M6 7 0.7
Headlight body and unit M5 3 0.3
Headlight stay and headlight M6 8 0.8
Front turn signal light and under bracket M6 7 0.7
Throttle cable and carburetor M6 4 0.4
Engine mounting:
Frame and stay (front upper) M8 35 3.5
Frame and stay (front lower right) M8 35 3.5
Frame and stay (rear upper) M8 35 3.5
Head cover and stay (front upper) M8 35 3.5
Engine and frame M8 35 3.5
Engine and stay (rear upper) M8 35 3.5
Engine and frame M8 35 3.5
Ignition coil and frame M5 4 0.4
Horn M8 16 1.6
Muffler and frame M8 30 3.0
Licence bracket and rear fender M6 7 0.7
Taillight and rear fender M6 7 0.7
Rear fender M6 7 0.7
Rear turn signal light and rear fender M12 7 0.7
Rear fender and wire harness holder 7 0.7
Rectifier/regulator and battery box M6 7 0.7
Starter relay and battery positive lead M6 7 0.7
Starter relay and wire harness lead M6 7 0.7
Pivot shaft and nut M12 46 4.6
Shock absorber and swingarm M8 23 2.3
Shock absorber and frame M8 23 2.3
Chain case and swingarm M6 7 0.7
Seal guard M5 4 0.4
Tension bar and swingarm M8 23 2.3
Tension bar and brake shoe plate M8 23 2.3
2-18
Thread Tightening torque

Part to be tightened Remarks
size Nm mkg
Fuel cock and tank M6 7 0.7
Fuel tank bracket and frame M8 23 2.3
Speedometer setting nut M5 3 0.3
Speedometer cable M12 3 0.3
Rides seat M6 7 0.7
Passenger seat M8 16 1.6
Front wheel axle shaft M16 59 5.9
Rear wheel axle shaft M14 104 10.4
Front brake caliper and front fork M10 40 4.0
Brake disk M8 23 2.3
Rear wheel sprocket M10 40 4.0
Caliper bleed screw M7 6 0.6
Brake hose union bolt M10 30 3.0
Chain puller lock nut M8 16 1.6
Sidestand bolt and nut M10 40 4.0
Footrest assembly mounting M10 40 4.0
Rear footrest bracket and frame M8 26 2.6
Sidestand switch M5 4 0.4
Sidestand switch panel and frame M6 7 0.7
NOTE:
1. First, tighten the ring nut approximately 52 Nm (5.2 mkg) by using the torque wrench, then loosen
the ring nut completely.
2. Retighten the ring nut to specification.
2-19
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB203000
LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE
Lubrication point Symbol
Oil seal lips
O-ring
Bearing
Connecting rod small end and big end
Crankshaft pin
Crankshaft journal/big end
Piston surface
Piston pin
Camshaft cam lobe/journal
Rocker arm shaft
Valve stem (IN, EX)
Valve stem end (IN, EX)
Timing chain drive gear shafts/sprockets
Oil pump rotor (inner/outer), housing
Starter idle gear
Starter idle gear shaft
Push rod 1, 2
Transmission gear (wheel/pinion)
Shift cam
Shift fork/guide bar
Shift shaft assembly
Push rod ball
Push lever assembly
Crankcase mating surface Yamaha bond No.1215
Crankcase cover Yamaha bond No.1215
2-20
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB203010
CHASSIS
Lubrication point Symbol
Steering head pipe (upper/lower), bearing
Steering head pipe, bearing cover lip
Steering head pipe, oil seal lip
Front wheel oil seal lip (right/left)
Rear wheel oil seal lip
Clutch hub fitting area
Rear brake pedal shaft
Shift pedal shaft
Sidestand bolt, sidestand sliding surface
Tube guide (throttle grip) inner surface
Brake lever pivot bolt, contact surface
Clutch lever pivot bolt, contact surface
Swingarm pivot bearing inner surface
Swingarm pivot oil seal lip
2-21
ENGINE OIL LUBRICATION CHART
SPECIFICATIONS SPEC
ENGINE OIL LUBRICATION CHART SPECIFICATIONS

Item Standard
Lubrication chart:
2-22
ENGINE OIL FLOW DIAGRAMS SPEC
EB205000
ENGINE OIL FLOW DIAGRAMS
2-23
2-24
2-25
CABLE ROUTING SPEC
CABLE ROUTING
1 Right handlebar switch lead A Install the coupler between left
2 Front brake light switch lead ignition coil and right ignition coil.
3 Main switch B Insert rubber bracket, into the
4 Brake hose relay stay tightly for the relay and
5 Clutch switch lead thermo switch.
6 Left handlebar switch lead C Route the clutch cable through
7 Starter cable forward of head pipe and outside
8 Clutch cable of throttle cable.
9 Headlight lead
10 Throttle cables
2-26
CABLE ROUTING SPEC
1 Rectifier/ regulator A Connect the ignition coil read.
2 Ignition coil (red lead: lower)
3 Front brake light switch lead (orange lead: upper)
4 Right handlebar switch lead Connect the ignition coil lead ter-
5 Brake hose minal so that it faces the out side
6 Throttle cables of the frame.
7 Clutch cable B Route the right handlebar switch
8 High tension code lead and front brake light switch
9 Rear brake light switch lead lead through the hole of the
frame from inside to outside.
C Connect the rear brake light
switch lead coupler between the
band and the holder.
2-27
CABLE ROUTING SPEC
1 Clutch switch lead 18 Thermo switch lead
2 Left handlebar switch lead 19 Thermo switch
3 Clutch cable 20 Horn lead
4 Starter cable 21 Horn
5 Speedometer 22 Ignition coil
6 Speedometer cable 23 Headlight lead
7 Igniter unit 24 Wire harness
8 Starting circuit cut-off relay 25 Throttle cables
9 Fuse box
10 Sidestand switch lead
11 Air filter breather hose
12 High tension code
13 Throttle position sensor lead
14 Carburetor heater ground lead
15 Carburetor heater lead
16 Flasher relay
17 Headlight relay
2-28
CABLE ROUTING SPEC
A Put in the speedometer lead cou- E Clamp the wire harness. K Clamp between the left handle-
pler into the fuel tank filler box. F Throttle position sensor coupler bar switch lead coupler and the
B Route the speedometer cable under the wireharness. right handlebar switch lead cou-
speedometer lead and fuel tank G To the engine. pler.
breather hose through the hole H Connect the ignition coil lead. L Line up the leads during installa-
of fuel tank. (red lead: lower) tion.
C Clamp the white tape of wire har- (gray lead: upper) M Run all leads along the frame.
ness. (fix the position) Face the clamp end (extra posi- N Pass between the holder and en-
D Clamp the back sides of the left tion) toward the at side of the gine stay (left side).
handlebar switch lead and clutch frame.
switch lead couplers (3 loca- I Insert the front turn signal light
tions). Face the end of the clamp leads and headlight lead from
(extra position) toward the inside outside of headlight to inside.
of the frame. Clamp immediately J Pass the throttle position sensor
after the wireharness branch lead through the fuel hose down
(leftand right hand lebar switch stream side.
lead.)
2-29
CABLE ROUTING SPEC
1 Throttle cables A Through the speedometer cable H Fasten the wireharness, high
2 Brake hose between frame of tank rail and tension code, and throttle posi-
3 Battery negative (–) lead wireharness. tion sensor with a band.
4 Regulator lead B Through the fuel tank breather I Fasten the wireharness, left
5 Tail/ brake light lead hose between wireharness and handlebar switch lead, high ten-
6 Starter relay leads. sion code, clutch switch lead,
7 Clutch cable C Position an open side of clamp to right handlebar switch lead and
8 Starter cable rear frame and assemble. front brake light switch lead with
9 Alarm lead D Face the end of the band (extra a band.
10 Inner panel portion) toward the bottom of the J To the fuel tank.
11 Battery positive (+) lead frame. K Fasten the wireharness, left
Items to be clamped with a band: handlebar switch lead clutch
regulator lead, brake light lead. switch lead, right handlebar
E To the rear fender. switch lead front brake switch
F Cut the end of band position: lead, throttle cables, and starter
Front upper band of frame. cable with a band.
G To the engine.
2-30
CABLE ROUTING SPEC
L Put an alarm coupler into this O Face the end of the band (extra
position. portion) toward the bottom of the
(surrounded part by vertical frame. Item to be clamped: regu-
panel inner wall.) lator lead, brake light lead, A, C.
M To the starter motor. magneto lead, pickup coil lead,
N Face the end of the clamp (extra side stand switch lead.
portion) toward the inside of the P Berd the alarm lead once and
frame. band to burdle it together with
Item to be clamped: wirehar- the wireharness.
ness, battery negative leads (2
leads), starter motor lead, alarm
read, A, C. magneto lead, side
stand switch read.
2-31
CHK
ADJ
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE/LUBRICATON INTERVALS . . . . . . . . . . . . 3-1
RIDER AND PASSENGER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
FUEL TANK AND AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . 3-6
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . 3-9
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . 3-11
CHECKING THE SPARK PUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-15
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . 3-19
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . 3-20
CHECKING THE CARBURETOR JOINT AND
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
CHECKING THE FUEL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . 3-22
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 3-26
CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
CHECKING THE BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
ADJUSTING THE REAR BRAKELIGHT SWITCH . . . . . . . . . . . . . . . 3-27
CHECKING THE BRAKE HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . 3-28
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . . 3-30
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
CHECKING THE ADJUSTING THE STEERING HEAD . . . . . . . . . . 3-32
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . 3-35
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
CHECKING AND TIGHTENING THE SPOKES . . . . . . . . . . . . . . . . . 3-38
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . 3-39
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . 3-39
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 3-39
CHK
ADJ
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . 3-40
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
REPLACING THE HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
INTRODUCTION/PERIODIC MAINTENANCE/ CHK
LUBRICATION INTERVALS ADJ
EB300000
PERIODIC CHECKS AND ADJUSTMENTS

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

Initial Every Every Annual
NO. ITEM CHECKS AND MAINTENANCE JOBS 1,000 km 6,000 km 12,000 km check
Check fuel hoses and vacuum hose for cracks or damage.
1 * Fuel line Replace if necessary. √ √
Check condition.
2 Spark plugs Clean, regap or replace if necessary. √
Check valve clearance.

3 * Valves Adjust if necessary. √
4 Air filter Clean or replace if necessary. √

Check operation.
5 Clutch Adjust or replace cable. √ √
Check operation, fluid level and vehicle for fluid leakage.

6 * Front brake Correct accordingly. √ √ √
Replace brake pads if necessary.
Check operation.
7 * Rear brake Adjust brake pedal freeplay and replace brake shoes if √ √ √
necessary.
Check for cracks or damage.
8 * Brake hose Replace if necessary. √ √
Check balance, runout, spoke tightness and for damage.

9 * Wheels Tighten spokes and rebalance, replace if necessary. √
Check tread depth and for damage.

Replace if necessary.
10 * Tires Check air pressure. √
Correct if necessary.
Check bearing for looseness or damage.
11 * Wheel bearings Replace if necessary. √
Check swingarm pivoting point for play.

Correct if necessary. √
12 * Swingarm
g
Lubricate with molybdenum disulfide grease. √
Check chain slack.
Adjust if necessary. Make sure that the rear wheel is prop- Every 1,000 km and after washing the
13 Drive chain erly aligned. motorcycle or riding in the rain
Clean and lubricate.
Check bearing play and steering for roughness.
Correct accordingly. √ √
14 * Steering
g bearings
g
Lubricate with lithium soap base grease. √
Make sure that all nuts, bolts and screws are properly tight-
15 * Chassis fasteners ened. √ √
Tighten if necessary.
Check operation.
16 Sidestand Lubricate and repair if necessary. √ √
Check operation.
17 * Sidestand switch Replace if necessary. √ √ √
Check operation and for oil leakage.

18 * Front fork Correct accordingly. √
Rear shock absorber Check operation and shock absorbers for oil leakage.
19 * assemblies Replace shock absorber assembly if necessary. √
Check engine idling speed and starter operation.

20 * Carburetor Adjust if necessary. √ √ √
Check oil level and vehicle for oil leakage.

21 * Engine oil Correct if necessary. √ √ √
Change. (Warm engine before draining.)
3-1
CHK
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
Initial Every Every Annual
NO. ITEM CHECKS AND MAINTENANCE JOBS 1,000 km 6,000 km 12,000 km check
22 Engine oil filter element S Replace. √ √
Front and rear brake S Check operation.
23 * switches S Correct accordingly. √ √ √
24 * Moving parts and cables S Lubricate if necessary. √ √
Lights, signals and S Check operation.

25 * switches S Correct if necessary. √ √ √
S Adjust headlight beam if necessary.
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
NOTE:
D The annual checks must be performed every year, except if a 6,000 km or 12,000 km maintenance is
performed instead.
D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
D Hydraulic brake service
S Regularly check and, if necessary, correct the brake fluid level.
S Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
S Replace the brake hoses every four years and if cracked or damaged.
CAUTION:
The carburetor on this motorcycle has a built-in accelerator pump. Therefore, when engine is
stopped or is operated without load, do not open and shut a throttle grip.
It may cause starting and revolution trouble due to over-emitting fuel of accelerating pump.
3-2
CHK
RIDER AND PASSENGER SEATS ADJ
RIDER AND PASSENGER SEATS
7 Nm (0.7 mkg)
16 Nm (1.6 mkg)
Order Job/Part Q’ty Remarks

Removing the rider and passenger Remove the parts in the order listed.
seats
1 Passenger seat 1
2 Seat bracket 1
3 Rider’s seat 1
For installation reverse the removal
procedure.
3-3
CHK
FUEL TANK AND AIR FILTER ADJ
FUEL TANK AND AIR FILTER
7 Nm (0.7 mkg)
23 Nm (2.3 mkg)

Removing the fuel tank and air filter Remove the parts in the order listed.
Rider and passenger seats Refer to “RIDER AND PASSENGER
SEATS”.
1 Fuel hoses 2 NOTE:
Set the fuel cock to “OFF” before discon-
necting the fuel hose.
2 Speedometer 1
3 Fuel tank breather hose 1
4 Speedometer cable 1
5 Speedometer lead coupler 1 Disconnect.
6 Fuel tank 1
7 Air filter 1
For installation, reverse the removal
procedure.
3-4
CHK
FUEL TANK AND AIR FILTER ADJ
REMOVAL
1. Remove:
Ignitor plate
NOTE:
To remove the quick fastener, push its center in
with a screwdriver, then pull the fastener out.
INSTALLATION
1. Install:
Ignitor plate
NOTE:
To install the quick fastener, push its pin so that it
protrudes from the fastener head, then insert
the fastener into the cowling and push the pin a
in with a screwdriver. Make sure that the pin is
flush with the fastener’s head.
3-5
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00047
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
Valve clearance adjustment should be made
on a cold engine, at room temperature.
When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
rider and passenger seats
Refer to “RIDER AND PASSENGER SEATS”.
fuel tank
Refer to “FUEL TANK”.
2. Disconnect:
spark plug caps
3. Remove:
spark plugs
4. Remove:
air filter assembly 1
5. Remove:
frame cover 1
silencer assembly 2
6. Remove:
cylinder head side covers 1
(front cylinder)
cylinder head side covers 2
(rear cylinder)
3-6
CHK
7. Remove:
tappet covers 1
8. Remove:
camshaft sprocket cover (front cylinder) 1
camshaft sprocket cover (rear cylinder)
9. Remove:
timing plug 1
straight plug 2
10. Measure:
valve clearance
Out of specification Adjust.
Valve clearance (cold)

Intake valve
0.08 0.12 mm
Exhaust valve
0.10 0.14 mm
3-7
CHK
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-
sion stroke, align either the alignment mark
in the camshaft sprocket (front cylinder) a or
alignment mark in the camshaft sprocket
(rear cylinder) c , dependant on which cylin-
der you are checking, with the stationary
pointer b on the cylinder head. When the
hole in the camshaft sprocket plate or punch
mark in the camshaft sprocket is aligned with
A B
the stationary pointer, the piston is at top
dead center (TDC).
c. Align the TDC mark d on the generator rotor
with the stationary pointer e on the genera-
tor cover.
A Front cylinder (“T” mark)
B Rear cylinder (“I” mark)
d. Measure the valve clearance with a thick-

ness gauge 1 .
e. Turn the crankshaft clockwise 300_, and
then measure the another cylinder.
11. Adjust
S valve clearance
a. Loosen the locknut.

b. Insert a thickness gauge between the end of
the adjusting screw and the valve tip.
c. Turn the adjusting screw 1 in direction a or
b until the specified valve clearance is ob-
tained.
Valve adjusting tool

90890-01311
Valve clearance is
Direction a
decreased.
Valve clearance is
Direction b
increased.
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica-
tion.
3-8
ADJUSTING THE VALVE CLEARANCE/ CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
Locknut:
7 Nm (0.7 mkg)
e. Measure the valve clearance again.

f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
12. Install:
all removed parts
NOTE:
Install all removed parts in the reverse order of
their disassembly. Note the following points.
camshaft sprocket covers

10 Nm (1.0 mkg)
tappet covers
18 Nm (1.8 mkg)
spark plugs
13 Nm (1.3 mkg)
EAS00054
ADJUSTING THE ENGINE IDLING SPEED

NOTE:
Prior to adjusting the engine idling speed, the air
filter should be clean, and the engine should
have adequate compression.
1. Start the engine and let it warm up for several

minutes.
2. Install:
engine tachometer
(to the spark plug lead of cyl. #1)
Engine tachometer
90890-03113
3. Check:
engine idling speed
Engine idling speed

1.250 1.450 r/min
4. Adjust:
engine idling speed
3-9
CHK
ADJUSTING THE IDLING SPEED ADJ
a. Turn the pilot screw in or out until it is lightly
seated.
b. Turn the pilot screw out the specified number
of turns.
Pilot screw
2 turns out
c. Turn the throttle stop screw 1 in direction a

or b until the specified engine idling speed is
obtained.
Engine idling speed is

Direction a
increased.
Engine idling speed is
Direction b
decreased.
5. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the

3 5 mm
3-10
CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
EAS00058
ADJUSTING THE THROTTLE CABLE FREE

PLAY
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted.
1. Check:
throttle cable free play a

3 5 mm
2. Remove:
fuel tank
3. Adjust:
Carburetor side
a. Loosen the locknut 1 .
b. Turn the adjusting nut 2 in direction a or b
until the specified throttle cable free play is
obtained.
Throttle cable free play

Direction a
is increased.
Direction b
is decreased.
c. Tighten the locknuts 1 .
NOTE:
If the specified throttle cable free play cannot be
obtained on the carburetor side of the cable, use
the adjusting nut on the handlebar side.
Handlebar side
b. Turn the adjusting nut 2 in direction a or b
until the specified throttle cable free play is
obtained.

Direction a
is increased.
Direction b
is decreased.
c. Tighten the locknut 1 .
3-11
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHK
CHECKING THE SPARK PLUGS ADJ
WARNING
After adjusting the throttle cable free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the en-
gine idling speed to change.
4. Install:
fuel tank
EAS00060
CHECKING THE SPARK PLUGS

1. Disconnect:
spark plug cap
2. Remove:
spark plug
CAUTION:
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from fal-
ling into the cylinder.
3. Check:
spark plug type
Incorrect Change.
Spark plug type (manufacturer)

CR7HSA (NGK)
U22FSR-U (DENSO)
4. Check:
electrode 1
Damage/wear Replace the spark plug.
insulator 2
Abnormal color Replace the spark plug.
Normal color is a medium-to-light tan color.
5. Clean:
spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
spark plug gap a
(with a wire gauge)
Out of specification Regap.
Spark plug gap

0.6 0.7 mm
3-12
CHK
CHECKING THE SPARK PLUGS ADJ
7. Install:
spark plug 13 Nm (1.3 mkg)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
8. Connect:
spark plug cap
3-13
CHK
CHECKING THE IGNITION TIMING ADJ
EAS00062
CHECKING THE IGNITION TIMING

NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure that all connections are tight and free
of corrosion.
1. Remove:
timing plug 1
2. Install:
timing light 1
engine tachometer 2
(to the spark plug lead of cyl. #1)
Timing light
90890-03141
Engine tachometer
90890-03113
3. Check:
ignition timing
a. Start the engine, warm it up for several min-

utes, and then let it run at the specified en-
gine idling speed.
Engine idling speed

1.250 1.450 r/min
b. Check that the mark a on the generator ro-

tor is within the firing range b on the genera-
tor cover.
Incorrect firing range Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
4. Install:
timing plug 1
3-14
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
EAS00065
MEASURING THE COMPRESSION PRES-

SURE
The following procedure applies to all of the cyl-
inders.
NOTE:
Insufficient compression pressure will result in a
loss of performance.
1. Measure:
valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Disconnect:
spark plug cap
4. Remove:
spark plug
CAUTION:
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
5. Install:
compression gauge 1
Compression gauge set

90890-03081
6. Measure:
compression pressure
Above the maximum pressure Inspect the
cylinder head, valve surfaces, and piston
crown for carbon deposits.
Below the minimum pressure Squirt a few
drops of oil into the affected cylinder and
measure again.
3-15
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
Refer to the following table.
Compression pressure
(with oil applied into cylinder)
Reading Diagnosis
Higher than Piston wear or damage
without oil Repair.
Piston ring(-s), valves,
cylinder head gasket or
Same as piston possibly defec-
without oil tive Repair.
Compression pressure
(at sea level)
Compression pressure (at sea

level):
Standard:
1.200 kPa (12 kg/cm2, 12 bar)
Minimum:
1.100 kPa (11 kg/cm2, 11 bar)
Maximum:
1.300 kPa (13 kg/cm2, 13 bar)
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 be-
tween cylinders should not exceed 100 kPa (1
kg/cm2, 1 bar).
7. Install:
spark plug 13 Nm (1.3 mkg)
8. Connect:
spark plug cap
3-16
CHK
CHECKING THE ENGINE OIL LEVEL ADJ
EAS00069
CHECKING THE ENGINE OIL LEVEL

1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Let the engine idle for a few minutes.

3. Check:
engine oil level
The engine oil level should be between the
minimum level marks a and maximum level
marks b .
Below the minimum level mark Add the
recommended engine oil to the proper level.
Recommended engine oil

Refer to the chart for the engine
oil grade which is best suited
for certain atmospheric
temperatures.
API standard
SE or higher grade
ACEA standard
G4 or G5
CAUTION:
Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD a or higher and do
not use oils labeled “ENERGY CONSERV-
ING II” b or higher.
Do not allow foreign materials to enter the
crankcase.

5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
3-17
CHK
CHANGING THE ENGINE OIL ADJ
EAS00075
CHANGING THE ENGINE OIL

2. Place a container under the engine oil drain
bolt.
3. Remove:
WARNING
Be careful not touch the exhaust pipe when
removing or attaching the engine oil filler
cap 1 or when adding oil.
engine oil filler cap 1

engine oil drain bolt 2
(along with the gasket)
4. Drain:
engine oil
(completely from the crankcase)
5. If the oil filter element is also to be replaced,
perform the following procedure.
a. Remove the oil filter element cover 1 and oil

filter element 2 .
b. Check the O-ring 3 and replace it if it is
cracked or damaged.
c. Install the new oil filter element and the oil fil-
ter element cover.
Oil filter element cover bolt

10 Nm (1.0 mkg)
6. Check:
engine oil drain bolt gasket
Damage Replace.
7. Install:
engine oil drain bolt 32 Nm (3.2 mkg)
oil filter element drain bolt
8. Fill:
crankcase
(with the specified amount of the recom-
mended engine oil)
3-18
CHANGING THE ENGINE OIL/ CHK
ADJUSTING THE CLUTCH CABLE FREE PLAY ADJ
Quantity
Total amount
1.75 L
Without oil filter element
replacement
1.4 L
With oil filter element
replacement
1.6 L
9. Install:
engine oil filler cap
11. Check:
engine
(for engine oil leaks)
12. Check:
engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
EAS00078
ADJUSTING THE CLUTCH CABLE FREE

PLAY
1. Check:
clutch cable free play a
Clutch cable free play (at the end

5 10 mm
2. Adjust:
clutch cable free play
Handlebar side
b. Turn the adjusting bolt 2 in direction a or b
until the specified clutch cable free play is ob-
tained.
Clutch cable free play is

Direction a
increased.
Direction b
decreased
c. Tighten the locknut.
NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
Engine side
a. Loosen the locknuts 1 .
3-19
ADJUSTING THE CLUTCH CABLE FREE PLAY/ CHK
CLEANING THE AIR FILTER ELEMENT ADJ
until the specified clutch cable free play is ob-
tained.

Direction a
increased.
Direction b
decreased
c. Tighten the locknuts 1 .
CLEANING THE AIR FILTER ELEMENT

1. Remove:
air filter case assembly 1
air filter element 2
2. Clean:
air filter element
Apply compressed air to the inner surface of
the air filter element.
3. Check:
air filter element
Damage Replace.
4. Install:
air filter element
air filter case cover
3-20
CLEANING THE AIR FILTER ELEMENT/CHECKING THE CHK
CARBURETOR JOINT AND INTAKE MANIFOLD ADJ
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor en-
gine performance and possible overheat-
ing.
NOTE:
When installing the air filter element into the air
filter case cover, be sure their sealing surfaces
are aligned to prevent any air leaks.
EAS00094
CHECKING THE CARBURETOR JOINT AND

INTAKE MANIFOLD
1. Remove:
fuel tank
silencer
2. Check:
carburetor joint 1
Cracks/damage Replace.
Refer to “CARBURETOR” in chapter 6.
3. Install:
silencer
fuel tank
3-21
CHECKING THE FUEL HOSES/ CHK
CHECKING THE CRANKCASE BREATHER HOSE ADJ
EAS00097
CHECKING THE FUEL HOSES

The following procedure applies to all of the fuel
hoses.
1. Remove:
fuel tank
silencer
2. Check:
fuel hose 1
Damage/dirt Replace.
NOTE:
Drain and flush the fuel tank if abrasive dam-
age to any components of the fuel line is evi-
dent.
3. Install:
silencer
fuel tank
EAS00098
CHECKING THE CRANKCASE BREATHER

HOSE
1. Remove:
fuel tank
silencer
2. Check:
crankcase breather hose 1
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.
3. Install:
silencer
fuel tank
3-22
CHK
CHECKING THE EXHAUST SYSTEM ADJ
EAS00100
CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the ex-
haust pipe, muffler and gaskets.
1. Check:
exhaust pipe 1
muffler 2
gaskets 3
Exhaust gas leaks Replace.
2. Check:
tightening torque
Exhaust pipe nut 4

10 Nm (1.0 mkg)
Exhaust pipe and muffler bolt 5
10 Nm (1.0 mkg)
Muffler and muffler bracket bolt 6
25 Nm (2.5 mkg)
Front exhaust pipe and muffler 7
12 Nm (1.2 mkg)
3-23
ADJUSTING THE FRONT BRAKE/ CHK
ADJUSTING THE REAR BRAKE ADJ
EAS00108
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
brake lever free play a
Brake lever free play (at the end

of the brake lever)
5 8 mm
2. Adjust:
brake lever free play

until the specified brake lever free play is ob-
tained.
Brake lever free play is

Direction a
increased.
Brake lever free play is
Direction b
decreased.
c. Tighten the locknut.
WARNING
A soft or spongy feeling in the brake lever
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 consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.
CAUTION:
After adjusting the brake lever free play,
make sure that there is no brake drag.
EAS00112
ADJUSTING THE REAR BRAKE

1. Check:
brake pedal position
(distance a from the top of the rider footrest
to the top of the brake pedal)
Brake pedal position (above the

top of the rider footrest)
76.6 mm
3-24
CHK
ADJUSTING THE REAR BRAKE ADJ
2. Adjust:
brake pedal position

until the specified brake pedal position is ob-
tained.
Direction a Brake pedal is raised.
Direction b Brake pedal is lowered.
c. Tighten the locknut to specification.
Locknut
10 Nm (1.0 mkg)
3. Check:
brake pedal free play a
Brake pedal free play

20 30 mm
4. Adjust:
brake pedal free play
a. Turn the adjusting nut 1 in direction a or b

until the specified brake pedal free play is ob-
tained.
Brake pedal free play is

Direction a
increased.
Brake pedal free play is
Direction b
decreased.
CAUTION:
After adjusting the brake pedal position and
free play, make sure that there is not brake
drag.
5. Adjust:
rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
3-25
CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
EAS00115
CHECKING THE BRAKE FLUID LEVEL

NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Recommended brake fluid

DOT 4
Front brake
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reser-
voir is horizontal.
3-26
CHECKING THE BRAKE PADS/CHECKING THE BRAKE SHOES/ CHK
ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ
EAS00117
CHECKING THE BRAKE PADS

brake pads.
1. Operate the brake.
2. Check:
brake pad
Wear indicators 1 almost touch the brake
disc ! Replace the brake pads as a set.
Refer to “FRONT BRAKE” in chapter 6.
EAS00126
CHECKING THE BRAKE SHOES

1. Operate the brake.
2. Check:
wear indicator 1
Reaches the wear limit line 2 ! Replace the
brake shoes as a set.
Refer to “REAR WHEEL” in chapter 6.
EAS00128
ADJUSTING THE REAR BRAKE LIGHT

SWITCH
NOTE:
The rear brake light switch is operated by move-
ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1. Check:
rear brake light operation timing
Incorrect ! Adjust.
2. Adjust:
rear brake light operation timing
a. Hold the main body 1 of the rear brake light

switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper time.
Direction a ! Brake light comes on

sooner.
Direction b ! Brake light comes on
later.
3-27
CHECKING THE BRAKE HOSE/ CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00129
CHECKING THE BRAKE HOSE

1. Check:
brake hose 1
Cracks/damage/wear Replace.
2. Check:
brake hose clamp
Loose connection Tighten.
3. Hold the motorcycle upright and apply the
front or rear brake.
4. Check:
brake hose
Activate the brake several times.
Brake fluid leakage Replace the damaged
hose.
Refer to “FRONT BRAKE” in chapter 6.
EAS00133
BLEEDING THE HYDRAULIC BRAKE SYS-

TEM
WARNING
Bleed the hydraulic brake system whenev-
er:
The system was disassembled.
A brake hose was loosened or removed.
The brake fluid level is very low.
Brake operation is faulty.
NOTE:
Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to over-
flow.
When bleeding the hydraulic brake system,
make sure that there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the hydrau-
lic brake system, considerably lengthening the
bleeding procedure.
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
3-28
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
1. Bleed:
hydraulic brake system
a. Add the recommended brake fluid to the

proper level.
b. Install the brake master cylinder reservoir di-
aphragm.
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2 .
d. Place the other end of the hose into a con-
tainer.
e. Slowly squeeze the brake lever several
times.
f. Fully squeeze the brake lever without releas-
ing it.
g. Loosen the bleed screw.
This will release the tension and cause the
brake lever to contact the throttle grip.
h. Tighten the bleed screw and then release the
brake lever.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 mkg)
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.
3-29
ADJUSTING THE SHIFT PEDAL/ CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
EAS00137
ADJUSTING THE SHIFT PEDAL

NOTE:
The shift pedal position is determined by the ad-
justing bolt length a .
1. Measure:
adjusting the length a
Incorrect Adjust.
Adjusting bolt length

276.8 mm
2. Adjust:
adjusting bolt length a
a. Loosen both locknuts 1

b. Turn the adjusting bolt 2 in direction b or c
to obtain the correct shift pedal position.
Direction b shift pedal is raised.

Direction c shift pedal is lowered.
EAS00141
ADJUSTING THE DRIVE CHAIN SLACK

NOTE:
The drive chain slack must be checked at the
tightest point on the chain.
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.

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.
3-30
CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
2. Rotate the rear wheel several times and
check the drive chain to locate its tightest
point.
3. Check:
drive chain slack a
Drive chain slack

30 40 mm
4. Adjust:
drive chain slack
a. Loosen the wheel axle nut 1 .

Loosen the locknut 3 .
b. Turn the chain puller nut 2 in direction a or
b until the specified drive chain slack is ob-
tained.
Direction a Drive chain is tightened.

Direction b Drive chain is loosened.
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
c. Tighten the wheel axle nut.
Wheel axle nut

104 Nm (10.4 mkg)
CAUTION:
Do not loosen the wheel axle nut after tight-
ening 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.
3-31
LUBRICATING THE DRIVE CHAIN/ CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
EAS00142
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out rapidly. Therefore, the drive
chain should be serviced, especially when the
motorcycle is used in dusty areas.
This motorcycle has a drive chain with small
rubber O-rings between each side plate. Steam
cleaning, high-pressure washing, certain sol-
vents, and the use of a coarse brush can dam-
age these O-rings. Therefore, use only kerosine
to clean the drive chain. Wipe the drive chain dry
and thoroughly lubricate it with engine oil or
chain lubricant that is suitable for O-ring chains.
Do not use any other lubricants on the drive
chain since they may contain solvents that
could damage the O-rings.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
EAS00146
CHECKING AND ADJUSTING THE STEER-

ING HEAD
WARNING
NOTE:
the front wheel is elevated.
2. Check:
steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness or binding Adjust the steering
head.
3-32
CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
3. Remove:
handlebar
upper bracket pinch bolt 1
steering stem nut 2
upper bracket 3
4. Adjust:
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

90890-01043
Lower ring nut (initial tightening

torque)
52 Nm (5.2 mkg)
c. Loosen the lower ring nut 4 completely, then

tighten it to specification.
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening

torque)
18 Nm (1.8 mkg)
d. Check the steering head for looseness or

binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and inspect the upper and
lower bearings.
Refer to “STEERING HEAD AND HAN-
DLEBAR” in chapter 7.
3-33
CHECKING AND ADJUSTING THE STEERING HEAD/ CHK
CHECKING THE FRONT FORK 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 cor-
rectly in the ring nut slots b .
5. Install:
upper bracket
steering stem nut 110 Nm (11.0 mkg)
upper bracket pinch bolt
20 Nm (2.0 mkg)
EAS00149
CHECKING THE FRONT FORK

WARNING
2. Check:
inner tube
Damage/scratches Replace.
oil seal
Oil leakage Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation Repair.
Refer to “FRONT FORK” in chapter 7.
3-34
CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
EAS00156
ADJUSTING THE REAR SHOCK ABSORB-

ER ASSEMBLY
WARNING
Spring preload
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
spring preload
NOTE:
Adjust the spring preload with the special
wrench and extension bar included in the own-
er’s tool kit.
a. Turn the adjusting ring 1 in direction a or

b.
Spring preload is
Direction a increased (suspension
is harder).
Spring preload is
Direction b decreased (suspension
is softer).
Adjusting positions
Standard: 2
Minimum: 1
Maximum: 5
3-35
CHK
CHECKING THE TIRES ADJ
EAS00164
CHECKING THE TIRES

The following procedure applies to both of the
tires.
1. Measure:
tire pressure
Out of specification Regulate.
WARNING
The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil and a 156 kg
full fuel tank)
Maximum
183 kg
load*
Cold tire
Front tire Rear tire
pressure
Up to 90 kg 175 kPa 200 kPa
load* (1.75 kgf/cm2) (2.00 kgf/cm2)
90 kg
225 kPa 225 kPa
maximum
(2.25 kgf/cm ) (2.25 kgf/cm2)
2
load*
High 175 kPa 200 kPa
speed riding (1.75 kgf/cm ) (2.00 kgf/cm2)
2
*: total of cargo, rider, passenger and accesso-

ries
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
2. Check:
tire surfaces
Damage/wear Replace the tire.
Minimum tire tread depth

0.8 mm
3-36
CHK
CHECKING THE TIRES ADJ
1 Tire tread depth
2 Side wall
3 Wear indicator
WARNING
Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden defla-
tion.
When using tube tires, be sure to install the
correct tube.
Always replace a new tube tire and a new
tube as a set.
To avoid pinching the tube, make sure that
the wheel rim band and tube are centered in
the wheel groove.
Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.
Tube wheel Tube tire only

Tubeless wheel Tube or tubeless tire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufactur-
er and of the same design. No guarantee
concerning handling characteristics can
be given if a tire combination other than
one approved by Yamaha is used on this
motorcycle.
Front tire
Manufacturer Type Size

80/100-18
CHENG SHIN C-916
47P
MARBELLA 80/100-18
INOUE
NF27 47P
3-37
CHECKING THE TIRES/ CHK
CHECKING AND TIGHTENING THE SPOKES ADJ
Rear tire
Manufacturer Type Size

130 / 90-15
CHENG SHIN C-915
M / C 66P
MARBELLA 130 / 90-15
INOUE
NR31 M / C 66P
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any highspeed riding is done.
NOTE:
For tires with a direction of rotation mark 1 :
Install the tire with the mark pointing in the
direction of wheel rotation.
Align the mark 2 with the valve installation
point.
EAS00169
CHECKING AND TIGHTENING THE SPOKES

spokes.
1. Check:
spoke 1
Bends/damage Replace.
Loose Tighten.
Tap the spokes with a screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
2. Tighten:
spoke
(with a spoke wrench 2 )
NOTE:
Be sure to tighten the spokes before and after
break-in.
Spoke nipple
3 Nm (0.3 mkg)
3-38
CHECKING AND LUBRICATING THE CABLES / CHK
LUBRICATING THE LEVERS AND PEDALS / LUBRICATING
THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION ADJ
EAS00170
CHECKING AND LUBRICATING THE

CABLES
cable sheaths and cables.
WARNING
Damaged cable sheaths may causes the
cable to corrode and interfere with its move-
ment. Replace damaged cable sheaths and
cables as soon as possible.
1. Check:
cable sheath
Damage Replace.
2. Check:
cable operation
Unsmooth operation Lubricate.
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubing device.
EAS00171
LUBRICATING THE LEVERS AND PEDALS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Engine oil
EAS00172
LUBRICATING THE SIDESTAND

moving parts of the sidestand.
Engine oil
EAS00174
LUBRICATING THE REAR SUSPENSION

moving parts of the rear suspension.
Molybdenum disulfide grease
3-39
CHK
CHECKING AND CHARGING THE BATTERY ADJ
EB305020
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling or
working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
First aid in case of bodily contact:
External
SKIN – Wash with water.
EYES – Flush with water for 15 minutes and
get immediate medical attention.
Internal
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
CAUTION:
This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery per-
formance will deteriorate.
Charging time, charging amperage and
charging voltage for a MF battery are differ-
ent from those of conventional batteries.
The MF battery should be charged as ex-
plained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
3-40
CHK
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:
S battery cover 1
2. Disconnect:
S battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then
the positive lead 2 .
3. Remove:
S battery
4. Check:
S battery charge
a. Connect a pocket tester to the battery termi-

nals.
Tester positive lead battery positive

terminal
Tester negative lead battery negative
terminal
Volt meter
NOTE:
S The charge state of a MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive terminal is
disconnected).
S No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in

Relationship between open-circuit the charts and the following example.
voltage and charging time at 20_C
Example
c. Open-circuit voltage = 12.0 V
Open-circuit voltage
d. Charging time = 6.5 hours

e. Charge of the battery = 20 30 %
5. Charge:
S battery
Charging time (Hours)
D This varies depending on the temperature, the state of (refer to the appropriate charging method il-
charge in battery plates and the electro lyte level.
lustration)
3-41
CHK
Ambient
WARNING
temperature 20_C
Do not quick charge a battery.
Open-circuit voltage (V)
CAUTION:
S Make sure that the battery breather hose
and battery vent are free of obstructions.
Condition of charge in battery (%)
S Never remove the MF battery sealing caps.
S Do not use a high-rate battery charger.
They force a high-amperage current into
Charging Ambient temperature
20_C
the battery quickly and can cause battery
18 overheating and battery plate damage.
S If it is impossible to regulate the charging
Open-circuit voltage (V)
17
16
15 current on the battery charger, be careful
14 not to overcharge the battery.
13
12
S When charging a battery, be sure to remove
11 it from the motorcycle. (If charging has to
10
0 10 20 30 40 50 60 Time (Minutes)
be done with the battery mounted on the
Check the Open-circuit motorcycle, disconnect the negative lead
voltage
from the battery terminal.)
S To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
S Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
S Make sure that the battery charger lead
clips are in full contact with the battery ter-
minal and that they are not shorted. A cor-
roded battery charger lead clip may gener-
ate heat in the contact area and a weak clip
spring may cause sparks.
S If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!
S As shown in the following illustration, the
open-circuit voltage of a MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
3-42
CHK
Charging method using a variable-current (voltage) type charger
Charger
AMP meter
Measure the open-circuit NOTE:
voltage prior to charging. Voltage should be measured 30 min-
utes after the machine is stopped.
Connect a charger and NOTE:

AMP meter to the battery Set the charging voltage at 16 17 V.
and start charging. (If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)
Make sure the current is

YES higher than the standard NO
charging current written on
the battery.
By turning the charging volt-

age adjust dial, set the charg-
ing voltage at 20 25 V.
Adjust the voltage so that cur- YES Monitor the amperage for 3
rent is at standard charging 5 minutes to check if the stan-
level. dard charging current is
reached.
NO
Set the timer according to the If the current does

charging time suitable for the not exceed stan-
open-circuit voltage. dard charging cur-
Refer to “Battery condition rent after 5 min-
checking steps.” utes, replace the
battery.
In case that charging requires more than 5 hours, it is advisable to

check the charging current after a lapse of 5 hours. If there is any
charge in the amperage, readjust the voltage to obtain the standard
charging current.
Measure the battery open-circuit voltage after having left the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
3-43
CHK
Charging method using a constant-voltage type charger
Measure the open-circuit NOTE:

voltage prior to charging. Voltage should be measured 30 min-
utes after the machine is stopped.
Connect a charger and

AMP meter to the battery
and start charging.
Make sure the current is

YES higher than the standard NO
charging current written on
the battery.
Charge the battery until the battery’s This type of battery charger cannot
charging voltage is 15 V. charge the MF battery. A variable volt-
age charger is recommended.
NOTE:
Set the charging time at 20 hours (maxi-
mum).
Measure the battery open-circuit

voltage after having left the battery
Charger
unused for more than 30 minutes.
12.8 V or more --- Charging is com-
plete. AMP meter
Volt meter
12.7 V or less --- Recharging is re-
quired.
Under 12.0 V --- Replace the battery.
Charging method using a constant-current type charger

This type of battery charger cannot charge the MF battery.
3-44
CHK
6. Check:
battery breather hose and battery vent
Obstruction Clean.
Damage Replace.
7. Install:
battery
CAUTION:
When inspecting the battery, make sure
that the battery breather hose is properly
attached and routed correctly. If the battery
breather hose is positioned so as to allow
electrolyte or hydrogen gas from the bat-
tery to contact the frame, the motorcycle
and its finish may be damaged.
Make sure that the battery breather hose is
properly routed away from the drive chain
and from below the swingarm.
8. Connect:
battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the
negative lead 2 .
9. Check:
battery terminals
Dirt Clean with a wire brush.
10. Lubricate:
battery terminals
Dielectric grease
11. Install:
battery cover
3-45
CHK
CHECKING THE FUSES ADJ
EAS00181
CHECKING THE FUSES

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

check it for continuity.
NOTE:
Set the pocket tester selector to “Ω 1”.
Pocket tester
90890-03112
b. If the pocket tester indicates “∞”, replace the
fuse.
3. Replace:
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 30A 1
Headlight 15A 1
Carburetor
10A 1
heater
Signals 10A 1
Ignition 10A 1
Reserve 30A 1
Reserve 15A 1
Reserve 10A 1
3-46
CHECKING THE FUSES/ CHK
REPLACING THE HEADLIGHT BULB ADJ
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:
left side cover
EAS00182
REPLACING THE HEADLIGHT BULB

1. Disconnect:
connectors 1
2. Remove
headlight bulb cover 2
3. Remove:
headlight bulb holder 1
4. Remove:
headlight bulb 2
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
5. Install:
headlight bulb
Secure the new headlight bulb with the head-
light bulb holder.
3-47
REPLACING THE HEADLIGHT BULB/ CHK
ADJUSTING THE HEADLIGHT BEAM ADJ
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install:
headlight bulb holder
7. Install:
headlight bulb cover
8. Connect:
leads
EAS00184
ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a or

b.
Direction a Headlight beam is raised.

Direction b Headlight beam is
lowered.
2. Adjust:
headlight beam (horizontally)
a. Turn the adjusting screw 2 in direction a or

b.
Direction a Headlight beam moves to

the right.
Direction b Headlight beam moves to
the left.
3-48
ENG
CHAPTER 4.
ENGINE
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

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

REMOVING THE ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . 4-16
CHECKING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
INSTALLING THE CAMSHAFT AND ROCKER ARMS . . . . . . . . . . . 4-18
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . 4-21
CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
CYLILNDERS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

REMOVING THE PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . . 4-28
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
INSTALLING THE PISTONS AND CYLINDERS . . . . . . . . . . . . . . . . . 4-31
GENERATOR AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

STATOR COIL AND PICKUP COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
GENERATOR ROTOR AND STARTER CLUTCH . . . . . . . . . . . . . . . 4-34
REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
INSTALLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
PUSH LEVER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
ENG
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
REMOVING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . 4-43
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . 4-46
CHECKING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . 4-46
INSTALLING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . 4-47
INSTALLILNG THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

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

SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . 4-54
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
CHECKING THE SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
INSTALLILNG THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . 4-57

CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . 4-59
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
CHECKING THE CRANKSHAFT AND CONNECTING ROD . . . . . . 4-61
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . 4-62
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND
TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
TRANSMISSION, SHIFT DRUM ASSEMBLY AND
SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . 4-66
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
INSTALLING THE TRANSMISSION, SHIFT FORKS
AND SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
ENGINE REMOVAL ENG
ENGINE
ENGINE REMOVAL
DRIVE SPROCKET AND EXHAUST PIPES
60 Nm (6.0 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)
10 Nm
(1.0 mkg)
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
25 Nm (2.5 mkg)

Removing the drive sprocket and Remove the parts in the order listed.
exhaust pipes
Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycles so
Rider and passenger seats Refer to “RIDER AND PASSENGER

SEATS” in chapter 3.
Fuel tank Refer to “FUEL TANK” in chapter 3.
Airfilter case assembly Refer to “CARBURETOR” in
Carburetor assembly chapter 5.
1 Muffler assembly 1
2 Exhaust pipe 1
4-1
ENGINE REMOVAL ENG
60 Nm (6.0 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)
10 Nm
(1.0 mkg)
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
25 Nm (2.5 mkg)

3 Rear brake switch lead 1 Disconnect.
4 Footrest/brake pedal 1/1
5 Drive chain case 1
6 Chain cover 1
7 Sprocket holder 1
8 Drive sprocket 1
procedure.
4-2
ENGINE REMOVAL ENG
LEADS, SHIFT PEDAL AND CLUTCH CABLE

Removing the leads, shift pedal and Remove the parts in the order listed.
clutch cable
1 Battery negative lead 1
2 Pickup coil coupler 1
3 A.C. magneto coupler 1
4 Plug codes 2
5 Starter motor lead 1
6 Clutch cable 1
procedure.
4-3
ENGINE REMOVAL ENG
EAS00191
ENGINE
35 Nm (3.5 mkg)
35 Nm (3.5 mkg)
35 Nm (3.5 mkg)
35 Nm (3.5 mkg)
35 Nm (3.5 mkg)

Removing the engine Remove the parts in the order listed.
1 Bolt (front upper) 2 NOTE:
2 Bolt (front under) 1 Place a suitable stand under the frame and
3 Bolt (rear upper) 1 engine.
4 Bolt (rear under) 1
5 Engine stay (front upper) 1
6 Engine stay (front under) 1 Refer to “INSTALLING THE ENGINE”.
7 Engine stay (rear upper) 2
procedure.
4-4
ENGINE ENG
EAS00192
INSTALLING THE ENGINE

1. Install:
bolt (front under) 1
bolt (rear under) 2
bolt (rear upper) 3
bolt (front upper) 4
engine bracket 5
engine bracket 6
engine brackets 7
NOTE:
Do not fully tighten the bolts.
2. Tighten the bolts in the following order.

self locking nut 8 35 Nm (3.5 mkg)
bolt (front upper) 4 35 Nm (3.5 mkg)
engine bracket bolts 9
35 Nm (3.5 mkg)
3. Install:
chain cover
CAUTION:
Connecting the neutral switch lead, starter
motor and A.C. generator leads should be
through under the neutral switch.
Face the terminal cover to right-under side,
then assemble the chain cover without the
both leads being caught.
4. Install:
shift arm 1 10 Nm (1.0 mkg)
NOTE:
Align the punch mark a in the shift shaft with
the slot in the shift arm.
Align the bottom edge of the shift pedal with
the mark on the frame-to-swingarm bracket.
ADJUSTING bolt length b

276.8 mm
4-5
CYLINDER HEADS ENG
CYLINDER HEADS
FRONT CYLINDER HEAD
10 Nm (1.0 mkg) 10 Nm (1.0 mkg)
22 Nm (2.2 mkg)
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
26 Nm (2.6 mkg)

Removing the front cylinder head Remove the parts in the order listed.
Engine assembly Refer to “ENGINE REMOVAL”.
1 Carburetor joint 1
2 Camshaft sprocket cover 1
3 Chain tensioner 1
4 Camshaft sprocket 1
5 Bracket 1
6 Cylinder head 1
7 Dowel pins 2
8 Head gasket 1
procedure.
4-6
CYLINDER HEADS ENG
REAR CYLINDER HEAD
22 Nm (2.2 mkg)
12 Nm (1.2 mkg)
26 Nm
(2.6 mkg)
12 Nm (1.2 mkg)
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)

Removing the rear cylinder head Remove the parts in the order listed.
1 Camshaft sprocket cover 1
2 Chain tensioner 1
3 Camshaft sprocket 1
4 Bracket 1
5 Cylinder head 1
6 Dowel pins 2
7 Head gasket 1
procedure.
4-7
CYLINDER HEADS ENG
REMOVING THE CYLINDER HEADS
Front cylinder head
1. Remove:
camshaft sprocket cover
tappet cover
timing plug
straight plug
2. Align:
“T” mark a on the generator rotor (with the
stationary pointer b on the crank case cov-
er)

b. Align the “T” mark a with the stationary
pointer b on the crankcase cover (left) when
the rear piston is at TDC on the compression
stroke.
c. Check that the front piston is at TDC in the
compression stroke.
d. The front piston is at TDC on the compres-
sion stroke when there is clearance at both of
the rocker arms. If there is no clearance then
turn the crankshaft counterclockwise one full
turn.
e. When to “T” mark is aligned with the station-
ary pointer the alignment mark c on the
camshaft sprocket should be aligned with the
stationary pointer d on the cylinder head.
3. Loosen:
bolt (camshaft sprocket) 1
NOTE:
Use the sheave holder 2 to hold the rotor.
Sheave holder:
90890-01701
4-8
CYLINDER HEADS ENG
4. Remove:
S timing chain tensioner 1
S gasket 2
5. Remove:
S bolt (camshaft sprocket) 1
S camshaft sprocket 2
NOTE:
To prevent the timing chain from falling into the
crankcase fasten a wire to it.
6. Remove:
S cylinder head
NOTE:
S Loosen the bolts in the proper sequence.
S Follow the numerical order shown in the il-
lustration. Loosen each bolt 1/4 of a turn at a
time until all of the bolts are loose.
Rear cylinder head

NOTE:
When removing the rear cylinder head, repeat
the front cylinder head removal procedures.
However, note the following points.
1. Align:
S “I” mark
(with the stationary pointer)
Removal steps:
S Turn the crankshaft counterclockwise 300_.
S Align the “I” mark a with the stationary pointer
b on the crankcase cover (left) when the rear
piston is at TDC on the compression stroke.
S When the “I” mark is aligned with the stationary
pointer the alignment mark c on the camshaft
sprocket should be aligned with the stationary
pointer d on the cylinder head.
S The rear piston is at TDC on the compression
stroke when there is clearance at both of the
rocker arms.
4-9
CYLINDER HEADS ENG
EAS00228
CHECKING THE CYLINDER HEADS

inder heads.
1. Eliminate:
combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
spark plug threads
valve seats
2. Check:
cylinder head
Damage/scratches Replace.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylin-
der head.
Cylinder head warpage

Less than 0.05 mm
a. Place a straightedge 1 and a thickness

gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limited is exceeded, resurface the cylin-
der head as follows.
d. Place 400 – 600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
4-10
CYLINDER HEADS ENG
EB401430
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
timing chain tensioner
Cracks/damage/rough movement Re-
place.
a. Lightly press the timing chain tensioner rod

into the timing chain tensioner housing by
hand.
NOTE:
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver 1 until
it stops.
b. Remove the screwdriver and slowly release

the timing chain tensioner rod.
c. Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.
INSTALLING THE CYLINDER HEADS

Front cylinder
1. Install:
dowel pins
gasket New
2. Install:
cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
4-11
CYLINDER HEADS ENG
3. Tighten:
bolts (cylinder head)
M8 1 22 Nm (2.2 mkg)
M6 2 12 Nm (1.2 mkg)
NOTE:
Lubricate the cylinder head bolts with engine
oil.
Tighten the cylinder head bolts in the proper
tightening sequence as shown and torque
them in two stages.
4. Install:
camshaft sprocket

b. Align the “T” mark a with the stationary
pointer b on the generator cover.
c. Install the camshaft sprocket with the timing
mark c facing out.
d. Turn the camshaft just enough to remove any
slack from the intake side of the timing chain.
e. Insert your finger into the hole and timing
chain tensioner hole and push the timing
chain guide inward.
f. While pushing the timing chain guide, be
sure that the timing mark c and the station-
ary pointer d are properly aligned at TDC.
5. Install:
timing chain tensioner
a. Lightly press the timing chain tensioner rod

into the timing chain tensioner housing by
hand.
b. While pressing the timing chain tensioner
rod, wind it clockwise with a thin screwdriver
1 until it stops.
c. With the screwdriver still inserted into the
timing chain tensioner, install the timing
chain tensioner 2 , and gasket.
Then, tighten the timing chain tensioner bolts
3 to the specified torque.
4-12
CYLINDER HEADS ENG
WARNING
Always use a new gasket.
Timing chain tensioner bolt

10 Nm (1.0 mkg)
d. Remove the screwdriver, make sure that the

timing chain tensioner rod releases, and
tighten the cap bolt to the specified torque.
Cap bolt
8 Nm (0.8 mkg)
6. Install:
camshaft sprocket 1
bolt (camshaft sprocket) 2
26 Nm (2.6 mkg)
NOTE:
Be sure the projection on the camshaft sprock-
et plate is aligned with the hole in the sprocket.
Use the sheave holder to hold the rotor.
Sheave holder:
90890-01701
7. Check:
alignment marks
If the marks do not align Adjust.
8. Measure:
valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3.
Rear cylinder head
NOTE:
When installing the rear cylinder head, repeat
the front cylinder head installation procedure.
However, note the following points.
4-13
CYLINDER HEADS ENG
1. Install:
S camshaft sprocket
a. Turn the crankshaft counterclockwise 300_.

b. Align the “I” mark a with the stationary point-
er b on the generator cover.
c. Install the camshaft sprocket with the timing
mark c facing out.
d. Turn the camshaft just enough to remove any
slack from the intake side of the timing chain.
e. Insert your finger into the hole and timing
chain tensioner hole and push the timing
chain guide inward.
f. While pushing the timing chain guide, be
sure that the timing mark c and the station-
ary pointer d are properly aligned at TDC.
4-14
ROCKER ARMS AND CAMSHAFT ENG
ROCKER ARMS AND CAMSHAFT
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)
12 Nm (1.2 mkg)

Removing the rocker arms and Remove the parts in the order listed.
camshaft
Cylinder head Refer to “CYLINDER HEAD”.
1 Stopper plate 1
2 Camshaft bushing 1 Refer to “REMOVING/INSTALLING THE
ROCKER ARM AND CAMSHAFT”.
3 Rocker arm shafts 2 Refer to “REMOVING/INSTALLING THE
4 Rocker arms 2 ROCKER ARM AND CAMSHAFT”.
5 Lock nuts 2
6 Valve adjusting screw 2
7 Camshaft 1
For installation reverse the removal
procedure.
4-15
REMOVING THE ROCKER ARMS AND CAM-
SHAFT
1. Loosen:
lock nuts 1
adjusting screws 2
2. Remove:
rocker arm shaft
rocker arm 3
NOTE:
Remove the rocker arm shafts with the slide
hammer 1 and weight.
Slide hammer bolt

90890-01083
Weight:
90890-01084
3. Remove:
camshaft bushing 1
camshaft 2
NOTE:
Screw a 10 mm bolt 3 into the threaded end of
the camshaft and then pull out the camshaft.
EAS00205
CHECKING THE CAMSHAFT

1. Check:
camshaft bushings
Damage/wear Replace.
2. Check:
camshaft lobes
Blue discoloration/pitting/scratches Re-
place the camshaft.
3. Measure:
camshaft lobe dimensions a and b
Out of specification Replace the cam-
shaft.
Camshaft lobe dimension limit

Intake
a 26.190 mm
b #1: 21.045 mm
#2: 21.087 mm
Exhaust
a 26.190 mm
b #1: 21.087 mm
#2: 21.045 mm
4-16
4. Check:
camshaft oil passage
Obstruction Blow out with compressed air.
EAS00206
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
rocker arm 1
2. Check:
rocker arm lobe 2
Excessive wear Replace the rockerarm.
3. Check:
rocker arm shaft
Blue discoloration/excessive wear/pit-
ting/scratches Replace or check the lu-
brication system.
4. Measure:
rocker arm inside diameter a
Out of specification Replace.
Rocker arm inside diameter

10.000 10.015 mm
<Limit>: 10.035 mm
5. Measure:
rocker arm shaft outside diameter b
Rocker arm shaft outside diameter

9.981 9.991 mm
<Limit>: 9.961 mm
6. Calculate:
rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.
Above 0.08 mm Replace the defective

part(-s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 0.034 mm
<Limit>: 0.08 mm
4-17
EAS00220
INSTALLING THE CAMSHAFT AND ROCK-

ER ARMS
1. Lubricate:
camshaft
Camshaft/Bushing
Molybdenum disulfide oil
2. Install:
camshaft 1
camshaft bushing 2
NOTE:
Make sure that the No.1 camshaft 3 is
installed in the front cylinder head and the No.2
camshaft 4 is installed in the rear cylinder
head.
3. Install:
stopper plate 1 12 Nm (1.2 mkg)
4. Lubricate:
rocker arm shafts
Engine oil
4-18
5. Install:
rocker arms
rocker arm shafts
NOTE:
Make sure that the rocker arm shafts is com-
pletely pushed into the cylinder head.
4-19
VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS

Removing the valves and valve Remove the parts in the order listed.
springs
Cylinder heads Refer to “CYLINDER HEADS”.
Rocker arms and camshafts Refer to “ROCKER ARMS AND
CAMSHAFTS”.
1 Valve cotters 4 Refer to “REMOVING/INSTALLING
THE VALVES”.
2 Valve spring retainers 2
3 Valve springs 2
4 Valve (intake) 1
5 Valve (exhaust) 1 Refer to “INSTALLING THE VALVES”.
6 Valve stem seals 2
7 Valve spring seats 2
procedure.
4-20
EAS00237
REMOVING THE VALVES

valves and related components.
NOTE:
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure that the valves properly seal.
1. Check:
valve sealing
Leakage at the valve seat Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent 1 into the intake and

exhaust ports.
b. Check that the valves properly seal.
There should be no leakage at the valve seat
2.
2. Remove:
valve cotters
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
1.

90890-04019
EAS00239
CHECKING THE VALVES AND VALVE GUIDES

valve and valve guides.
1. Measure:
valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
4-21
Out of specification Replace the valve
guide.
Valve-stem-to-valve-guide
clearance
Intake 0.010 0.037 mm
<Limit>: 0.08 mm
<Limit>: 0.1 mm
2. Replace.
S valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100_C (212_F) in an oven.
a. Remove the valve guide with a valve guide

remover 1 .
b. Install the new valve guide with a valve guide
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 (5.0 mm)

90890-04097
Valve guide installer (5.0 mm)
90890-04098
3. Eliminate:
S carbon deposits
(from the valve face and valve seat)
4. Check:
S valve face
Pitting/wear Grind the valve face.
S valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
4-22
5. Measure:
valve margin thickness a
Out of specification Replace the valve.
Valve margin thickness

Intake 0.5 0.9 mm
Exhaust 0.7 1.3 mm
6. Measure:
valve stem runout
Out of specification Replace the valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.02 mm
EAS00240
CHECKING THE VALVE SEATS

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 limit

Intake: 1.6 mm
Exhaust: 1.6 mm
a. Apply Mechanic’s blueing dye (Dykem) b

onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
d. Measure the valve seat width. Where the
valve seat and valve face contacted one
another, the blueing will have been removed.
4-23
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
a. Apply a coarse lapping compound to the

valve face.
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
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 be-
tween 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. Apply Mechanic’s blueing dye (Dykem) onto
the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width again. If the
valve seat width is out of specification, reface
and lap the valve seat.
4-24
EAS00241
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
S valve spring free length a
spring.
Valve spring free length (intake

and exhaust)
29.71 mm
<Limit>: 27.81 mm
2. Measure:
S compressed spring force a
spring.
b Installed length
Compressed spring force

Intake and exhaust spring
129 N at 25.6 mm
3. Measure:
S valve spring tilt c
spring.
Spring tilt limit

Intake and exhaust valve spring
2.5_/1.3 mm
EAS00245
INSTALLING THE VALVES

valves and related components.
1. Deburr:
S valve stem end
(with an oil stone)
2. Lubricate:
S valve stem
S oil seal New
(with the recommended lubricant)
Molybdenum disulfide oil
3. Install:
S valve
S lower spring seat
S oil seal New
S valve spring
S upper spring seat
(into the cylinder head)
4-25
NOTE:
Install the valve spring with the larger pitch a
facing up.
b Smaller pitch
4. Install:
valve cotters
NOTE:
Install the valve cotters by compressing the valve
spring with the valve spring compressor 1 .

90890-04019
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
4-26
CYLINDERS AND PISTONS ENG
CYLINDERS AND PISTONS

Removing the cylinders and pistons Remove the parts in the order listed.
Cylinder heads Refer to “CYLINDER HEADS”.
1 Timing chain guide 1
2 Cylinder 1
Refer to “INSTALLING THE PISTONS
3 Dowel pins 2
AND CYLINDERS”.
4 Cylinder gasket 1
5 Piston pin clips 2
6 Piston pin 1 Refer to “REMOVING/INSTALLING
7 Piston 1 THE CYLINDERS AND PISTONS”.
8 Piston ring set 1
procedure.
4-27
EAS00254
REMOVING THE PISTONS

The following procedure applies to all of the pis-
tons.
1. Remove:
piston pin clip 1
piston pin 2
piston 3
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
For reference during installation, put an identi-
fication mark on each piston crown.
Before removing the piston pin, deburr the pis-
ton pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller 4 .
Piston pin puller

90890-01304
2. Remove:
top ring
2nd ring
oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
EB404405
CHECKING THE CYLINDERS AND PISTONS

inders and pistons.
1. Check:
piston wall
cylinder wall
Vertical scratches Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
4-28
2. Measure:
piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder

bore gauge.
a 45 mm from the top of the cylinder
NOTE:
Measure cylinder bore “C” by taking side-to-
side and front-to-back measurements of the cyl-
inder. Then, find the average of the measure-
ments.
Wear
Standard
limit
Cylinder
40.99 41.03 mm 41.1 mm
bore C:
X+Y
C=
2
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
b 3 mm from the bottom edge of the piston.
Piston size P
Standard 40.96 41.00 mm
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.02 0.04 mm
<Limit>: 0.15 mm
f. If out of specification, replace the cylinder, and

replace the piston and piston rings as a set.
4-29
EB404410
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 clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance

Top ring
0.02 0.08 mm
<Limit>: 0.12 mm
2nd ring
0.02 0.06 mm
<Limit>: 0.12 mm
2. Install:
piston ring
(into the cylinder)
NOTE:
Using the piston crown pash the ring into the cyl-
inder so that the ring will be at a right angle to the
cylinder bore.
a 20 mm from the top of the cylinder

3. Measure:
piston ring end gap
Out of specification Replace the piston ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring end gap

Top ring
0.15 0.30 mm
<Limit>: 0.4 mm
2nd ring
0.15 0.30 mm
<Limit>: 0.4 mm
Oil ring
0.2 0.7 mm
4-30
EAS00266
CHECKING THE PISTON PINS

ton pins.
1. Check:
piston pin
Blue discoloration/grooves ! Replace, then
inspect the lubrication system.
2. Measure:
piston pin outside diameter a
Out of specification ! Replace the piston pin.
Piston pin outside diameter

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

13.002 13.013 mm
4. Calculate:
piston-pin-to-piston clearance
Out of specification ! Replace the piston pin.
Piston-pin-to-piston clearance =
Piston pin bore size b –
Piston pin outside diameter a
Piston-pin-to-piston clearance
0.002 0.017 mm
EB404701
INSTALLING THE PISTONS AND CYLINDERS

tons and cylinders.
1. Install:
oil ring expander
lower oil ring rail
upper oil ring rail
2nd ring
top ring
NOTE:
Be sure to install the piston rings so that the
manufacuturer’s marks or numbers face up.
4-31
2. Install:
piston 1
piston pin 2
piston pin clip New 3
NOTE:
Apply engine oil onto the piston pin.
Make sure that the “EX” mark a on the piston
faces towards the exhaust side of the engine.
Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the clip from falling into the crankcase.
3. Install:
gasket New
dowel pins
4. Lubricate:
piston
piston rings
cylinder
Engine oil
5. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
6. Install:
cylinder 22 Nm (2.2 mkg)
NOTE:
While compressing the piston rings with one
hand, install the cylinder with the other hand.
Pass the timing chain and timing chain guide
through the timing chain cavity.
4-32
GENERATOR AND STARTER CLUTCH ENG
GENERATOR AND STARTER CLUTCH

STATOR COIL AND PICKUP COIL
5 Nm (0.5 mkg)
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg) 10 Nm (1.0 mkg)

Removing the stator coil and pickup Remove the parts in the order listed.
coil
Engine oil Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
A.C. magneto lead/pickup coil lead
Refer to “ENGINE REMOVAL”.
Footrest/shift pedal
1 Generator cover 1
2 Dowel pins 2
3 Gasket 1
4 Stator coil 1
5 Pickup coil 1
procedure.
4-33
GENERATOR ROTOR AND STARTER CLUTCH
80 Nm (8.0 mkg)

Removing the generator rotor and Remove the parts in the order listed.
starter clutch
1 Generator rotor 1
2 Starter clutch assembly 1
3 Starter clutch drive gear 1
4 Idler gear 1
5 Idler gear shaft 1
procedure.
4-34
REMOVING THE GENERATOR
1. Remove:
footrest/shift pedal
Refer to “ENGINE REMOVAL”.
generator cover
2. Remove:
generator rotor nut 1
washer
NOTE:
While holding the generator rotor 2 with the
sheave holder 3 , loosen the generator rotor
nut.
Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
4. Remove:
generator rotor 1
(with the flywheel puller set 2 )
woodruff key
CAUTION:
To protect the end of the crankshaft, place
an appropriate sized socket between the fly-
wheel puller set’s center bolt and the crank-
shaft.
NOTE:
Make sure that the flywheel puller is centered
over the generator rotor.
Flywheel puller set

90890-01361
4-35
EAS00351
CHECKING THE STARTER CLUTCH

1. Check:
starter clutch idler gear 1
starter clutch drive gear 2
Burrs/chips/roughness/wear Replace
the defective part(-s).
2. Check:
starter clutch gear’s contacting surfaces a
Damage/pitting/wear Replace the starter
clutch gear.
3. Check:
starter clutch operation
a. Install the starter clutch drive gear 1 onto

the starter clutch 2 and hold the starter
clutch.
b. When turning the starter clutch drive gear
clockwise A , the starter clutch and the start-
er clutch drive gear should engage.
If the starter clutch drive gear and starter
clutch do not engage, the starter clutch is
faulty and must be replaced.
c. When turning the starter clutch drive gear
counterclockwise B , it should turn freely.
If the starter clutch drive gear does not turn
freely, the starter clutch is faulty and must be
replaced.
4-36
INSTALLING THE GENERATOR
1. Install:
starter clutch assembly
woodruff key
generator rotor
washer
generator nut
NOTE:
Clean the tapered portion of the crankshaft
and the generator rotor hub.
When installing the generator rotor, make sure
the woodruff key is properly seated in the key
way of the crankshaft.
2. Tighten:
generator rotor nut 1 80 Nm (8.0 mkg)
NOTE:
While holding the generator rotor 2 with the
sheave holder 3 , tighten the generator rotor
nut.
Sheave holder
90890-01701
3. Apply:
sealant
(onto stater coil assembly lead grommet)
Yamaha bond No.1215

90890-85505
4. Install:
stator coil
generator cover
NOTE:
Tighten the generator cover bolts in stages and
in a crisscross pattern.
5. Install:
footrest/shift pedal
4-37
CLUTCH ENG
CLUTCH
CLUTCH COVER
10 Nm
(1.0 mkg)
10 Nm
(1.0 mkg)

Removing the clutch cover Remove the parts in the order listed.
WARNING
Securely support the motorcycle so
Engine oil Drain.

Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Muffler assembly Refer to “ENGINE REMOVAL”.
Exhaust pipes
1 Oil filter cover 1
2 O-ring 1
4-38
CLUTCH ENG
10 Nm
(1.0 mkg)
10 Nm
(1.0 mkg)

3 Oil filter 1
4 Clutch cover 1
5 Dowel pins 2
6 Clutch cover gasket 1
procedure.
4-39
CLUTCH ENG
CLUTCH
80 Nm
(8.0 mkg)
75 Nm (7.5 mkg)
8 Nm (0.8 mkg)
8 Nm
(0.8 mkg)

Removing the clutch Remove the parts in the order listed.
1 Pressure plate 1
2 Push plate 1 1
3 Friction plate 5
4 Clutch plate 4
5 Push rod (short) 1
6 Ball 1
7 Push rod (long) 1
8 Clutch boss nut 1
9 Lock washer 1
10 Clutch boss 1
11 Holding plate 1
12 Clutch housing 1
13 Nut 1
14 Lock washer 1
4-40
CLUTCH ENG
80 Nm
(8.0 mkg)
75 Nm (7.5 mkg)
8 Nm (0.8 mkg)
8 Nm
(0.8 mkg)

15 Washer 1
16 Primary drive gear 1
17 Spacer 1
18 Key 1
procedure.
4-41
CLUTCH ENG
PUSH LEVER SHAFT
12 Nm (1.2 mkg)

Removing the push lever shaft Remove the parts in the order listed.
1 Push lever 1
2 Spring 1
3 Circlip 1
4 Oil seal 1
5 Bearing 1
procedure.
4-42
CLUTCH ENG
EAS00276
REMOVING THE CLUTCH

1. Straighten the lock washer tab.
2. Loosen:
clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the univer-
sal clutch holder, loosen the clutch boss nut.
Universal clutch holder

90890-04068
3. Remove:
clutch boss nut 1
lock washer 2
clutch boss 3
EAS00279
REMOVING THE PRIMARY DRIVE GEAR

1. Straighten the lock washer tab.
2. Remove:
primary drive gear nut 1
lock washer 2
NOTE:
While holding the generator rotor with the
sheave holder, loosen the primary drive gear
nut.
Sheave holder
90890-01701
4-43
CLUTCH ENG
EAS00280
CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric-
tion plates.
1. Check:
friction plate
Damage/wear Replace the friction plates
as a set.
2. Measure:
friction plate thickness
Out of specification Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate thickness

2.9 3.1 mm
<Limit>: 2.5 mm
EAS00281
CHECKING THE CLUTCH PLATES

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 0.05 mm
4-44
CLUTCH ENG
EAS00282
CHECKING THE CLUTCH SPRINGS

clutch springs.
1. Check:
clutch spring
Damage Replace the clutch springs as a
set.
2. Measure:
clutch spring free length
Out of specification Replace the clutch
springs as a set.
Clutch spring free length

34.6 mm
<Limit>: 33.6 mm
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 er-
ratic clutch operation.
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 er-
ratic clutch operation.
4-45
CLUTCH ENG
EAS00286
CHECKING THE PRESSURE PLATE

1. Check:
pressure plate 1
EAS00288
CHECKING THE CLUTCH PUSH RODS

1. Check:
O-ring 1
short clutch push rod 2
long clutch push rod 3
ball 4
Cracks/damage/wear Replace the de-
fective 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

0.5 mm
EAS00292
CHECKING THE PRIMARY DRIVE GEAR

1. Check:
primary drive gear 1
primary driven gear 2
Damage/wear Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation Re-
place the primary drive and primary driven
gears as a set.
2. Check:
primary -drive-gear-to-primary-driven-gear
free play
Free play exists Replace the primary drive
and primary driven gears as a set.
4-46
CLUTCH ENG
INSTALLING THE PRIMARY DRIVE GEAR
1. Install:
straight key
primary drive gear 1
thrust washer
lock washer 2
primary drive gear nut 3
80 Nm (8.0 mkg)
NOTE:
While holding the generator rotor with the
sheave holder, tighten the primary drive gear
nut.
Sheave holder
90890-01701
EAS00298
INSTALLING THE CLUTCH

1. Install:
clutch housing 1
thrust washer 2
clutch boss 3
lock washer
clutch boss nut
NOTE:
Make sure that the teeth on the lock washer are
correctly aligned with the grooves on the clutch
boss.
2. Tighten:
clutch boss nut 1 75 Nm (7.5 mkg)
NOTE:
While holding the clutch boss with the universal
clutch holder, tighten the clutch boss nut.
Universal clutch holder

90890-04086
3. Bend the lock washer tab along a flat side of

the nut.
4. Lubricate:
friction plates
clutch plates
Engine oil
4-47
CLUTCH ENG
5. Install:
friction plates
clutch plates
NOTE:
First, install a friction plate and then alternate
between a clutch plate and a friction plate.
Align the slot a in the friction plates with the
marks b in the clutch housing.
6. Install:
long clutch push rod
ball
7. Install:
short clutch push rod 1
O-ring 2 New
push plate 3
washer 4
nut 5
8. Install:
pressure plate 1
clutch springs 2
clutch spring bolts 3 8 Nm (0.8 mkg)
NOTE:
Align the punch mark a in the clutch boss with
the punch mark b in the pressure place.
Tighten the clutch spring bolts in stages and in
a crisscross pattern.
9. Check:
push lever position
Push lever mark a and crankcase mark b
not aligned Correct.
NOTE:
Push the push lever in direction c and make
sure that the marks are aligned.
4-48
CLUTCH ENG
10. Adjust:
push lever position

b. Turn the adjusting screw 2 in or out until the
marks are aligned.
c. Hold the adjusting screw to prevent it from
moving and then tighten the locknut to speci-
fication.
CAUTION:
Do not overtighten the locknut since this will
remove the free play between both push
rods.
Push lever lock nut

8Nm (0.8mkg)
11. Install:
clutch cover 1 10 Nm (1.0 mkg)
NOTE:
Tighten the clutch cover bolts in stages and in a
crisscross pattern.
4-49
OIL PUMP ENG
OIL PUMP
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)

Removing the oil pump Remove the parts in the order listed.
Engine oil Drain.
Clutch cover Refer to “REMOVING THE CLUTCH
COVER”.
Clutch Refer to “REMOVING THE CLUTCH”.
1 Circlip 1
2 Washers 2
3 Oil pump drive gear 1
4 O-rings 2
5 Oil pump 1
procedure.
4-50
OIL PUMP ENG
7 Nm (0.7 mkg)

Disassembling the oil pump Disassemble the parts in the order listed.
1 Oil pump cover 1
2 Inner rotor 1
3 Outer rotor 1
4 Dowel pins 2
5 Dowel pin 1
6 Oil pump driven gear 1
7 Housing 1
For assembly, reverse the disassembly
procedure.
4-51
OIL PUMP ENG
CHECKING THE OIL PUMP
1. Check:
oil pump drive gear 1
oil pump driven gear 2
oil pump housing
oil pump housing cover
Cracks/damage/wear Replace the de-
fective 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-outer-
rotor clearance c
Out of specification Replace the oil pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.15 mm
<Limit>: 0.2 mm
Outer-rotor-to-oil-pump-housing
clearance
0.03 0.09 mm
<Limit>: 0.15 mm
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
0.03 0.09 mm
<Limit>: 0.15 mm
3. Check:
oil pump operation
Unsmooth Repeat steps (1) and (2) or re-
place the defective part(-s).
EAS00375
ASSEMBLING THE OIL PUMP

1. Lubricate:
inner rotor
outer rotor
oil pump shaft
Engine oil
4-52
OIL PUMP ENG
2. Install:
oil pump shaft 1
(to the oil pump cover 2 )
pin 3
inner rotor 4
outer rotor 5
pins 6
oil pump housing 7
screw 7 Nm (0.7 mkg)
NOTE:
When installing the inner rotor, align the pin 3 in
the oil pump shaft with the groove a on the in-
ner rotor 4 .
3. Check:
oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP

1. Install:
O-ring
oil pump 1
oil pump drive gear 2
7 Nm (0.7 mkg)
CAUTION:
After tightening the bolts, make sure that the
oil pump turns smoothly.
4-53
SHIFT SHAFT ENG
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER

Removing the shift shaft and stopper Remove the parts in the order listed.
lever
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Clutch cover
Refer to “CLUTCH”.
Clutch
Oil pump drive gear Refer to “OIL PUMP”.
1 Circlip 1
2 Shift lever 1
3 Spring 1
4 Shift lever arm 1
5 Shift shaft 1
4-54
SHIFT SHAFT ENG

6 Shift cam stopper lever 1
7 Collar 1
procedure.
4-55
SHIFT SHAFT ENG
EAS00328
CHECKING THE SHIFT SHAFT

1. Check:
shift shaft 1
stopper lever 2
Bends/damage/wear Replace
stopper lever spring 3
Roller turns roughly Replace the shift le-
ver.
EB408410
CHECKING THE SHIFT LEVER

1. Check:
shift lever 1
Bends/damage/wear Replace.
shift lever spring 2
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.
Mesh the stopper lever with the shift drum seg-
ment assembly.
4-56
CRANKSHAFT AND CONNECTING RODS ENG
CRANKSHAFT AND CONNECTING RODS

CRANKSHAFT ASSEMBLY
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)

Removing the crankshaft assembly Remove the parts in the order listed.
Engine assembly Refer to “ENGINE REMOVAL”.
Cylinder head Refer to “CYLINDER HEADS”.
Cylinder and piston Refer to “CYLINDER AND PISTONS”.
Clutch assembly Refer to “CLUTCH”.
A.C. magneto and starter clutch Refer to “GENERATOR AND STARTER
CLUTCH”.
Shift shaft Refer to “SHIFT SHAFT”.
Oil pump Refer to “OIL PUMP”.
Primary drive gear Refer to “CLUTCH”.
1 Chain guide 4
2 Timing chain holder 1
3 Timing chain 2
4-57
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)

4 Timing chain drive gear 1
5 Crankcase (right) 1
6 Dowel pins 2
procedure.
4-58
CRANKSHAFT AND CONNECTING RODS

Removing the crankshaft and Remove the parts in the order listed.
connecting rods
1 Timing chain drive gear 2
2 Bearings 2
3 Crank 2
4 Washer 3
5 Crank pin 1
6 Connecting rod 2
procedure.
4-59
EAS00386
DISASSEMBLING THE CRANKCASE

1. Remove:
crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical or-
der (refer to the numbers in the illustration).
The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
2. Remove:
right crankcase
NOTE:
For this removal, slits a in the crankcase can
be use as shown.
CAUTION:
Use a soft hammer to tap on one side of the
crankcase. Tap only on reinforced portions
of the crankcase. Do not tap on the crank-
case mating surfaces. Work slowly and
carefully. Make sure that the crankcase
halves separate evenly.
4-60
EAS00394
CHECKING THE CRANKSHAFT AND CON-

NECTING ROD
1. Measure:
crankshaft runout
Out of specification Replace the crank-
shaft, bearing or both.
NOTE:
Turn the crankshaft slowly.
Crankshaft runout
Less than 0.03 mm
2. Measure:
big end side clearance
Out of specification Replace the big end
bearing, crankshaft pin, or connecting rod.
Big end side clearance

0.40 1.05 mm
Limit 1.5 mm
3. Measure:
crankshaft width
Out of specification Replace the crank-
shaft.
Crankshaft width
67.95 68.00 mm
4. Check:
crankshaft sprocket 1
Damage/wear Replace the crankshaft.
bearing 2
Cracks/damage/wear Replace the
crankshaft.
5. Check:
crankshaft journal
Scratches/wear Replace the crankshaft.
crankshaft journal oil passage
4-61
EAS00401
CHECKING THE BEARINGS AND OIL

SEALS
1. Check:
bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement Replace.
2. Check:
oil seals
EAS00207
CHECKING THE TIMING CHAIN, CAMSHAFT

SPROCKET AND TIMING CHAIN GUIDES
1. Check:
timing chain
Damage/stiffness Replace the timing
chain and camshaft sprocket as a set.
2. Check:
camshaft sprocket
More than 1/4 tooth a wear Replace the
camshaft sprocket and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
timing chain guide (exhaust side)
timing chain guide (intake side)
Damage/wear Replace the defective
part(-s).
4-62
EAS00408
INSTALLING THE CRANKSHAFT

1. Install:
crankshaft assembly 1
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, apply
grease onto the oil seal lips and apply en-
gine oil onto each bearing.
EAS00418
ASSEMBLING THE CRANKCASE

1. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
2. Apply:
sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215

90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery a .
3. Install:
dowel pins 1
4. Tighten:
crankcase left half
7 Nm (0.7 mkg)
NOTE:
Tighten the screws in decreasing numerical or-
der (see numbers on the illustration).
4-63
TRANSMISSION ENG
TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS

Removing the transmission, shift Remove the parts in the order listed.
drum assembly and shift forks
Crankcase separating Refer to “CRANKCASE AND
CRANKSHAFT”.
1 Shift fork guide bar 2 (short length) 1
2 Shift fork guide bar 1 (long length) 1
Refer to “INSTALLING THE
3 Shift drum 1
TRANSMISSION, SHIFT FORK AND
4 Shift fork 1 “C” (center) 1
SHIFT DRUM ASSEMBLY”.
5 Shift fork 2 “R” (right) 1
6 Shift fork 3 “L” (left) 1
7 Main axle assembly 1 Refer to “REMOVING THE
8 Drive axle assembly 1 TRANSMISSION”.
procedure.
4-64
TRANSMISSION ENG

Disassembling the drive axle and Disassemble the parts in the order listed.
main axle
1 Bearing 1
2 Circlip 1
3 Washer 1
4 First wheel gear 1
5 Forth wheel gear 1
6 Third wheel gear 1
7 Fifth wheel gear 1
8 Second wheel gear 1
9 Drive axle 1
10 Second pinion gear 1
11 Fifth pinion gear 1
12 Third pinion gear 1
13 Forth pinion gear 1
14 Main axle 1
15 Collar 1
For assembly, reverse the removal
procedure.
4-65
TRANSMISSION ENG
EAS00420
REMOVING THE TRANSMISSION

1. Remove:
drive axle assembly 1
main axle assembly 2
Remove them at same the time.
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. Check:
shift fork movement
(on the shift fork guide bar)
Rough movement Replace the shift forks
and shift fork guide bar as a set.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:
shift drum grooves
Damage/scratches/wear Replace the
shift drum.
shift drum segment
shift drum bearing
Damage/pitting Replace.
4-66
TRANSMISSION ENG
EAS00424
CHECKING THE TRANSMISSION

1. Measure:
main axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the main
axle.
Main axle runout limit

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

0.08 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.
NOTE:
When reassembling the main axle, press the
2nd pinion gear 1 onto it 2 as shown.
5. Check:
transmission gear movement
Rough movement Replace the defective
part(-s).
6. Check:
87.2 87.4 mm circlips
Damage/bends/looseness Replace.
4-67
TRANSMISSION ENG
EAS00426
INSTALLING THE TRANSMISSION, SHIFT

FORKS AND SHIFT DRUM ASSEMBLY
1. Install:
shift fork 3 “L” (left) 1
(face the “L” side for the clutch side.)
shift fork 2 “R” (right) 2
(face the “R” side for the clutch side.)
shift fork 1 “C” (center) 3
(face the “C” side for the magneto side.)
shift fork guide bar 1 4 (long)
shift fork guide bar 2 5 (short)
NOTE:
Install the shift forks with the embossed mark to
the right and in sequence (R, C, L) beginning
from the right.
2. Check:
shift drum operation
Unsmoothy operation Repair.
NOTE:
Check the transmission and shift forks for
smooth operation by turning the shift drum with
your hand.
4-68
CARB
CHAPTER 5.
CARBURETOR
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHECKING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
INSTALLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . 5-7
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
DISASSEMBLING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
ASSEMBLING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
CARB
CARBURETOR CARB
CARBURETOR
CARBURETOR
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)

Removing the carburetor Remove the parts in the order listed.
Fuel tank Refer to “FUEL TANK” in chapter 3.
1 Air filter case assembly 1
2 Silencer assembly 1
3 Fuel hose 1 Disconnect.
4 Throttle position sensor lead 1 Disconnect.
5 Carburetor heater lead 2 Disconnect.
6 Carburetor 1
7 Starter cable 1
8 Throttle cables 2
9 Thermo lead 1
procedure.
5-1
CARBURETOR CARB

Disassembling the carburetor Disassemble the parts in the order listed.
1 Vacuum chamber cover 1
2 Piston valve spring 1 NOTE:
3 Piston valve 1 Before disassembling the carburetor,
4 Jet needle holder set 1 make sure to note the number of times the
5 Jet needle set 1 pilot screw is turned out from the seated
6 Fuel drain bolt 1 position to its set position.
7 Float chamber 1
8 Float 1
9 Needle valve 1
10 Main jet 1
11 Main jet holder 1
12 Pilot screw 1
13 Starter plunger 1
14 Pilot air screw 1
15 Heater 1
16 Pilot jet 1
5-2
CARBURETOR CARB

17 Throttle stop screw 1
18 Throttle position sensor 1
procedure.
5-3
CARBURETOR CARB
EB600031
CHECKING THE CARBURETOR

NOTE:
Before disassembling the carburetor, make
sure to note the number of times the pilot screw
is turned out from the seated position to its set
position.
1. Check:
carburetor body
float chamber
jet housing
2. Check:
fuel passages
Obstruction Clean.
a. Wash the carburetor in a petroleumbased

solvent. Do not use any caustic-carburetor-
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
3. Check:
float chamber body
Dirt Clean.
4. Check:
float chamber rubber gasket
5. Check:
float
Damage Replace.
6. Check:
needle valve 1
needle valve seat 2
O-ring 3
Damage/obstruction/wear Replace the
needle valve, needle valve seat and O-ring
as a set.
5-4
CARBURETOR CARB
7. Check:
piston valve 1
Damage/scratches/wear Replace.
rubber diaphragm 2
Cracks/tears Replace.
8. Check:
vacuum chamber cover 1
piston valve spring 2
plastic cap 3
plastic cap 4
spring 5
9. Check:
jet needle 1
needle jet 2
main jet 3
Pilot screw 4
pilot jet 5
main air jet 6
Obstruction Clean.
Blow out the jets with compressed air.
10. Check:
piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness Replace the piston valve.
11. Check.
fuel feed pipes
hose joint
Obstruction Clean.
Blow out the pipes with compressed air.
12. Check:
fuel feed hoses
fuel hoses
Obstruction Clean.
Blow out the hoses with compressed air.
5-5
CARBURETOR CARB
EB600042
ASSEMBLING THE CARBURETOR

NOTE:
Before disassemblling the carburetor, make
sure to note the number of times, the pilot screw
is turned out from the seated position to its set
position.
CAUTION:
Before assembling the carburetors, wash
all of the parts in a petroleum-based sol-
vent.
Always use a new gasket.
1. Install:
main jet holder 1
main jet 2
pilot jet 3
2. Install:
needle valve seat
3. Install:
needle valve
float 1
float pin 2
4. Install:
float chamber
pilot screw
piston valve
piston valve spring
vacuum chamber cover
5-6
CARBURETOR CARB
EB600051
INSTALLING THE CARBURETOR

1. Adjust:
engine idling speed
Engine idling speed

1,250 1,450 r/min
Refer to “ADJUSTING THE ENGINE ID-

LLING SPEED” in chapter 3.
2. Adjust:

(at the flange of the throttle grip)
3 5 mm

CABLE FREE PLAY” in chapter 3.
EB600063
MEASURING AND ADJUSTING THE FUEL

LEVEL
1. Measure:
fuel level a
Fuel level (above the line on

the float chamber b )
9.5 10.5 mm
a. Stand the motorcycle on a level surface.

b. Place the motorcycle on a suitable stand to
ensure that the motorcycle is standing
straight up.
c. Install the fuel level gauge 1 to the fuel drain
pipe 2 .
Fuel level gauge

90890-01312
d. Loosen the fuel drain screw 3 .

e. Hold the fuel level gauge vertically next to the
upper face of the float chamber.
f. Measure the fuel level a .
NOTE:
Fuel level readings should be equal on both
sides of the carburetor assembly.
5-7
CARBURETOR CARB
2. Adjust:
fuel level
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 slight-
ly 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.
5-8
CARBURETOR CARB
EAS00502
CHECKING AND ADJUSTING THE

THROTTLE POSITION SENSOR
NOTE:
Before adjusting the throttle position sensor, the
engine idling speed should be properly ad-
justed.
1. Check:
S throttle position sensor
(installed on the carburetor)
a. Disconnect the throttle position sensor cou-

pler from the wire harness.
b. Connect the pocket tester (Ω 1k) to the
throttle position sensor coupler.
Positive tester probe blue terminal 1

Negative tester probe black terminal 2
c. Measure the maximum throttle position sen-

sor resistance.
Out of specification Replace the throttle
position sensor.
Maximum throttle position sensor

resistance
4.0 X 6.0 kΩ at 20_C
(blue – black)
d. Connect the pocket tester (Ω 1k) to the

throttle position sensor.
Positive tester probe yellow terminal 3

e. While slowly opening the throttle, check that

the throttle position sensor resistance is with-
in the specified range.
NOTE:
Check mainly that the resistance changes grad-
ually when turning the throttle, since the read-
ings (from closed to wide-open throttle) may dif-
fer slightly from those specified.
Out of specification or the resistance

changes abruptly Go to step 2 below.
Throttle position sensor

resistance
(520 X 900 Ω) X (4.0 X 6.0 kΩ)
at 20_C
(yellow – black)
5-9
CARBURETOR CARB
2. Check:
S throttle position sensor
(removed from the carburetor)

b. Remove the throttle position sensor from the
carburetor.
c. Connect the pocket tester (Ω 1k) to the

d. Measure the maximum throttle position sen-

sor resistance.
Out of specification Replace the throttle
position sensor.
Maximum throttle position

sensor resistance
4.0 X 6.0 kΩ at 20_C
(blue – black)
e. Connect the pocket tester (Ω 1k) to the


f. While slowly opening the throttle, check that

the throttle position sensor resistance is with-
in the specified range.
The resistance does not change or it
changes abruptly Replace the throttle
position sensor.
The slot is worn or broken Replace the
NOTE:
Check mainly that the resistance changes grad-
ually when turning the throttle, since the read-
ings (from closed to wide-open throttle) may dif-
fer slightly from those specified.
Throttle position sensor

resistance
0 X 5 ± 1.0 kΩ at 20_C
(yellow – black)
5-10
CARBURETOR CARB
3. Adjust:
throttle position sensor angle

b. Connect the pocket tester (Ω 1k) to the

c. Measure the throttle position sensor maxi-

mum resistance.
d. Calculate the throttle position sensor maxi-
mum resistance when the throttle is fully
closed.
Throttle position sensor maximum

resistance (throttle is fully closed) =
Maximum resistance (0.13 0.15)
Example
If the maximum resistance = 5 kΩ, then the
throttle position sensor’s maximum resistance
when the throttle is fully closed should be:
4 5 kΩ (0.13 0.15) = 650 750 Ω
Lift the carburetor assembly slightly out of the
intake manifolds.
Loosen the throttle position sensor screws 4 .
Connect the pocket tester (Ω 100) to the
4 throttle position sensor.

e. Adjust the throttle position sensor angle so

that the measured resistance is within the
specified range.
Throttle position sensor resis-

tance
650 750 Ω
(yellow – black terminal)
After adjusting the throttle position sensor

angle, tighten the throttle position sensor
screws.
5-11
FUEL PUMP CARB
CHECKING THE FUEL PUMP
1. Check:
fuel pump
a. Turn the fuel cock “OFF”.

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

pump.
DISASSEMBLING THE FUEL PUMP

Turn the fuel cock “OFF”.
1. Remove:
fuel hoses
pulser hose
fuel pump
2. Remove:
fuel pump cover 1
diaphragm 2
fuel pump body 3
fuel pump cover 4
3. Check:
fuel pump body 1
Obstruction Clean.
Cracks/damage Replace fuel pump as-
sembly.
5-12
FUEL PUMP CARB
4. Check:
diaphragms and gaskets
Turn/fatigue/cracks Replace fuel pump
assembly.
5. Check:
valves 1
Cracks/damage Replace fuel pump as-
sembly.
ASSEMBLING THE FUEL PUMP

Reverse the disassembly procedure.
NOTE:
Be sure to connect the hoses correctly.
5-13
CHAS
CHAPTER 6.
CHASSIS
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
CHECKING THE BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
CHECKING THE SPEEDOMETER GEAR UNIT . . . . . . . . . . . . . . . . 6-7
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . . 6-9
REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
REAR BRAKE AND REAR WHEEL SPROCKET . . . . . . . . . . . . . . . . 6-12
REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . . 6-16
CHECKING AND REPLACING THE REAR WHEEL SPROCKET . 6-16
CHECKING THE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
ASSEMBLILNG THE BRAKE SHOE PLATE . . . . . . . . . . . . . . . . . . . . 6-18
INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . . 6-19
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . 6-22
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
REMOVING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . 6-26
CHECKING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . 6-27
INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . 6-28
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
DISASSEMBLING THE FRONT BRAKE CALIPER . . . . . . . . . . . . . . 6-32
CHECKING THE FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 6-33
ASSEMBLLING AND INSTALLILNG THE FRONT BRAKE
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . 6-39
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . 6-39
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . 6-41
ASSEMBLILNG THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . 6-41
INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . 6-45
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
CHAS
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . 6-57

REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 6-57
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
HANDLING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . 6-59
DISPOSING OF A REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . 6-59
REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES . . . . . 6-60
REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
CHECKING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . 6-62
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
FRONT WHEEL AND BRAKE DISC CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC
40 Nm (4.0 mkg)
59 Nm (5.9 mkg)
20 Nm (2.0 mkg)
23 Nm (2.3 mkg)

Removing the front wheel and brake Remove the parts in the order listed.
disc NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
WARNING
1 Brake caliper 1
2 Front wheel axle pinch bolt 1 Refer to “REMOVING/INSTALLING
3 Front wheel axle 1 THE FRONT WHEEL”.
4 Front wheel assembly 1
5 Collars 1 Refer to “INSTALLING THE FRONT
6 Speedometer gear 1 WHEEL”.
7 Brake disc 1
procedure.
6-1

Disassembling the front wheel Disassemble the parts in the order listed.
1 Oil seals 2
2 Speedometer clutch retainer 1
3 Speedometer clutch 1
4 Bearings 2
5 Collar 1
procedure.
6-2
EAS00519
REMOVING THE FRONT WHEEL

WARNING
NOTE:
2. Remove:
brake caliper 1
NOTE:
Do not squeeze the brake lever when removing
the brake caliper.
3. Remove:
pinch bolt (front wheel axle) 2
front wheel axle 3
4. Elevate:
front wheel
NOTE:
EAS00526
CHECKING THE FRONT WHEEL

1. Check:
wheel axle
Roll the wheel axle on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
tire
front wheel
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
6-3
3. Check:
spokes
Bends/damage Replace.
Loose Tighten.
Tap the spokes with a screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone, a
loose spoke will sound flat.
4. Tighten:
spokes 3 Nm (0.3 mkg)
NOTE:
After tightening the spokes, measure the front
wheel runout.
5. Measure:
front wheel radial runout 1
front wheel lateral runout 2
Over the specified limits Replace.
Front wheel radial runout limit

2.0 mm
Front wheel lateral runout limit
2.0 mm
6. Check:
collars
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn.
Therefore, approximately 100 km should
be traveled at normal speed before any
highspeed riding is done.
7. Check:
wheel bearings
Front wheel turns roughly or is loose Re-
place the wheel bearings.
oil seals
8. Replace:
wheel bearings New
oil seals New
6-4
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 be-
tween the screwdriver and the wheel surface.
c. Remove the wheel bearings with a general

bearing puller 2 .
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing center race
4 or balls 5 . Contact should be made only
with the outer race 6 .
NOTE:
Use a socket 3 that matches the diameter of
the wheel bearing outer race and oil seal.
EAS00531
CHECKING THE BRAKE DISC

1. Check:
brake disc
Damage/galling Replace.
2. Measure:
brake disc deflection 1
Out of specification Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit

(maximum)
Front: 0.15 mm
a. Place the motorcycle on a suitable stand so

that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
6-5
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the center part of the brake disc that
the brake pads touches.
3. Measure:
brake disc thickness 1
Measure the brake disc thickness at a few
different locations.
Brake disc thickness limit

(minimum)
Front: 4.5 mm
4. Adjust:
brake disc deflection
a. Remove the brake disc.

b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
Brake disc bolt

23 Nm (2.3 mkg)
LOCTITE
d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
6-6
CHECKING THE SPEEDOMETER GEAR
UNIT
1. Check:
speedometer clutch
2. Check:
speedometer drive gear 1
speedometer driven gear 2
EAS00542
INSTALLING THE FRONT WHEEL

1. Lubricate:
wheel axle
wheel bearings
oil seal lips
speedometer drive gear
speedometer driven gear
Lithium soap base grease
2. Install:
speedometer gear unit
NOTE:
Make sure that the speedometer gear unit and
the wheel hub are installed with the two projec-
tions meshed into the two slots respectively.
3. Install:
front wheel assembly
NOTE:
Make sure that the slot b in the speedometer
gear unit fits over the stopper c on the outer
tube.
The arrow mark a on the tire must point in the
direction of the wheel.
6-7
4. Tighten:
59 Nm (5.9 mkg)
wheel axle 1
wheel axle pinch bolt 2
20 Nm (2.0 mkg)
brake caliper bolts 3 40 Nm (4.0 mkg)
WARNING
Make sure that the brake cable is routed
properly.
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds smooth-
ly.
6-8
EAS00549
ADJUSTING THE FRONT WHEEL STATIC

BALANCE
NOTE:
S After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
S Adjust the front wheel static balance with the
brake discs installed.
1. Remove:
S balancing weight (-s)
NOTE:
Place the front wheel on a suitable balancing
stand.
2. Find:
S front wheel’s heavy spot
a. Spin the front wheel.

b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
c. Turn the front wheel 90_ so that the “X1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
f. Repeat steps (b) through (d) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
3. Adjust:
S front wheel static balance
a. Install a balancing weight 1 onto the rimex-

actly 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 posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
6-9
4. Check:
front wheel static balance
a. Turn the front wheel and make sure that it

stays at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
6-10
REAR WHEEL AND REAR BRAKE CHAS
REAR WHEEL AND REAR BRAKE

REAR WHEEL
23 Nm (2.3 mkg)
104 Nm (10.4 mkg)
16 Nm (1.6 mkg)
16 Nm (1.6 mkg)

Removing the rear wheel Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevant.
1 Tension bar 1
2 Adjuster 1
3 Pin 1
4 Compression spring 1
5 Rear wheel axle 1
6 Nut/washer 1/1
7 Lock nut/nut/washer 2/2/2
8 Chain pullers 2
9 Rear wheel assembly 1
procedure.
6-11
REAR BRAKE AND REAR WHEEL SPROCKET
40 Nm (4.0 mkg)

Removing the rear brake and rear Remove the parts in the order listed.
wheel sprocket
1 Shoe plate 1
2 Sprocket 1
3 Collar 3
4 Oil seal 1
5 Bearing 1
6 Rear wheel drive hub 1
7 Rear wheel drive hub dampers 4
8 Rear wheel 1
procedure.
6-12

Disassembling the rear wheel Disassemble the parts in the order listed.
1 Bearings 2
2 Spacer 1
procedure.
6-13
10 Nm (1.0 mkg)

Disassembling the brake shoe plate Disassemble the parts in the order listed.
1 Brake shoe 2
2 Tension springs 2 Refer to “REMOVING THE REAR
3 Camshaft lever 1 WHEEL/ASSEMBLING THE BRAKE
4 Indicator plate 1 SHOE PLATE”.
5 Camshaft 1
6 Brake shoe plate 1
procedure.
6-14
EAS00563
REMOVING THE REAR WHEEL

WARNING
NOTE:
2. Remove:
tension bar 1
3. Remove:
wheel axle 2
rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
4. Remove:
brake shoe plate
5. Remove:
brake shoes 1
brake camshaft lever 2
NOTE:
Mark the position on the brake camshaft lever
where it is aligned with the punch mark in the
brake camshaft.
6-15
EAS00566
CHECKING THE REAR WHEEL

1. Check:
wheel axle
rear wheel
wheel bearings
oil seals
Refer to “FRONT WHEEL”.
2. Check:
tire
rear wheel
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Check:
spokes
4. Measure:
rear wheel radial runout
rear wheel lateral runout
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB

1. Check:
rear wheel drive hub 1
rear wheel drive hub dampers 2
EAS00568
CHECKING AND REPLACING THE REAR

WHEEL SPROCKET
1. Check:
rear wheel sprocket
rear wheel sprocket.
Bent teeth Replace the rear wheel sprock-
et.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
2. Replace:
rear wheel sprocket
a. Remove the self-locking nuts and the rear

wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.
6-16
Rear wheel sprocket self-locking

nut
40 Nm (4.0 mkg)
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00569
CHECKING THE BRAKE

brake shoes.
1. Check:
brake shoe lining
Glazed areas Repair.
Sand the glazed areas with course sandpa-
per.
NOTE:
After sanding the glazed areas, clean the brake
shoe with a cloth.
2. Measure:
brake shoe lining thickness a
Brake shoe lining thickness limit

(minimum)
2 mm
WARNING
Do not allow oil or grease to contact the
brake shoes.
NOTE:
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Measure:
brake drum inside diameter b
b Out of specification Replace the wheel.
Brake drum inside diameter limit

(maximum)
131 mm
6-17
4. Check:
brake drum inner surface
Oil deposits Clean.
Remove the oil with a rag soaked in lacquer
thinner or solvent.
Scratches Repair.
Lightly and evenly polish the scratches with
an emery cloth.
5. Check:
brake camshaft
EAS00570
ASSEMBLING THE BRAKE SHOE PLATE

1. Install:
brake camshaft 1
spring
brake shoe wear indicator 2
a. Install the camshaft lever so its punch mark

c is positioned as shown.
b. Align the projection a on the brake shoe
wear indicator with the notch b in the brake
shoe camshaft.
c. Check that the brake shoes are properly
positioned.
6-18
EAS00571
INSTALLING THE REAR WHEEL

1. Lubricate:
wheel axle
wheel bearings
oil seal lips
2. Adjust:
drive chain slack
Drive chain slack

30 40 mm
Refer to “ADJUSTING THE DRIVE CHAIN

SLACK” in chapter 3.
3. Tighten:
wheel axle nut 104 Nm (10.4 mkg)
WARNING
Make sure that the brake hose is routed
properly.
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. Adjust:
rear wheel static balance
6-19
FRONT AND REAR BRAKES CHAS
FRONT AND REAR BRAKES

FRONT BRAKE PADS
27 Nm (2.7 mkg)

Removing front brake pads Remove the parts in the order listed.
1 Retaining bolt 2
2 Brake caliper 1 Refer to “REPLACING THE FRONT
3 Brake pads 2 BRAKE PADS”.
4 Pad spring 3
procedure.
6-20
EAS00579
CAUTION:
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
Never disassemble brake components un-
less absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
Never use solvents on internal brake com-
ponents.
Use only clean or new brake fluid for clean-
ing brake components.
up any spilt fluid immediately.
Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
First aid for brake fluid entering the eyes:
Flush with water for 15 minutes and get im-
mediate medical attention.
6-21
EAS00581
REPLACING THE FRONT BRAKE PADS

NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove:
retaining bolt 1
2. Remove:
brake caliper 2
3. Remove:
brake pad spring 1
brake pads 2
4. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.
Brake pad wear limit

0.8 mm
5. Install:
brake pad spring
brake pads
NOTE:
Always install new brake pads and a new 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 mkg)
d. Install new brake pads and brake pad spring.
6. Lubricate:
retaining bolts 1
6-22
CAUTION:
Do not allow grease to contact the brake
pads.
Remove any excess grease.
7. Install:
brake caliper
retaining bolt 27 Nm (2.7 mkg)
8. Check:
brake fluid level
LEVEL” in chapter 3.
9. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6-23
FRONT BRAKE MASTER CYLINDER
7 Nm (0.7 mkg)
30 Nm (3.0 mkg)

Removing the front brake master Remove the parts in the order listed.
cylinder
Brake fluid Drain.
1 Rear view mirror 1
2 Brake lever/compression spring 1/1
3 Front brake switch 1
4 Union bolt 1
5 Copper washers 2
6 Brake hose 1
7 Master cylinder bracket 1
8 Master cylinder 1
procedure.
6-24

Disassembling the front brake Remove the parts in the order listed.
master cylinder
1 Dust boot 1
2 Circlip 1
3 Master cylinder cup 1
4 Spring 1
procedure.
6-25
EAS00588
REMOVING THE FRONT BRAKE MASTER

CYLINDER
NOTE:
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake
system.
1. Remove:
rear view mirror (right)
brake lever/compression spring
brake switch 1
2. Remove:
union bolt 2
copper washers
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove:
master cylinder bracket
master cylinder
6-26
EAS00592
CHECKING THE FRONT BRAKE MASTER

CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
brake master cylinder 1
brake fluid delivery passages 2
(brake master cylinder body)
2. Check:
brake master cylinder kit 1
3. Check:
brake fluid reservoir 1
brake fluid reservoir diaphragm 2
4. Check:
brake hoses 1
6-27
EAS00598
INSTALLING THE FRONT BRAKE MASTER

CYLINDER
WARNING
Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
ponents.

DOT 4
1. Install:
brake master cylinder 1
brake master cylinder bracket 2
7 Nm (0.7 mkg)
NOTE:
Install the brake master cylinder bracket with
the “UP” mark facing up.
Align the end of the brake master cylinder hold-
er with the punch mark a on the handlebar.
First, tighten the upper bolt, then the lower bolt.
2. Install:
copper washers New 1
brake hose 2
union bolt 3 30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
NOTE:
While holding the brake hose, tighten the
union bolt as shown.
Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e. g., wire harness, cables, leads).
Correct if necessary.
3. Fill:
brake master cylinder reservoir
mended brake fluid)
DOT 4
6-28
WARNING
Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
mance.
CAUTION:
4. Bleed:
brake system
5. Check:
brake fluid level
6. Check:
system.
6-29
EAS00612
FRONT BRAKE CALIPER
30 Nm (3.0 mkg)
27 Nm (2.7 mkg)

Removing the front brake caliper Remove the parts in the order listed.
Brake fluid Drain.
1 Brake hose holder 1
2 Union bolt 1
3 Copper washer 2 Refer to “REMOVING/INSTALLING
4 Brake hose 1 THE FRONT BRAKE CALIPER”.
5 Retaining bolt 2
6 Brake caliper assembly 1
procedure.
6-30
6 Nm (0.6 mkg)
Order Job name/Part name Q’ty Remarks

Disassembling the front brake Remove the parts in the order listed.
calipers
1 Pad spring 1
2 Brake caliper pistons 2
3 Dust seals 2 Refer to “REMOVING THE FRONT
4 Caliper piston seals 2 BRAKE CALIPERS”.
5 Bleed screw 1
procedure.
6-31
EAS00619
DISASSEMBLING THE FRONT BRAKE CAL-

IPER
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
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. Blow compressed air into the brake hose

joint opening to force out the pistons from the
brake caliper.
WARNING
Cover the brake caliper pistons with a rag.
Be careful not to get injured when the pis-
tons are expelled from the brake caliper.
Never try to pry out the brake caliper pis-
tons.
b. Remove the brake caliper piston seals.
6-32
EAS00633
CHECKING THE FRONT BRAKE CALIPERS
Recommended brake component

replacement schedule:
Brake pads If necessary
Piston seals Every two years
Brake hoses Every two years
Every two years
and whenever the
Brake fluid
brake is disas-
sembled.
1. Check:
brake caliper pistons 1
Rust/scratches/wear Replace the brake
caliper. Piston assembly.
brake caliper cylinders 2
Scratches/wear Replace the brake cali-
per.
brake calipers 3
brake fluid delivery passages
(brake caliper body)
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
2. Check:
brake caliper brackets 1
6-33
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPER
WARNING
Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
ponents as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.

DOT 4
1. Install:
brake caliper 1
(temporarily)
copper washers New 2
brake hose 3
union bolt 4 30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake caliper 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
2. Install:
brake pads
brake pad springs
brake caliper retaining bolt
27 Nm (2.7 mkg)
brake caliper
Refer to “REPLACING THE BRAKE PADS”.
6-34
3. Fill:
brake master cylinder reservoir
mended 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.
mance.
CAUTION:
4. Bleed:
brake system
5. Check:
brake fluid level
6. Check:
system.
6-35
FRONT FORK CHAS
EAS00646
FRONT FORK
20 Nm (2.0 mkg)
23 Nm (2.3 mkg)
7 Nm (0.7 mkg)
30 Nm
3.0 mkg)
40 Nm (4.0 mkg)
7 Nm (0.7 mkg)

Removing the front fork Remove the parts in the order listed.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISC”.
2 Brake caliper assembly 1
3 Front fender 1
4 Turn signal light pinch bolts 2 Loosen.
5 Upper bracket pinch bolts 2 Loosen.
6 Cap bolts 2 Loosen.
7 Lower bracket pinch bolts 2 Loosen.
8 Front fork legs 2
procedure.
6-36
FRONT FORK CHAS
23 Nm (2.3 mkg)
30 Nm (3.0 mkg)

Disassembling the front fork Disassemble the parts in the order listed.
1 Cap bolt 1
2 O-ring 1
3 Spacer 1
4 Spring seat 1
5 Fork spring 1
6 Dust seal 1 Refer to “DISASSEMBLING/ASSEM-
7 Oil seal clip 1 BLING THE FRONT FORK LEGS”.
8 Damper rod bolt 1
9 Copper washer 1
10 Damper rod/rebound spring 1/1
11 Oil seal 1
6-37
FRONT FORK CHAS
23 Nm (2.3 mkg)
30 Nm (3.0 mkg)

12 Seal spacer 1
13 Outer tube bushing 1
14 Inner tube/inner tube bushing 1/1 Refer to “DISASSEMBLING/ASSEM-
15 Oil lock piece 1 BLING THE FRONT FORK LEGS”.
16 Outer tube 1
procedure.
6-38
FRONT FORK CHAS
EAS00649
REMOVING THE FRONT FORK LEGS

front fork legs.
WARNING
NOTE:
2. Loosen:
cap bolt 1
lower bracket pinch bolt 3
front turn signal pinch bolt 4
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
3. Remove:
front fork leg
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
1. Remove:
cap bolt
O-ring
spacer
spring seat
fork spring
2. Drain:
fork oil
3. Remove:
dust seal 1
oil seal clip 2 (with a flat-head screwdriver)
6-39
FRONT FORK CHAS
CAUTION:
Do not scratch the inner tube.
4. Remove:
damper rod bolt
copper washer
NOTE:
While holding the damper rod with the damper
rod holder 1 and T-handle 2 , loosen the
damper rod bolt 3 .
Damper rod holder

90890-01365
T-Handle
90890-01326
5. Remove:
damper rod
inner tube
a. Hold the front fork leg horizontally.

b. Securely clamp the brake caliper bracket in a
vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but care-
fully.
CAUTION:
Excessive force will damage the oil seal
and bushing. A damaged oil seal or bush-
ing must be replaced.
Avoid bottoming the inner tube into the
outer tube during the above procedure, as
the oil flow stopper will be damaged.
6-40
FRONT FORK CHAS
EAS00657
CHECKING THE FRONT FORK LEGS

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

299.4 mm
3. Check:
damper rod 1
Obstruction Blow out all of the oil pas-
sages with compressed air.
oil lock piece 2
Damage Replace.
CAUTION:
When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
cap bolt O-ring
EAS00659
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
WARNING
Make sure that the oil levels in both front
fork legs are equal.
Uneven oil levels can result in poor han-
dling and a loss of stability.
6-41
FRONT FORK CHAS
NOTE:
When assembling the front fork leg, be sure to
replace the following parts:
-inner tube bushing
-outer tube bushing
-oil seal
-dust seal
Before assembling the front fork leg, make
sure that all of the components are clean.
1. Install:
damper rod 1
oil lock piece 2
CAUTION:
Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
2. Lubricate:
inner tube’s outer surface
Fork oil 10 W or equivalent
3. Tighten:
damper rod bolt 1 30 Nm (3.0 mkg)
NOTE:
While holding the damper rod with the damper
rod holder 1 and T-handle 2 , tighten the
damper rod bolt.
Damper rod holder

90890-01365
T-handle
90890-01326
4. Install:
outer tube bushing 1
(with the fork seal driver weight and adapter)
Fork seal driver weight 2

90890-01367
Adapter 3
90890-01369
6-42
FRONT FORK CHAS
5. Install:
washer
oil seal 1
(with the fork seal driver weight and adapter)
CAUTION:
Make sure that the numbered side of the oil
seal faces up.
NOTE:
Before installing the oil seal, apply lithium soap
base grease onto its lips.
Apply fork oil onto the outer surface of the inner
tube.
Before installing the oil seal, cover the top of
2
the front fork leg with a plastic bag 2 to protect
the oil seal during installation.
6. Install:
oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
7. Install:
dust seal 1
(with the fork seal driver weight)
Fork seal driver weight

90890-01367
Adapter
90890-01369
8. Fill:
front fork leg
mended fork oil)
Quantity (each front fork leg)

311 cm3
Yamaha fork and shock oil
10 W or equivalent.
6-43
FRONT FORK CHAS
Front fork leg oil level a (from

the top of the inner tube, with the
inner tube fully compressed and
without the fork spring)
112 mm
NOTE:
While filling the front fork leg, keep it upright.
After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
Be sure to stroke the inner tube slowly be-
cause the fork oil may spurt out.
9. Install:
spring 1
spring seat 2
spacer 3
cap bolt 4
NOTE:
Install the spring with the smaller pitch facing
up.
Before installing the cap bolt, apply grease
onto the O-ring.
Temporarily tighten the cap bolt.
6-44
FRONT FORK CHAS
EAS00662
INSTALLING THE FRONT FORK LEGS

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 handlebar holder.
2. Tighten:
lower bracket pinch bolt 1
30 Nm (3.0 mkg)
20 Nm (2.0 mkg)
cap bolt 3 23 Nm (2.3 mkg)
front turn signal pinch bolt 4
7 Nm (0.7 mkg)
WARNING
Make sure that the brake hoses are routed
properly.
6-45
HANDLEBAR CHAS
HANDLEBAR
7 Nm (0.7 mkg)
23 Nm (2.3 mkg)
32 Nm (3.2 mkg)

Removing the handlebar Remove the parts in the order listed.
WARNING
that there is no danger of it falling over.
1 Plastic locking ties 4

2 Rear view mirror 2
3 Clutch cable 1
4 Clutch lever assembly 1
5 Clutch switch lead 1
6 Starter cable 1
7 Left handlebar switch 1
8 Grip (left) 1
9 Master cylinder bracket 1
6-46
HANDLEBAR CHAS
7 Nm (0.7 mkg)
23 Nm (2.3 mkg)
32 Nm (3.2 mkg)

10 Master cylinder assembly 1
11 Right handlebar switch 1
12 Throttle cables 2
13 Throttle grip assembly 1
14 Handlebar holder (upper) 2
15 Handlebar 1
16 Cable guide 1
17 Handlebar holder (lower) 1
procedure.
6-47
HANDLEBAR CHAS
EAS00666
REMOVING THE HANDLEBAR

WARNING
2. Remove:
front brake master cylinder assembly 1
right handlebar switch 2
throttle grip 3
3. Remove:
clutch lever assembly
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

WARNING
2. Check:
handlebar 1
Bends/cracks/damage Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
6-48
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.
EAS00670
INSTALLING THE HANDLEBAR

WARNING
2. Install:
handlebar 1
upper handlebar holders 2
23 Nm (2.3 mkg)
CAUTION:
First, tighten the bolts on the front side of
the handlebar holder, then on the rear side.
Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
NOTE:
The upper handlebar holders should be
installed with the arrows a facing forward A .
Align the match marks b on the handlebar
with the upper surface of the lower handlebar
holders.
3. Install:
throttle grip
throttle cable
right handlebar switch
6-49
HANDLEBAR CHAS
NOTE:
Install the right handlebar switch alignment sur-
face position so that it is perpendicular ( a =
90_) to the master cylinder alignment surface.
4. Install:
S master cylinder
Refer to “FRONT AND REAR BRAKES”.
5. Install:
S clutch lever holder 1
NOTE:
Align the slit in the clutch lever holder with the
punch mark a in the handlebar.
6. Install:
S clutch cable
7. Connect:
S clutch switch
NOTE:
Apply a thin coat of lithium soap base grease
onto the end of the clutch cable.
8 Install:
S left handlebar switch
NOTE:
Align the clutch lever assembly matching face
with the left handlebar switch matching face in a
straight line a , then assemble them.
6-50
HANDLEBAR CHAS
9. Adjust:
clutch cable free play
Refer to “ADJUSTING THE CLUTCH
Clutch cable free play (at the end

5 10 mm
10. Adjust:

3 5 mm
6-51
STEERING HEAD CHAS
STEERING HEAD
LOWER BRACKET
110 Nm (11.0 mkg)
1st 52 Nm (5.2 mkg)

2nd 18 Nm (1.8 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)

Removing the lower bracket Remove the parts in the order listed.
WARNING
that there is no danger of it falling over.
Front fork legs Refer to “FRONT FORK”.

Handlebar Refer to “HANDLEBAR”.
1 Headlight lens unit 1
2 Leads (in the headlight body) – Disconnect
3 Front turn signal light (left/right) 1/1
4 Headlight body 1
6 Upper bracket 1
7 Lock washer 1
8 Upper ring nut 1
6-52
STEERING HEAD CHAS
110 Nm (11.0 mkg)
1st 52 Nm (5.2 mkg)

2nd 18 Nm (1.8 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)

9 Rubber washer 1
10 Lower ring nut 1 Refer to “REMOVING THE LOWER
11 Bearing cover 1 BRACKET/INSTALLING THE
12 Lower bracket 1 STEERING HEAD”.
13 Bearing (upper) 1
14 Rubber seal 1
15 Bearing (lower) 1
For installaiton, reverse the removal
procedure.
6-53
STEERING HEAD CHAS
EAS00677
REMOVING THE LOWER BRACKET

WARNING
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.
Exhaust and steering nut wrench

90890-01268
Ring nut wrench
90890-01403
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD

1. Wash:
bearings
bearing races
Recommended cleaning solvent

Kerosine
2. Check
bearings 1
bearing races 2
3. Replace:
bearings
bearing races
6-54
STEERING HEAD CHAS
a. Remove the bearing reces from the steering

head pipe with a long rod 1 and hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install a new rubber seal and new bearing re-
ces.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the bearings and bearing
races as a set.
Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:
upper bracket
lower bracket
(along with the steering stem)
EAS00683
INSTALLING THE STEERING HEAD

1. lubricate:
upper bearing
lower bearing
bearing races
2. Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
3. Install:
upper bracket
steering stem nut
6-55
STEERING HEAD CHAS
NOTE:
Temporarily tighten the steering stem nut.
4. Install:
front fork legs
Refer to “FRONT FORK”
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts.
6-56
REAR SHOCK ABSORBER AND SWINGARM CHAS
EAS00685
REAR SHOCK ABSORBER AND SWINGARM

REAR SHOCK ABSORBER ASSEMBLY
23 Nm (2.3 mkg)
23 Nm (2.3 mkg)

Removing the rear shock absorber Remove the parts in the order listed.
assembly Stand the motorcycle on a level surface.
1 Rear shock absorber assembly 2
procedure.
6-57
SWINGARM
46 Nm (4.6 mkg)
7 Nm (0.7 mkg)

Removing the swingarm Remove the parts in order listed.
Rear wheel Refer to “REAR WHEEL AND REAR
BRAKE”.
Rear shock absorber Refer to “REMOVING/INSTALLING THE
REAR SHOCK ABSORBER”.
Muffler and exhaust pipes
1 Chain cover 1
2 Chain case 1
3 Drive chain 1
4 Nut/washer 1/1
5 Pivot shaft 1
6 Cover 2
7 Coller 2
8 Oil seal 2
9 Bush 2
procedure.
6-58
EAS00687
HANDLING THE REAR SHOCK ABSORBER

WARNING
This rear shock absorber contain highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make sure
you understand the following information.
The manufacturer cannot be held responsi-
ble for property damage or personal injury
that may result from improper handling of
the rear shock absorber.
Do not tamper or attempt to open the rear
shock absorber.
Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
Do not deform or damage the rear shock
absorber in any way. If the rear shock ab-
sorber or both are damaged, damping per-
formance will suffer.
EAS00689
DISPOSING OF A REAR SHOCK ABSORB-

ER
a. Gas pressure must be released before dis-

posing of a rear shock absorber. To release
the gas pressure, drill 2 3 mm hole through
the gas cylinder at a point 15 20 mm from
its end as shown.
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
6-59
EAS00691
REMOVING THE REAR SHOCK ABSORBER

ASSEMBLIES
WARNING
NOTE:
2. Remove:
rear shock absorber (left and right)
EAS00706
REMOVING THE DRIVE CHAIN

WARNING
NOTE:
2. Remove:
chain cover 1
chain case
3. Remove:
drive chain 2
6-60
EAS00703
REMOVING THE SWINGARM

WARNING
NOTE:
2. Remove:
rear shock absorber assembly bolt 1
NOTE:
When removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Check:
swingarm side play A
swingarm vertical movement B
a. Check the tightening torque of the pivot shaft

nut.
Pivot shaft nut

46 Nm (4.6 mkg)
b. Check the swingarm side play A by moving

the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
Swingarm side play (at the end

of the swingarm)
1 mm
d. Check the swingarm vertical movement B

by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
6-61
EAS00696
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
rear shock absorber rod
Bends/damage Replace the rear shock
absorber assembly.
rear shock absorber
Gas leaks/oil leaks Replace the rear
shock absorber assembly.
spring
Damage/wear Replace the rear shock ab-
sorber assembly.
bushings
dust seals
bolts
EAS00707
CHECKING THE SWINGARM

1. Check:
swingarm
2. Check:
pivot shaft
Roll the pivot shaft on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash:
pivot shaft
dust covers
collars
washers
bearings
Recommended cleaning solvent

Kerosine
6-62
4. Check:
dust covers 1
spacer 2
oil seals 3
bearings
6-63
EAS00709
CHECKING THE DRIVE CHAIN

1. Measure:
ten-link section a of the drive chain
Out of specification Replace the drive
chain.
Max. ten-link drive chain section

119.5 mm
NOTE:
While measuring the ten-link section, push
down on the drive chain to increase its tension.
Measure the length between drive chain roller
1 and 11 as shown.
Perform this measurement at two or three dif-
ferent places.
2. Check:
drive chain
Stiffness Clean and lubricate or replace.
3. Clean:
drive chain
a. Wipe the drive chain with a clean cloth.

b. Put the drive chain in kerosine and remove
any remaining dirt.
6-64
c. Remove the drive chain from the kerosine
and completely dry it.
CAUTION:
This motorcycle has a drive chain with small
rubber O-rings 1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain.
High-pressure methods could force dirt or
water into the drive chain’s internals, and
solvents will deteriorate the O-rings. A
coarse brush can also damage the O-rings.
Therefore, use only kerosine to clean the
drive chain.
Don’t soak drive drain in kerosine more
them ten minutes. O-ring is damage by kero-
sine.
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
Cracks/damage/wear Replace the drive
chain.
5. Lubricate:
drive chain
6 Check:
drive sprocket
rear wheel sprocket
drive chain sprockets as a set.
Bent teeth Replace the drive chain sprock-
ets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
6-65
EAS00711
INSTALLING THE SWINGARM

1. Lubricate:
bearings
spacers
dust covers
pivot shaft
Molybdenum disulfide grease
2. Install:
rear shock absorber assembly
rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and “REAR
WHEEL”.
6-66
INSTALLING THE DRIVE CHAIN
1. Lubricate:
drive chain
2. Install:
drive chain
chain case
chain cover
CAUTION:
Connecting the neutral switch lead, starter
motor and A.C. generator leads should be
through under the neutral switch . Face the
terminal cover to right-under side, then as-
semble the chain cover without the both
leads being caught.
3. Install:
rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and “REAR
WHEEL”.
4. Adjust:
drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack

30 40 mm
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
6-67
ELEC
CHAPTER 7.
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CHECKING THE BULBS AND SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . 7-5

TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . 7-5
CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . 7-7
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 7-21
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
CHECKING THE SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 7-34
CARBURETOR HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
ELEC
ELECTRICAL COMPONENTS ELEC
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch 9 Fuse
2 Thermo switch 10 Starter relay
3 Flasher relay 11 Side stand switch
4 Relay unit 12 Neutral switch
5 Front brake light switch 13 Rectifier/ regulator
6 Clutch switch 14 Battery
7 Ignition coil 15 Rear brake light switch
8 Igniter unit 16 Horn
7-1
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 cou-
pler terminal slots 1 . Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
When checking for continuity, switch back and
forth between the switch positions a few times.
The terminal connections for switches (e.g.,

main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far left
column and the switch lead colors b are shown
in the top row in the switch illustration.
NOTE:
“ ” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows

that:
There is continuity between blue/red and red
when the switch is set to “ ”.
There is continuity between blue/red and blue,
between brown/blue and red, and between
blue/yellow and black when the switch is set to
“ON”.
7-2
CHECKING THE SWITCHES ELEC
EAS00731
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear Repair or replace the switch.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.
7-3
CHECKING THE SWITCHES ELEC
1 Clutch switch 9 Engine stop switch
2 Pass switch 10 Start switch
3 Horn switch 11 Fuse
4 Dimmer switch 12 Rear brake switch
5 Turn switch 13 Sidestand switch
6 Front brake switch 14 Neutral switch
7 Main switch
8 Lights switch
7-4
CHECKING THE BULBS AND BULB SOCKETS ELEC
EAS00732
CHECKING THE BULBS AND

BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity 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.
Bulbs A and B are used for headlights and
usually use a bulb holder which must be de-
tached before removing the bulb. The majority
of these bulbs can be removed from their re-
spective socket by turning them counterclock-
wise.
Bulb C is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclock-
wise.
Bulbs D and E are used for meter and indica-
tor lights and can be removed from their re-
spective socket by turn D and pulling E them
out.
CHECKING THE CONDITION OF THE

BULBS
bulbs.
1. Remove:
bulb
7-5
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
CAUTION:
Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:
bult (for continuity)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
a. Connect the tester positive probe to terminal

1 and the tester negative probe to terminal
2 , and check the continuity.
b. Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
3 , and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
7-6
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:
bulb socket (for continuity)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.

b. Connect the pocket tester probes to the re-
spective leads of the bulb socket.
c. Check the bulb socket for continuity.
If any of the readings indicate no continuity,
replace the bulb socket.
7-7
IGNITION SYSTEM ELEC
IGNITION SYSTEM
CIRCUIT DIAGRAM
3 Main switch
4 Fuse (main)
6 Battery
8 Fuse (ignition)
9 Relay unit
11 Sidestand switch
13 Ignitor
14 Ignition coil #1
15 Ignition coil #2
16 Spark plug
17 Pickup coil
18 Neutral switch
26 Engine stop switch
7-8
EAS00737 EAS00739
TROUBLESHOOTING 2. Battery
The ignition system fails to operate (no S Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main and ignition fuses Min. open-circuit voltage
2. battery 12.8 V or more at 20_C
3. spark plugs S Is the battery OK?
4. ignition spark gap
5. spark plug cap resistance YES NO
6. ignition coil resistance
7. pickup coil resistance
8. main switch S Clean the battery
9. engine stop switch terminals.
10. neutral switch S Recharge or re-
11. sidestand switch place the battery.
12. relay unit (diode)
13. wiring
(of the entire ignition system)
EAS00741
NOTE:
S Before troubleshooting, remove the following 3. Spark plugs
part(-s): The following procedure applies to all of the
1) battery cover spark plugs.
2) rider’s seat S Check the condition of the spark plug.
3) fuel tank S Check the spark plug type.
4) steering head side covers S Measure the spark plug gap.
5) tool box cover Refer to “CHECKING THE SPARK PLUGS”
6) left side cover in chapter 3.
7) cylinder head covers
S Troubleshoot with the following special Standard spark plug
tool(-s). Spark plug gap
0.6 X 0.7 mm
S Is the spark plug in good condition, is it of the
Ignition checker correct type, and its gap within specifica-
90890-06754 tion?
Pocket tester
90890-03112 YES NO
EAS00738
Re-gap or replace
1. Main and ignition fuses the spark plug.
S Check the main and ignition fuses for conti-
nuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.
S Are the main and ignition fuses OK?
YES NO
Replace the fuse(-s).
7-9
EAS00743
Spark plug cap resistance

4. Ignition spark gap
10 kΩ at 20_C
S Is the spark plug cap OK?
spark plugs.
S Disconnect the spark plug cap from the
YES NO
spark plug.
S Connect the ignition checker 1 as shown.
S 2 Spark plug cap Replace the spark
S Set the main switch to “ON”. plug cap.
S Measure the ignition spark gap a .
S Crank the engine by pushing the start switch
and gradually increase the spark gap until a
EAS00747
misfire occurs.
6. Ignition coil resistance
ignition coils.
S Disconnect the ignition coil connectors from
the ignition coil terminals.
S Connect the pocket tester (Ω 1) to the
ignition coil as shown.
Tester positive probe red/black
Tester negative probe orange (gray)
Min. ignition spark gap
6 mm
S Is there a spark and is the spark gap within
specification ?
NO YES
The ignition system

is OK.
S Measure the primary coil resistance.
EAS00745
5. Spark plug cap resistance. Primary coil resistance

3.4 X 4.6 Ω at 20_C
spark plug caps. S Connect the pocket tester (Ω 1k) to the
S Disconnect the spark plug cap from the ignition coil as shown.
spark plug. S Measure the secondary coil resistance.
S Connect the pocket tester (Ω 1k) to the Tester positive probe
spark plug cap as shown. spark plug lead 1
S Measure the spark plug cap resistance. Tester negative probe
Orange (gray) lead 2
7-10
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

Secondary coil resistance switch.
10.4 X 15.6 kΩ 20_C EAS00750
S Is the ignition coil OK? 9. Engine stop switch
YES NO S Check the engine stop switch for continuity.

S Is the engine stop switch OK?
Replace the ignition
coil. YES NO
EAS00748
Replace the right

7. Pickup coil resistance
handlebar switch.
S Disconnect the pickup coil coupler from the
wire harness. EAS00751
S Connect the pocket tester (Ω 100) to the 10. Neutral switch

pickup coil terminal.
S Check the neutral switch for continuity.
Tester positive probe green/white 1 Refer to “CHECKING THE SWITCHES”.
Tester negative probe blue/yellow 2 S Is the neutral switch OK?
YES NO
Replace the neutral

switch.
EAS00752
11. Sidestand switch

S Check the sidestand switch for continuity.
S Measure the pickup coil resistance.
S Is the sidestand switch OK?
Pickup coil resistance
192 X 288 Ω at 20_C YES NO
S Is the pickup coil OK?
Replace the side-
YES NO stand switch.
Replace the pickup

coil.
7-11
NOTE:
EAS00760 When you switch the “–” and “+” leads of the
12. Relay unit (Diode) digital pocket tester the readings in the above
chart will be reversed.
Disconnect the relay unit from the coupler.
Connect the pocket tester (Ω 1) to the Are the tester readings correct?
starting circuit cutoff relay terminals as
shown. YES NO
Measure the relay unit for continuity as
follws.
Replace the starting
Tester positive probe circuit cut-off relay.
blue/green 1
Tester negative probe Continuity
blue/yellow 2 EAS00754
Tester positive probe 13. Wiring

blue/yellow 2 No
Tester negative probe Check the entire ignition system’s wiring.
continuity
blue/green 1 Refer to “CIRCUIT DIAGRAM”.
Is the ignition system’s wiring properly con-
Tester positive probe nected and without defects?
light green 3
Tester negative probe Continuity NO YES
blue/yellow 2
Tester positive probe Properly connect or Replace the ignitor
blue/yellow 2 No repair the ignition unit.
Tester negative probe continuity system’s wiring.
lightgreen 3
7-12
ELECTRIC STARTING SYSTEM ELEC
ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM
3 Main switch
4 Fuse (main)
5 Starter relay
6 Battery
7 Starter motor
8 Fuse (ignition)
9 Relay unit
10 Clutch switch
11 Sidestand switch
18 Neutral switch
27 Start switch
7-13
EB803010
STARTING CIRCUIT OPERATION

The starting circuit on this model consists of the
starter motor, starter relay, and the starting cir-
cuit cut-off relay. If the engine stop switch is on
“RUN” and the main switch is on “ON” (both
switches are closed), the starter motor can op-
erate only if:
The transmission is in neutral (the neutral

switch is closed).
or if
The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the side-
stand is up (the sidestand switch is closed).
The starting circuit cut-off relay prevents the

starter from operating when neither of these
conditions have been met. In this instance, the
starting circuit cut-off relay is open so current
cannot reach the starter motor.
When at least one of the above conditions have

been met however, the starting circuit cut-off
relay is closed, and the engine can be started by
pressing the starter switch.
WHEN THE TRANSMISSION IS IN

NEUTRAL
WHEN THE SIDESTAND IS UP AND

THE CLUTCH LEVER IS PULLED IN
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
6 Starting circuit cut-off relay
7 Diode
8 Clutch switch
9 Sidestand switch
10 Neutral switch
11 Start switch
12 Starter relay
13 Starter motor
7-14
EAS00757 EAS00739
The starter motor fails to turn. S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
Check: THE BATTERY” in chapter 3.
1. main and ignition fuses
2. battery Open-circuit voltage
3. starter motor 12.8 V or more at 20_C
4. relay unit (starting circuit cutoff relay) S Is the battery OK?
5. relay unit (diode)
6. starter relay YES NO
7. main switch
8. engine stop switch
9. neutral switch S Clean the battery
10. sidestand switch terminals.
11. clutch switch S Recharge or re-
12. start switch place the battery.
13. wiring
(of the entire starting system) EAS00758
NOTE: 3. Starter motor

S Before troubleshooting, remove the following S Connect the battery positive terminal 1
part(-s): and starter motor lead 2 with a jumper lead
1) battery cover 3.
2) rider’s seat
3) fuel tank
4) steering head side covers
5) left side cover
S Troubleshoot with the following special
tool(-s).
Pocket tester
90890-03112
EAS00738
1. Main and ignition fuses

WARNING
S A wire that is used as a jumper lead
S Check the main and ignition fuses for conti-
must have at least the same capacity of
nuity.
the battery lead, otherwise the jumper
lead may burn.
ter 3.
S This check is likely to produce sparks,
S Are the main and ignition fuses OK?
therefore make sure that no flammable
gas or fluid is in the vicinity.
YES NO
S Does the starter motor turn?
Replace the fuse(-s).
YES NO
Repair or replace the

starter motor.
7-15
EAS00759
Tester positive probe
4. Relay unit (starting eircuit cutoff relay)
light green 1
Disconnect the relay unit (starting circuit cut- Tester negative probe Continuity
off relay) from the coupler. blue/yellow 3
Connect the pocket tester (Ω 1) and bat-
tery (12 V) to the relay unit terminals as
blue/yellow 3 No
shown.
Tester negative probe continuity
Battery positive terminal light green 1
red/black 1
Battery negative terminal
blue/green 4
black/yellow 2 Continuity
Tester negative probe
Tester positive probe blue 3 blue/yellow 3
Tester negative probe black 4
blue/yellow 3 No
blue/green 4
Does the relay unit (starting circuit cutoff

relay) have continuity between black and
blue?
YES NO NOTE:
When you switch the “–” and “+” leads of the
digital pocket tester the readings in the above
Replace the relay
chart will be reversed.
unit (starting circuit
cut-off relay).
Are the tester readings correct?
EAS00760
YES NO
5. Relay unit (Diode)
Disconnect the relay unit (Diode) from the
coupler. Replace the relay
Connect the pocket tester (Ω 1) to the unit (Diode).
starting circuit cutoff relay terminals as
shown.
Measure the relay unit (Diode) for continuity
as follows.
light green 1
Tester negative probe Continuity
black/yellow 2
black/yellow 2 No
light green 1
7-16
EAS00761 EAS00750
6. Starter relay 8. Engine stop switch

Disconnect the starter relay from the cou- Check the engine stop switch for continuity.
pler. Refer to “CHECKING THE SWITCHES”.
Connect the pocket tester (Ω 1) and bat- Is the engine stop switch OK?
tery (12 V) to the starter relay coupler as
shown. YES NO
Battery positive terminal red/white 1
Battery negative terminal blue 2 Replace the right
handlebar switch.
Tester positive probe red 3
EAS00751
9. Neutral switch
Check the neutral switch for continuity.
Is the neutral switch OK?
YES NO
Replace the neutral

Does the starter relay have continuity be- switch.
tween red and black?
YES NO EAS00752
10. Sidestand switch

Replace the starter Check the sidestand switch for continuity.
relay. Refer to “CHECKING THE SWITCHES”.
Is the sidestand switch OK?
EAS00749 YES NO
7. Main switch
Check the main switch for continuity. Replace the side-
Refer to “CHECKING THE SWITCHES”. stand switch.
Is the main switch OK?
EAS00763
YES NO
11. Clutch switch
Replace the main Check the clutch switch for continuity.

switch. Refer to “CHECKING THE SWITCHES”.
Is the clutch switch OK?
YES NO
Replace the clutch

switch.
7-17
EAS00764
12. Start switch

Check the start switch for continuity.
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 con-
nected and without defects?
NO YES
Properly connect or The starting system

repair the starting circuit is OK.
system’s wiring.
7-18
STARTER MOTOR
5 Nm (0.5 mkg)

Removing the starter motor Remove the parts in the order listed.
1 Starter motor lead 1
2 Starter motor assembly 1
procedure.
Disassembling the starter motor Disassembly the parts in the order listed.
1 Starter motor front cover
1
2 Washer
1
3 Washer
1
4 Oil seal
1
5 Bearing
1
6 Armature assembly
1
7 O-ring
1
8 Brush holder/brush
1/1
9 Starter motor rear cover
1
10 Starter motor yoke
1
procedure.
7-19
EAS00769
CHECKING THE STARTER MOTOR

1. Check:
S commutator
Dirt Clean with 600 grit sandpaper.
2. Measure:
S commutator diameter a
Out of specification Replace the starter
motor.
Min. commutator diameter

22 mm
3. Measure:
S mica undercut a
Out of specification Scrape the mica to the
proper measurement with a hacksaw blade
which has been grounded to fit the commuta-
tor.
Mica undercut
1.5 mm
NOTE:
The mica must be undercut to ensure proper op-
eration of the commutator.
4. Measure:
S armature assembly resistances (commuta-
tor and insulation)
Out of specification Replace the starter
motor.
a. Measure the armature assembly resis-

tances with the pocket tester.
Pocket tester
90890-03112
Armature assembly
Armature coil resistance 1
0.0171 X 0.0209 Ω at 20_C
Insulation resistance 2
Above 1 MΩ at 20_C
b. If any resistance is out of specification, re-

place the starter motor.
7-20
5. Measure:
brush length a
Out of specification Replace the brushes
as a set.
Min. brush length

3.5 mm
6. Measure:
brush spring force free length a
Out of specification Replace the brush
springs as a set.
Brush spring force

5.52 X 8.28 N (563 X 844 gf)
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. Install:
brush
commutator 1
2. Install:
starter motor yoke 1
7-21
3. Install:
Starter motor front cover 1
NOTE:
Align the match marks a on the rear cover with
the match marks b on the front cover.
7-22
CHARGING SYSTEM ELEC
CHARGING SYSTEM
CIRCUIT DIAGRAM
1 A.C. magneto
2 Rectifier/ regulator
4 Fuse (main)
6 Battery
7-23
EAS00774 EAS00739
The battery is not being charged. S Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
Check: BATTERY” in chapter 3.
1. main fuses
3. charging voltage 12.8 V or more at 20_C
4. stator coil assembly resistance S Is the battery OK
5. wiring
(of the entire charging system) YES NO
NOTE:
S Before troubleshooting, remove the following S Clean the battery
part(-s): terminals.
1) battery cover S Recharge or re-
2) rider’s seat place the battery.
3) left side cover
tool(-s).
EAS00775
3. Charging voltage
Engine tachometer
S Connect the engine tachometer to the spark
90890-03113
plug lead of cylinder #1.
Pocket tester
S Connect the pocket tester (DC 20 V) to the
90890-03112
battery as shown.
battery positive terminal
Tester negative probe
battery negative terminal
EAS00738
1. Main fuse
S Check the main fuse for continuity.
ter 3.
S Is the main fuse OK?
YES NO S Start the engine and let it run at approximate-

ly 5,000 r/min.
S Measure the charging voltage.
Replace the fuse.
Charging voltage
14 V at 5,000 r/min
7-24
EAS00779
5. Wiring
NOTE:
Make sure that the battery is fully charged. S Check the wiring connections of the entire
charging system.
S Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”.
S Is the charging system’s wiring properly con-
NO YES nected and without defects?
The charging circuit NO YES

is OK.
EAS00776
Properly connect or Replace the rectifi-
repair the charging er/regulator.
4. Stator coil assembly resistances
system’s wiring.
S Remove the generator cover.
S Connect the pocket tester (Ω 1) to the sta-
tor coil assembly coupler as shown.
Tester positive probe white 1
Tester negative probe white 2
Tester positive probe white 1
Tester negative probe white 3
S Measure the stator coil assembly resis-

tances.
Stator coil resistance
0.224 X 0.336 Ω at 20_C
S Is the stator coil assembly OK?
YES NO
Replace the stator

coil assembly.
7-25
LIGHTING SYSTEM ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM
3 Main switch
4 Fuse (main)
6 Battery
22 High beam indicator light
24 Meter light
28 Light switch
30 Pass switch
31 Dimmer switch
36 Headlight
37 Auxiliary light
42 Fuse (headlight)
46 Tail/ brake light
7-26
EAS00781 EAS00739
Any of the following fail to light: headlight, S Check the condition of the battery.
high beam indicator light, taillight, auxilia- Refer to “CHECKING AND CHARGING
ry light or meter light. THE BATTERY” in chapter 3.
Check: 12.8 V or more at 20_C
1. main and headlight fuses
2. battery S Is the battery OK?
3. main switch
4. lights switch YES NO
5. dimmer switch
6. pass switch S Clean the battery
7. wiring terminals.
(of the entire lighting system) S Recharge or re-
NOTE: place the battery.
S Before troubleshooting, remove the following
part(-s).
1) battery cover EAS00749
2) rider’s seat
3. Main switch
3) fuel tank
4) steering head side covers S Check the main switch for continuity.
5) headlight lens unit Refer to “CHECKING THE SWITCHES”.
6) tool box cover S Is the main switch OK?
tool(-s). YES NO
Replace the main

Pocket tester
switch.
90890-03112
EAS00738
1. Main, and headlight fuses EAS00783
4. Lights switch
S Check the main, and headlight fuses for con-
tinuity. S Check the lights switch for continuity.
Refer to “CHECKING THE FUSES” in chap- Refer to “CHECKING THE SWITCHES”.
ter 3. S Is the lights switch OK?
S Are the main, and headlight fuses OK?
YES NO
YES NO
The lights switch is
Replace the fuse(-s). faulty. Replace the
right handlebar
switch.
7-27
EAS00784 EAS00788
CHECKING THE LIGHTING SYSTEM
5. Dimmer switch
1. The headlight and the high beam indicator
Check the dimmer switch for continuity. light fail to came on.
Is the dimmer switch OK? 1. Headlight bulb and socket
Check the headlight bulb and socket for con-
YES NO
tinuity.
Refer to “CHECKING THE BULBS AND
The dimmer switch is BULB SOCKETS”.
faulty. Replace the Are the headlight bulb and socket OK?
left handlebar switch.
YES NO
EAS00786
Replace the head-
6. Pass switch light bulb, socket or
both.
Check the pass switch for continuity.
Is the pass switch OK?
2. Voltage
YES NO
Connect the pocket tester (DC 20 V) to the
headlight and high beam indicator light cou-
The pass switch is plers as shown.
faulty. Replace the
A When the dimmer switch is set to “ ”
left handlebar switch.
B When the dimmer switch is set to “ ”
Headlight
EAS00787 Tester positive probe
7. Wiring yellow 1 or green 2
Check the entire lighting system’s wiring. High beam indicator light
Refer to “CIRCUIT DIAGRAM”. Tester positive probe yellow 4
Is the lighting system’s wiring properly con- Tester negative probe black 5
nected and without defects?
Headlight coupler (wire harness side)
YES NO
Check the condition Properly connect or

G
of each of the lighting repair the lighting sys-
Y
system’s circuits. tem’s wiring.
Refer to “CHECKING
THE LIGHTING SYS-
TEM”.
7-28
2. Voltage
Connect the pocket tester (20 V) to the meter
assembly coupler (wire harness side) as
shown.
Tester positive probe blue 1
Set the main switch to “ON”.

Set the light switch to “ ”.
Set the dimmer switch to “ ” or “ ”.
Measure the voltage (12 V) of yellow 1 or
green 2 on the headlight coupler (headlight
side).
Measure the voltage (12 V) of yellow 4 on
the meter assembly coupler. Set the main switch to “ON”.
Is the voltage within specification? Set the light switch to “ ” or “ ”.
Measure the voltage (12 V) of blue 1 on the
YES NO meter assembly coupler (wire harness side).
Is the voltage within specification?
This circuit is OK. The wiring circuit YES NO

from the main switch
to the headlight cou-
pler is faulty and must This circuit is OK. The wiring circuit
be repaired. from the main switch
to the meter assem-
bly coupler is faulty
EAS00789 and must be re-
2. A meter light fails to come on. paired.
1. Meter light bulb and socket.
Check the meter light bulb and socket for
continuity. EAS00790
3. A tail/brake light fails to come on.
BULB SOCKETS”. 1. Tail/brake light bulb and socket
Are the meter light bulb and socket OK?
Check the tail/brake light bulb and socket for
YES NO continuity.
BULB SOCKETS”.
Replace the meter Are the tail/brake light bulb and socket OK?
light bulb, socket or
both. YES NO
Replace the tail/

brake light bulb, sock-
et or both.
7-29
2. Voltage 2. Voltage
Connect the pocket tester (DC 20 V) to the Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side) as auxiliary light couplers (wire harness side) as
shown. shown.
Tester positive probe blue 1 Tester positive probe blue/red 1
Tester negative probe black 2 Tester negative probe black 2
Set the main switch to “ON” Set the main switch to “ON”
Set the light switch to “ ” or “ ”. Set the light switch to “ ” or “ ”.
Measure the voltage (12 V) of blue 1 on the Measure the voltage (12 V) of blue/red 1 on
tail/brake light coupler (wire harness side). the auxiliary light couplers (wire harness
Is the voltage within specification? side).
YES NO
YES NO
This circuit is OK. The wiring circuit
from the main switch This circuit is OK. The wiring circuit
to the tail/brake light from the main switch
coupler is faulty and to the auxiliary light
must be repaired. connectors is faulty
and must be re-
EB05413 paired.
4. The auxiliary light fails to come on.
1. Auxiliary light bulb and socket

Check the auxiliary light bulb and socket for
continuity.
BULB SOCKETS”.
Are the auxiliary light bulb and socket OK?
YES NO
Replace the auxiliary

light bulb, socket or
both.
7-30
SIGNALING SYSTEM ELEC
SIGNALING SYSTEM
CIRCUIT DIAGRAM
7-31
3 Main switch
4 Fuse (main)
6 Battery
9 Relay unit (Diode)
18 Neutral switch
21 Neutral indicator light
23 Turn signal indicator light
32 Horn switch
33 Turn signal switch
34 Horn
35 Flasher relay
38 Front turn signal light (left)
39 Front turn signal light (right)
40 Rear turn signal light (left)
41 Rear turn signal light (right)
43 Fuse (signal)
44 Rear stop switch
45 Front stop switch
7-32
EB806010 EAS00739
S Any of the following fail to light: turn sig- S Check the condition of the battery.
nal light, brake light or an indicator light. Refer to “CHECKING AND CHRGING THE
S The forn fails to sound. BATTERY” in chapter 3.
Check: 12.8 V or more at 20_C
1. main and signaling system fuses
2. battery S Is the battery OK?
3. main switch
4. wiring YES NO
(of the entrire signaling system)
NOTE: S Clean the battery
S Before troubleshooting, remove the following terminals.
part(-s): S Recharge or re-
1) battery cover place the battery.
2) rider’s seat
3) fuel tank EAS00749
4) steering head side covers
3. Main switch
5) headlight lens unit
6) tool box cover S Check the main switch for continuity.
7) left side cover Refer to “CHECKING THE SWITCHES”.
S Troubleshoot with the following special S Is the main switch OK?
tool(-s).
YES NO
Pocket tester
Replace the main
90890-03112
switch.
EAS00738
1. Main, and signaling system fuses

EAS00795
S Check the main ignition and signaling sys- 4. Wiring

tem fuses for continuity.
Refer to “CHECKING THE FUSES” in chap- S Check the entire signaling system’s wiring.
ter 3. Refer to “CIRCUIT DIAGRAM”.
S Are the main ignition and signaling system S Is the signaling system’s wiring properly con-
fuses OK? nected and without defects?
YES NO YES NO
Replace the fuse(-s). Check the condition Properly connect or

of each of the signal- repair the signaling
ing system’s circuits. system’s wring.
Refer to “CHECKING
THE SIGNALING
SYSTEM”.
7-33
EAS00796
CHECKING THE SIGNALING SYSTEM 3. Horn

1. The horn fails to sound. Disconnect the pink connector at the horn
terminal.
1. Horn switch
Connect a jumper lead 1 to the horn terminal
Check the forn switch for continuity. and ground the jumper lead.
Refer to “CHECKING THE SWITCHES”. Set the main switch to “ON”.
Is the horn switch OK? Does the horn sound?
YES NO
Br
Replace the left han-

dlebar switch.
2. Voltage
horn connecter at the horn terminal as
shown. NO YES
Tester positive probe brown 1
Tester negative probe ground The horn is OK.
Br P
4. Voltage
horn connecter at the pink terminal as shown.
Tester positive probe pink 1
Tester negative probe ground
Br P
Set the main switch to “ON”.

Measure the voltage (12 V) of brown at the
horn terminal.
YES NO
The wiring circuit

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

horn.
7-34
EAS00797
2. A tail/brake light fails to come on. Set the main switch to “ON”.
Pull in the brake lever or push down on the
1. Tail/brake light bulb and socket brake pedal.
Measure the voltage (12 V) of yellow at the
Check the tail/brake light bulb and socket for
tail/brake light coupler (wire harness side).
continuity.
BULB SOCKETS”. YES NO
Are the tail/brake light bulb and socket OK?
YES NO This circuit is OK. The wiring circuit

to the tail/brake light
Replace the tail/
coupler is faulty and
brake light bulb, sock-
must bne repaired.
et or both.
2. Brake light switches

Check the brake light switches for continuity.
EAS00799
Is the brake light switch OK? 3. A turn signal light, turn signal indicator light
or both fail to blink.
YES NO
1. Turn signal light bulb and socket
Replace the brake Check the turn signal light bulb and socket for
light switch. continuity.
BULB SOCKETS”.
3. Voltage Are the turn signal light bulb and socket OK?
Connect the pocket tester (DC 20 V) to the YES NO

tail/brake light coupler (wire harness side) as
shown.
Replace the turn sig-
Tester positive probe yellow 1 nal light bulb, socket
Tester negative probe black 2 or both.
7-35
2. Turn signal switch Tester positive probe brown/white 1

Check the turn signal for continuity.
Is the turn signal switch OK?
YES NO
Replace the left han-

dlebar switch.
3. Voltage
Connect the pocket tester (DC 20 V) to the Set the main switch to “ON”.
flasher relay coupler (wire harness side) as Set the turn signal switch to “ ” or “ ”.
shown. Measure the voltage (12 V) of brown/white at
the flasher relay coupler (wire harness side).
Tester positive prove brown 1 Is the voltage within specification?
Tester negative prove ground
YES NO
The flasher relay is

faulty and must be re-
placed.
5. Voltage
Connect the pocket tester (DC 20 V) to the turn
signal light connectors or the meter assembly
Set the main switch to “ON”. coupler (wire harness side) as shown.
Measure the voltage (12 V) of brown 1 at the A Turn signal light
flasher relay coupler (wire harness side). B Turn signal indicator light
Left turn signal light
YES NO Tester positive probe chocolate 1
Right turn signal light
The wiring circuit
Tester positive probe dark green 2
to the flasher relay
coupler (flasher relay A B
side) is faulty and
must be repaired.
4. Voltage
Connect the tester (DC 20 V) to the flasher
relay coupler (wire harness side) as shown.
7-36
Set the main switch to “ON”. 3. Voltage

Set the turn signal switch to “ ” or “ ”.
Measure the voltage (12 V) of chocolate 1 or
meter assembly coupler (wire harness side)
dark green 2 at the turn signal light connec-
as shown.
tor (wire harness side).
Is the voltage within specification? Tester positive probe brown 1
Tester negative probe sky blue 2
YES NO

from the turn signal
switch to the turn sig-
nal light connector is
faulty and must re-
paired.
EAS00800
4. The neutral indicator light fails to come on. Set the main switch to “ON”.
1. Neutral indicator light bulb and socket Measure the voltage (12 V) of brown 1 and
sky blue 2 at the meter assembly coupler.
Check the neutral indicator light bulb and Is the voltage with specification?
socket for continuity.
Refer to “CHECKING THE BULBS AND YES NO
BULB SOCKETS”.
Are the neutral indicator light bulb and socket
OK?
YES NO to the meter light
bulb coupler is faulty
and must be re-
Replace the neutral paired.
indicator light bulb,
socket or both.
2. Neutral switch
Check the neutral switch for continuity.
Is the neutral switch OK?
YES NO
Replace the neutral

switch.
7-37
CARBURETOR HEATER SYSTEM ELEC
CARBURETOR HEATER SYSTEM

CIRCUIT DIAGRAM
3 Main switch
4 Fuse (main)
6 Battery
47 Fuse (carburetor heater)
48 Thermo switch
49 Carburetor heater
50 Carburetor heater ground
7-38
EAS00781 EAS00739
The carburetor heater fails to operate. S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
Check: THE BATTERY” in chapter 3.
1. main, and carburetor heater fuses
3. main switch 12.8 V or more at 20_C
4. thermo switch S Is the battery OK?
5. carburetor heater
6. wiring YES NO
(of the entire carburetor heater system)
NOTE: S Clean the battery
S Before troubleshooting, remove the following terminals.
part(-s): S Recharge or re-
1) battery cover place the battery.
2) rider’s seat
3) fuel tank
4) steering head side covers EAS00749
5) tool box cover
S Troubleshoot with the following special tool 3. Main switch
(-s). S Check the main switch for continuity.
S Is the main switch OK?
Pocket tester
90890-03112 YES NO
EAS00738
Replace the main

1. Main, and carburetor heater fuses
switch.
S Check the main, and carburetor heater
fuses for continuity.
ter 3.
4. Thermo switch
S Are the main, and carburetor heater fuses
OK? S Remove the thermo switch from the thermo
switch plate.
YES NO S Connect the pocket tester to the thermo
switch lead.
Replace the fuse(-s). Tester (+) lead
Brown/Yellow terminal 1
Tester (–) lead
Black/Yellow terminal 2
7-39
5. Carburetor heater
S Remove the carburetor heater from the car-
buretor body.
S Connect the pocket tester to the carburetor
heater.
Tester (+) lead Heater terminal 1
Tester (–) lead Heater body 2
S Immerse the thermo switch in the water 3 .

S Check the thermo switch for continuity.
Note the temperatures while heating the wa-
S Measure the heater resistance.
ter with the temperature gauge 4 .
Carburetor heater resistance:
Good 12 V 30 W : 6 X 10 Ω at 20_C
Test step Water temperature
condition
S Is the carburetor heater OK?
1 Less than 23 ± 3_C f
YES NO
2 More than 23 ± 3_C
3 More than 12 ± 4_C Replace the carbure-

tor heater.
4 Less than 12 ± 4_C f
Test 1 & 2 : Heat-up test

Test 3 & 4 : Cool-down test EAS00766
f : Continuity : No continuity 6. Wiring

S Check the entire carburetor heater system’s
wiring.
OFF Refer to “CIRCUIT DIAGRAM”.
S Is the carburetor heater system’s wiring
properly connected and without defects?
ON NO YES
Thermoswitch Thermoswitch
12 ± 4_C 23 ± 3_C
Properly connect or The carburetor heat-
S Is the thermo switch OK? repair the carburetor er system circuit is
heater system’s wir- OK.
YES NO ing.
Replace the thermo

switch.
7-40
SELF-DIAGNOSIS ELEC
SELF-DIAGNOSIS
The XVS125 features self-diagnosis.
When the main switch is turned to “ON”, the following items are monitored and the condition codes are
displayed on the engine indicator light (irrespective of whether the engine is running or not).
NOTE:
The XVS125 features a self-diagnosing system.
In the XVS125, when the main switch is turned on the “Engine indicator light” in the speedometer
comes on for 1.4 seconds then goes off. However, if there is a malfunction, it comes on for 1.4 seconds,
goes off and then begins flashing. (However, it is on while the engine is running.)
Display condition
code
Item Condition Response When When
engine is engine is
stationary running
Throttle position Disconnected Enables the motorcycle to run Blinks in Light on
sensor (TPS) Short-circuit so that the ignition timing is Fault code: 3
Locked fixed when the throttle is fully
opened.
Displays the condition code
on the engine indicator light.
Speed sensor Disconnected Displays the condition code Blinks in Light on
(5JX2) short-circuit on the enigne indicator light. Fault code: 4
Missing coupler
Failure in the
electronic
component
Display order on the engine indicator light
(Example: for throttle position sensor trouble)
1 Light on (seconds) . . . . . 0.5 seconds

2 Light off (seconds) . . . . . 0.5 seconds
3 Number of blinks . . . . . . Fault code
4 Light off (seconds) . . . . . 3 seconds
Light on
Light off
1 2 Repetition
3 4
7-41
SELF-DIAGNOSIS ELEC
EAS00835
TROUBLESHOOTING 1. Wire harness

Check the wire harness for continuity.
The engine warning light starts to display
the self-diagnosis sequence.
Is the wire harness OK?
Check:
YES NO
1. throttle position sensor
NOTE:
Before troubleshooting, remove the following Repair or replace the
part(-s): wire harness.
1) rider seat and passenger seat
EB812401
2) fuel tank
3) air filter assembly 2. Throttle position sensor
4) silencer assembly Check the throttle position sensor for conti-
Troubleshoot with the following special nuity.
tool(-s). Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR” in
chapter 6.
Pocket tester Is the throttle position sensor OK?
90890-03112
YES NO
EAS00836
1. Throttle position sensor

CIRCUIT DIAGRAM Replace the ignitor Replace the throttle
unit. position sensor.
12 Throttle position sensor

13 Ignitor unit
7-42
SELF-DIAGNOSIS ELEC
2. Speed sensor (5JX2)
1. Wire harness
CIRCUIT DIAGRAM
NOTE: Check the wire harness for continuity.
The speed sensor into the speedometer.
Is the wire harness OK?
YES NO
Replace the speed Repair or replace the

meter. wire harness.
13 Ignitor unit
19 Meter
7-43
TRBL
SHTG
CHAPTER 8.
TROUBLESHOOTING
STARTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 8-2
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
FAULTY FRONT LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
FAULTY LIGHTNING AND SIGNALING SYSTEMS . . . . . . . . . . . . . . . . 8-5

TRBL
SHTG
TRBL
STARTING PROBLEMS SHTG
EAS00844
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for
checks, adjustments, and replacement of parts.
STARTING PROBLEMS
ENGINE FUEL SYSTEM
Cylinders and cylinder head(-s) Fuel tank
Loose spark plug Empty fuel tank
Loose cylinder head Clogged fuel filter
Damaged cylinder head gasket Clogged fuel tank breather hole
Worn or damaged cylinder Deteriorated or contaminated fuel
Incorrect valve clearance Fuel cock
Incorrectly sealed valve Clogged or damaged fuel hose
Incorrect valve-to-valve-seat contact Carburetor
Incorrect valve timing Deteriorated or contaminated fuel
Faulty valve spring Clogged pilot jet
Seized valve Clogged pilot air passage
Pistons and piston rings Sucked-in air
Incorrectly installed piston ring Damaged float
Damaged, worn or fatigued piston ring Worn needle valve
Seized piston ring Incorrectly installed needle valve seat
Seized or damaged piston Incorrect fuel level
Air filter Incorrectly installed pilot jet
Incorrectly installed air filter Clogged starter jet
Clogged air filter element Faulty starter plunger
Crankcase and crankshaft Incorrectly adjusted starter cable
Incorrectly assembled crankcase
Seized crankshaft
ELECTRICAL SYSTEMS Ignition system

Battery Faulty TCI unit
Faulty battery Faulty pickup coil
Discharged battery Switches and wiring
Fuse Faulty main switch
Blown, damaged or incorrect fuse Faulty engine stop switch
Incorrectly installed fuse Broken or shorted wiring
Spark plug Faulty neutral switch
Incorrect spark plug gap Faulty start switch
Incorrect spark plug heat range Faulty sidestand switch
Fouled spark plug Faulty clutch switch
Worn or damaged electrode Incorrectly grounded circuit
Worn or damaged insulator Loose connections
Faulty spark plug cap Starting system
Ignition coil Faulty starter motor
Damaged ignition coil Faulty starter relay
Broken or shorted primary or secondary coils Faulty neutral relay
Faulty spark plug lead Faulty starter clutch
8-1
INCORRECT ENGINE IDLING SPEED/POOR MEDIUM AND- TRBL
HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING SHTG
EAS00846
INCORRECT ENGINE IDLING SPEED

ENGINE ELECTRICAL SYSTEMS
Cylinders and cylinder head Battery
Incorrect valve clearance Faulty battery
Damaged valve train components Discharged battery
Air filter Spark plug
Clogged air filter element Incorrect spark plug gap
Incorrect spark plug heat range
FUEL SYSTEM Fouled spark plug
Carburetor Worn or damaged electrode
Faulty starter plunger Worn or damaged insulator
Loose or clogged pilot jet Faulty spark plug cap
Loose or clogged pilot air jet Ignition coil
Damaged or loose carburetor joint Broken or shorted primary or secondary
Incorrectly adjusted engine idling speed coils
(throttle stop screw) Faulty spark plug lead
Incorrect throttle cable free play Damaged ignition coil
Flooded carburetor Ignition system
Faulty CDI unit
Faulty pickup coil
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Refer to “STARTING PROBLEMS”.
ENGINE FUEL SYSTEM
Air filter Carburetors
Clogged air filter element Faulty diaphragm
Incorrect fuel level
Loose or clogged main jet
EAS00850
FAULTY GEAR SHIFTING

SHIFTING IS DIFFICULT JUMPS OUT OF GEAR
Refer to “CLUTCH DRAGS”. Shift shaft
SHIFT PEDAL DOES NOT MOVE Incorrect shift pedal position
Shift shaft Incorrectly returned stopper lever
Incorrectly adjusted shift rod Shift forks
Bent shift shaft Worn shift fork
Shift drum and shift forks Shift drum
Foreign object in a shift drum groove Incorrect axial play
Seized shift fork Worn shift drum groove
Bent shift fork guide bar Transmission
Transmission Worn gear dog
Seized transmission gear
Foreign object between transmission gears
Incorrectly assembled transmission
8-2
TRBL
FAULTY CLUTCH/OVERHEATING SHTG
EAS00851
FAULTY CLUTCH
CLUTCH SLIPS CLUTCH DRAGS
Clutch Clutch
Incorrectly assembled clutch Unevenly tensioned clutch spring
Incorrectly adjusted clutch cable Warped pressure plate
Loose or fatigued clutch spring Bent clutch plate
Worn friction plate Swollen friction plate
Worn clutch plate Bent clutch push rod
Engine oil Damaged clutch boss
Incorrect oil level Burnt primary driven gear bushing
Incorrect oil viscosity (low) Match marks not aligned
Deteriorated oil Engine oil
Incorrect oil level
Incorrect oil viscosity (high)
Deteriorated oil
EAS00854
OVERHEATING
ENGINE CHASSIS
Cylinder head(-s) and piston(-s) Brakes
Heavy carbon buildup Dragging brake
Engine oil
Incorrect oil level ELECTRICAL SYSTEMS
Incorrect oil viscosity Spark plugs
Inferior oil quality Incorrect spark plug gap
FUEL SYSTEM Incorrect spark plug heat range
Carburetors Ignition system
Incorrect main jet setting Faulty CDI unit
Incorrect fuel level
Damaged or loose carburetor joint
Air filter
Clogged air filter element
8-3
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK TRBL
LEGS/UNSTABLE HANDLING SHTG
EAS00859
POOR BRAKING PERFORMANCE

Front brake Rear brake
Worn brake pad Improper brake pedal adjustment
Worn brake disc Worn brake shoe
Air in hydraulic brake system Improper brake shoe contact
Leaking brake fluid Worn camshaft
Faulty brake caliper piston seal Worn brake drum
Loose union bolt Mud or water into brake drum inside
Damaged brake hose Oily or greasy brake lining
Oil or grease on the brake disc Faulty brake cable
Oil or grease on the brake pad Broken or fatigued tension spring
Incorrect brake fluid level Faulty camshaft, cam lever
EAS00861
FAULTY FRONT FORK LEGS

LEAKING OIL MALFUNCTION
Bent, damaged or rusty inner tube Bent or damaged inner tube
Damaged outer tube Bent or damaged outer tube
Incorrectly installed oil seal Damaged fork spring
Damaged oil seal lip Worn or damaged outer tube busing
Incorrect oil level (high) Bent or damaged damper rod
Loose damper rod assembly bolt Incorrect oil viscosity
Damaged damper rod assembly, bolt, or Incorrect oil level
copper washer
Damaged cap bolt O-ring
EAS00864
UNSTABLE HANDLING
Handlebar Swingarm
Bent or incorrectly installed handlebar Worn bearing or bushing
Steering head components Bent or damaged swingarm
Incorrectly installed upper bracket Rear shock absorber assembly
Incorrectly installed lower bracket Faulty rear shock absorber spring
(incorrectly tightened ring nut) Leaking oil or gas
Bent steering stem Tires
Damaged ball bearing or bearing race Uneven tire pressures (front and rear)
Front fork legs Incorrect tire pressure
Unevenoil levels (both front fork legs) Uneven tire wear
Unevenly tensioned fork spring (both front Wheels
fork legs) Incorrect wheel balance
Damaged fork spring Loose sporks
Bent or damaged inner tube Deformed wheel rim
Bent or damaged outer tube Damaged wheel bearing
Bent or loose wheel axle
Excessive wheel runout
Frame
Bent frame
Damaged steering head pipe
Incorrectly installed bearing race
8-4
TRBL
FAULTY LIGHTING AND SIGNALING SYSTEMS SHTG
EAS00866
FAULTY LIGHTING AND

SIGNALING SYSTEMS
HEADLIGHT DOES NOT LIGHT TURN SIGNAL BLINKS SLOWLY
Wrong headlight bulb Faulty flasher relay
Too many electrical accessories Faulty main switch
Hard charging Faulty turn signal switch
Incorrect connection Wrong turn signal bulb
Incorrectly grounded circuit
Poor contacts (main or light switch) TURN SIGNAL REMAINS LIT
Burnt-out headlight bulb Faulty flasher relay
Burnt-out-turn signal bulb
HEADLIGHT BULB BURNT OUT
Wrong headlight bulb TURN SIGNAL BLINKS QUICKLY
Faulty battery Incorrect turn signal bulb
Faulty rectifier/regulator Faulty flasher relay
Incorrectly grounded circuit Burnt-out turn signal bulb
Faulty main switch
Faulty light switch HORN DOES NOT SOUND
Headlight bulb life expired Incorrectly adjusted horn
Damaged or faulty horn
TAIL/BRAKE LIGHT DOES NOT LIGHT Faulty main switch
Wrong tail/brake light bulb Faulty horn switch
Too may electrical accessories Faulty battery
Incorrect connection Blown, damaged or incorrect fuse
Burnt-out tail/brake light bulb Faulty wire harness
TAIL/BRAKE LIGHT BULB BURNT OUT

Wrong tail/brake light bulb
Faulty battery
Incorrectly adjusted rear brake light switch
Tail/brake light bulb life expired
TURN SIGNAL DOES NOT LIGHT

Faulty turn signal switch
Faulty flasher relay
Burnt-out turn signal bulb
Incorrect connection
Damaged or faulty wire harness
Incorrectly grounded circuit
Faulty battery
Blown, damaged or incorrect fuse
8-5
XVS125 2000 WIRING DIAGRAM
1 A.C. magneto
2 Rectifier/ regulator
3 Main switch
4 Fuse (main)
5 Starter relay
6 Battery
7 Starter motor
8 Fuse (ignition)
9 Relay unit
10 Clutch switch
11 Sidestand switch
12 Throttle position sensor
13 Ignitor unit
14 Ignition coil #1
15 Ignition coil #2
16 Spark plug
17 Pickup coil
18 Neutral switch
19 Meter
20 Engine warning light
21 Neutral indicator light
22 High beam indicator light
23 Turn signal indicator light
24 Meter light
25 Right handlebar switch
27 Start switch
28 Light switch
29 Left handlebar switch
30 Pass switch
31 Dimmer switch
32 Horn switch
33 Turn signal switch
34 Horn
35 Flasher relay
36 Headlight
37 Auxiliary light
38 Front turn signal light (left)
39 Front turn signal light (right)
40 Rear turn signal light (left)
41 Rear turn signal light (right)
42 Fuse (headlight)
43 Fuse (signal)
44 Rear stop switch
45 Front stop switch
47 Fuse (carburetor heater)
48 Thermo switch
49 Carburetor heater
50 Carburetor heater ground
COLOR CODE
B ..... Black Lg . . . . Light green B/ L . . . Black/ Blue G/Y . . Green / Yellow R/ L . . . Red/ Blue
Br . . . . Brown O .... Orange B/ R . . . Black/ Red L/B . . . Blue/ Black R/ W . . Red/ White
Ch . . . Chocolate P ..... Pink B/ Y . . . Black/ Yellow L/G . . . Blue/ Green R/ Y . . . Red/ Yellow
Dg . . . Dark green R..... Red Br/ L . . Brown/ Blue L/R . . . Blue/ Red W/ B . . White/ Black
G .... Green Sb . . . . Sky blue Br/ W . Brown/ White L/W . . Blue/ White W/ G . . WHite/ Green
Gy . . . Gray W .... White Br/ Y . . Brown/ Yellow L/Y . . . Blue/ Yellow W/ R . . White/ Red
L ..... Blue Y ..... Yellow G/W . . Green / White R/ B . . . Red/ Black

Yamaha XVS 125 00 Service Manual

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Yamaha XVS 125 00 Service Manual

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The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

Failure to follow WARNING instructions could result in severe injury or death to

NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

Symbols 17 to 22 in the exploded diagrams indi-

MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

VEHICLE IDENTIFICATION NUMBER

2. Use proper tools and cleaning equipment.

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

CHECKING THE CONNECTIONS

Tool No. Tool name / How to use Illustration

Weight These tools are used to remove the rocker

This tool is used to adjust the valve

This tool is used to remove the piston pin.

Adapter These tools are needed when installing the

This tool is needed to remove the valve guide.

This tool is needed for observing engine r/min.

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

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

ELECTRICAL SPECIFICATONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

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

ENGINE OIL LUBRICATION CHART SPECIFICATIONS . . . . . . . . . . . . 2-22

ENGINE OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Item Standard Limit

Item Standard Limit

Head diameter Face width Seat width Margin thickness

Valve seat width

Item Standard Limit

Intake SSS 2.5_/1.3 mm

Item Standard Limit

Ring type Barrel

Ring type Taper

Dimensions (B T) 1.5 1.6 mm

Item Standard Limit

Width A 67.95 68.00 mm

Item Standard Limit

Main air jet #120

Tire pressure (cold)

Item Standard Limit

Master cylinder inside diameter 12.7 mm

Item Standard Limit

Item Standard Limit

GENERAL TORQUE CONVERSION TABLE

Crankcase tightening sequence:

Thread Tightening torque

Thread Tightening torque

LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point Symbol

Oil seal lips

Connecting rod small end and big end

Crankshaft journal/big end

Camshaft cam lobe/journal