VMX12

SERVICE MANUAL
 1986 by Yamaha Motor Co., Ltd.
1st Edition, March 1986
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
 NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their
qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is
assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles
have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair
technology. Without such knowledge, attempted repairs or service to this model may render it unfit to
use and/or unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all Autho-
rized Yamaha dealers and will, where applicable, appear in future editions of this manual.

TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLES OPERATIONS
YAMAHA MOTOR CO., LTD.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT INFORMATION
This material is distinguished by the following notation.

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

CAUTION: A CAUTION indicates special procedures that must be followed to avoid damage
to the motorcycle.

WARNING: A WARNING indicates special procedures that must be followed to avoid injury to
a motorcycle operator or person inspecting or repairing the motorcycle.

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information
has been compiled to provide the mechanic with an easy to read, handy reference that contains com-
prehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course
of action required will follow the symbol, e.g.,

Bearings
Pitting/Damage
Replace.

EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
1 2 ILLUSTRATED SYMBOLS
(Refer to the illustration)
GEN INSP
INFO Illustrated symbols 1 to 8 are designed as
ADJ thumb tabs to indicate the chapter’s number
3 4 and content.
1 General information

ENG COOL 2 Periodic inspection and adjustment

3 Engine
4 Cooling system
5 6
5 Carburetion
6 Chassis
CARB CHAS 7 Electrical
8 Appendices
7 8

ELEC APPX
Illustrated symbols 9 to 14 are used to identify
9 10
the specifications appearing in the text.
9 Filling fluid
10 Lubricant
11 Tightening
11 12 12 Wear limit, clearance
13 Engine speed
14 Ω, V, A

13 14

15 16 17
Illustrated symbols 15 to 21 in the exploded dia-
gram indicate grade of lubricant and location of
lubrication point.
15 Apply engine oil
16 Apply gear oil
18 19 20 17 Apply molybdenum disulfide oil
18 Apply wheel bearing grease
19 Apply lightweight lithium-soap base grease
20 Apply molybdenum disulfide grease

21 21 Apply locking agent (LOCTITE)

 INDEX
GENERAL INFORMATION GEN
INFO 1
PERIODIC INSPECTIONS
AND ADJUSTMENTS INSP
ADJ 2
ENGINE OVERHAUL ENG
3
COOLING SYSTEM COOL
4
CARBURETION CARB
5
CHASSIS CHAS
6
ELECTRICAL ELEC
7
APPENDICES APPX
8
 GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

ALL REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
GASKETS, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . 1-2
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

FOR TUNE-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
FOR ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FOR CHASSIS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
FOR MIDDLE GEAR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
GEN
INFO
 GEN
MOTORCYCLE IDENTIFICATION INFO
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number 1 is stamped into the
steering head pipe.

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the
left side of the engine.
NOTE:
The first three digits of these numbers are for
model identifications; the remaining digits are
the unit production number.

Starting Serial Number:

VMX12 . . . . . . . . . . . 2EN-000101
NOTE:
Designs and specifications are subject to
change without notice.

1-1
 GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for as-
sembly and adjustment.

GASKETS, OIL SEALS, AND O-RINGS

1. All gaskets, seals, and O-rings should be re-
placed when an engine is overhauled. 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.

LOCK WASHERS/PLATES AND COTTER

PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been prop-
erly tightened.

BEARINGS AND OIL SEALS

1. Install the bearing(s) 1 and oil seal(s) 2
with their manufacturer’s marks or numbers
facing outward. (In other words, the stamped
letters must be on the side exposed to view.)
When installing oil seal(s), apply a light coat-
ing of light-weight lithium base grease to the
seal lip(s). Oil the bearings liberally when
installing.

CAUTION:
Do not use compressed air to spin the bear-
ings dry. This causes damage to the bearing
surfaces.

1-2
 GEN
SPECIAL TOOLS INFO
CIRCLIPS
1. All circlips should be inspected carefully be-
fore reassembly. Always replace piston pin
clips after one use. Replace distorted cir-
clips. When installing a circlip 1 , make sure
that the sharp-edged corner 2 is positioned
opposite to the thrust 3 it receives. See the
sectional view.
4 Shaft

SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Us-
ing the correct special tool will help prevent
damage caused by the use of improper tools or
improvised techniques.

FOR TUNE UP
1. Inductive Tachometer
P/N 90890-03113
This tool is needed for detecting engine rpm.

2. Inductive Timing Light

P/N 90890-03109
This tool is necessary for checking ignition tim-
ing.

3. Compression Gauge
P/N 90890-03081
This gauge is used to measure the engine com-
pression.

1-3
 GEN
SPECIAL TOOLS INFO
4. Fuel Level Gauge
P/N 90890-01312
This gauge is used to measure the fuel level in
the float chamber.

5. Vacuum Gauge
P/N 90890-03094
This gauge is needed for carburetor synchro-
nization.

6. Radiator Cap Tester

P/N 90890-01325
This tester is needed for checking the cooling
system.

FOR ENGINE SERVICE

1. Clutch Holder
P/N 90890-04086
This tool is used to hold the clutch when remov-
ing or installing the clutch boss locknut.

2. Tappet Adjusting Tool

P/N 90890-04105
This tool is necessary to replace valve adjusting
pads.

1-4
 GEN
SPECIAL TOOLS INFO
3. Valve Spring Compressor
P/N 90890-04019
This tool is needed to remove and install the
valve assemblies.

4. Valve Guide Remover (5.5 mm)

P/N 90890-01122
This tool is used to remove the valve guides.

5. Valve Guide Reamer (5.5 mm)

P/N 90890-01196
This tool is used to rebore the new valve guide.

6. Valve Guide Installer

P/N 90890-04015
This tool is needed to install the valve guides
properly.

7. Valve Seat Cutter Set

P/N YM-91043
This tool is needed to resurface the valve seat.

1-5
 GEN
SPECIAL TOOLS INFO
8. Flywheel Puller
P/N 90890-01362 – 1
Adapter
P/N 90890-04089 – 2
These tools are used to remove the flywheel.

9. 8 mm Wrench Adapter
P/N 90890-04076
This tool is used to loosen or tighten the cylinder
head securing nut.

10. Piston Ring Compressor

P/N 90890-05158
This tool is used when installing the piston into
the cylinder.

11. Water Pump Seal Installer

Handle
P/N 90890-04058 – 1
Adapter
P/N 90890-04078 – 2
This tool is needed for proper installation of the
water pump seal.

12. Piston Pin Puller

P/N 90890-01304
This tool is used to remove the piston pin.

1-6
 GEN
SPECIAL TOOLS INFO
13. #40 Torx Driver
P/N 90890-04049
This tool is used to loosen or tighten the middle
gear bearing retainer bolt.

14. #30 Torx Driver

P/N YU-29843-6
This tool is used to loosen or tighten the drive
axle bearing retainer bolt.

15. #25 Torx Driver

P/N YU-29843-4
This tool is used to loosen or tighten the shift
cam segment securing bolt.

16. Plastigage Set “Green”

P/N YU-33210
This gauge is needed to measure the clearance
for the connecting rod bearing.

17. Special Torx Driver

P/N 90890-05349
This tool is used when overhauling the carbure-
tors.

1-7
 GEN
SPECIAL TOOLS INFO
18. Yamaha Bond No.1215
P/N 90890-85505
This sealant (bond) is used for crankcase mat-
ing surfaces, etc.

FOR CHASSIS SERVICE

1. T-Handle
P/N 90890-01326 – 1
Damper Rod Holder (24 mm)
P/N 90890-01328 – 2
This tool is used to loosen and tighten the front
fork cylinder holding bolt.

2. Front Fork Cap Socket (17 mm)

P/N 90890-01104
This tool is needed when loosening and tighten-
ing the front fork cap bolt.

3. Front Fork Seal Driver Weight

P/N 90890-01367 – 1
Adapter (40 mm)
P/N 90890-01373 – 2
These tools are used when installing the fork
seal.

4. Ring Nut Wrench

P/N 90890-01403
This tool is used to loosen and tighten the steer-
ing ring nut.

1-8
 GEN
SPECIAL TOOLS INFO
FOR MIDDLE GEAR SERVICE
1. Universal Joint Holder
P/N 90890-04062
This tool is used when adjusting the gear lash in
the middle gear.

2. Middle Drive Gear Holder

P/N 90890-04080
This tool is needed when measuring the middle
gear lash.

3. Damper Spring Compressor

P/N 90890-04090
This tool is used to disassemble and reas-
semble the middle gear damper.

4. Dial Gauge
P/N 90890-03097
This tool is used to measure the gear lash for
the middle gear and final gear.

5. 55 mm Offset Wrench
P/N 90890-04054
This tool is used to loosen and tighten the drive
shaft nut.

1-9
 GEN
SPECIAL TOOLS INFO
6. Final Drive Shaft Holder
P/N 90890-01229
This tool is used when adjusting the gear lash
for the final gear.

7. Final Drive Shaft Bearing Retainer Wrench

P/N 90890-04050
This tool is used to remove and install the bear-
ing retainer.

8. Gear Lash Measurement Tool

P/N 90890-01230
This tool is used to measure gear lash.

FOR ELECTRICAL COMPONENTS

1. Electro Tester
P/N 90890-03021
This instrument is necessary for checking the
ignition system components.

2. Pocket Tester
P/N 90890-03112
This instrument is invaluable for checking the
electrical system.

1-10
 INSP
ADJ
CHAPTER 2.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 2-1

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CRANKCASE VENTILATION SYSTEM INSPECTION . . . . . . . . . . . 2-8
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
INTAKE MANIFOLD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
CARBURETOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
IDLING SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
COOLING SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . 2-16

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
FINAL GEAR OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 2-17
FINAL GEAR OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
FRONT AND REAR BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . 2-20
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
CABLE INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . 2-22
BRAKE AND CHANGE PEDALS/BRAKE AND CLUTCH LEVERS
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
CENTERSTAND AND SIDESTAND LUBRICATION . . . . . . . . . . . . . 2-22
SWINGARM LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
FRONT FORK OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
FRONT FORK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
REAR SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 2-25
RECOMMENDED COMBINATIONS OF THE FRONT FORK
AND THE REAR SHOCK ABSORBER SETTINGS . . . . . . . . . . . 2-27
STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
STEERING HEAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
WHEEL BEARINGS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
TIRES CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
WHEELS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
 INSP
ADJ
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
BRAKE LIGHT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 2-36
SPAR PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
 INTRODUCTION/PERIODIC MAINTENANCE/ INSP
LUBRICATION INTERVALS ADJ
PERIODIC INSPECTIONS 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 operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information applies
to vehicles already in service as well as new vehicles that are being prepared for sale. All service tech-
nicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Unit: km (miles)
EVERY
Break-in 6,000 12,000
Item Remarks
1,000 (600) (4,000) or (8,000) or
6 months 12 months
Valve(s)* Check valve clearance. Adjust if necessary.


Spark plug(s) Check condition. Clean or replace if necessary.



Air filter Clean. Replace if necessary.


Check idle speed / synchronization / starter
Carburetor*



operation. Adjust if necessary.
Check fuel hose (and vacuum pipe) for cracks or
Fuel line*


damage. Replace if necessary.
Fuel filter* Check condition. Replace if necessary.

Replace (Warm engine before draining).
Engine oil


See NOTE.
Engine oil filter* Replace.


Check oil level / oil leakage.
Final gear oil Replace


Replace every 24,000 (16,000) or 24 months.
Check operation / fluid leakage / See NOTE.
Brake*


Correct if necessary.
Check operation / fluid leakage / See NOTE.
Clutch*


Correct if necessary.
Check rear arm assembly for looseness.
Rear arm pivot* Correct if necessary. Moderately repack

every 24,000 (16,000) or 24 months.**
Check balance / damage / runout.
Wheels*


Repair if necessary.
Check bearings assembly for looseness / damage.
Wheel bearings*


Replace if damaged.
Check bearings assembly for looseness.
Steering bearing* Correct if necessary. Moderately repack


every 24,000 (16,000) or 24 months.**
Front forks* Check operation / oil leakage. Repair if necessary.


Rear shock absorber* Check operation / oil leakage. Repair if necessary.


Check coolant leakage. Repair if necessary.
Cooling system Replace coolant every 24,000 (16,000) or


24 months.

2-1
 INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
EVERY
Break-in 6,000 12,000
Item Remarks
1,000 (600) (4,000) or (8,000) or
6 months 12 months
Check all chassis fittings and fasterners.
Fittings / Fasteners* f f f
Correct if necessary.
Center and sidestand* Check operation. Repair if necessary. f f f
Check specific gravity. Check breather pipe for
Battery* f f
proper operation. Correct if necessary.

**: It is recommended that these items be serviced by a Yamaha dealer.

**: Medium weight wheel bearing grease.
NOTE:
S Brake fluid replacement (brake and clutch):
1) When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add the fluid as required.
2) On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3) Replace the brake (clutch) hoses every four years, or it cracked or damaged.
S Engine oil:

SAE 20W40 Type SE Motor Oil

SAE 10W30 Type SE Motor Oil

2-2
 INSP
VALVE CLEARANCE ADJUSTMENT ADJ
ENGINE
VALVE CLEARANCE ADJUSTMENT
Removal
1. Remove:
S Top cover 1
S Covers (left and right) 2

2. Remove:
S Electrical components board 1
3. Disconnect:
S All electrical component leads

4. Remove:
S Side covers (radiator) 1
S Bolts (radiator)
NOTE:
It is not necessary to remove the radiator com-
pletely from the motorcycle.

5. Disconnect:
S Spark plug caps 1
6. Remove:
S Air baffle plate (rear) 2

7. Remove:
S Cylinder head covers
NOTE:
Be sure you do not lose the oil plugs 1 on the
camshaft caps.

2-3
 INSP
VALVE CLEARANCE ADJUSTMENT ADJ
8. Remove:

Crankcase cover plate 1

Special washer 2

Timing plug 3
NOTE:
Check for clog of oil passage 4 in the bolt.
If any, clean the oil passage.

Inspection and Adjustment

1. Measure:

Valve clearance
NOTE:
Be sure piston is at Top Dead Center (TDC)
when measuring clearance.

Valve Clearance measurement steps:

Turn the crankshaft counterclockwise with a
32 mm (1.26 in) socket wrench 1 .
NOTE:
Valve clearance must be measured when the
engine is cool to the touch.

Align the “T1” mark (for the No.1 cylinder) on

the flywheel with the stationary pointer 2
on the crankcase cover. When the “T1” mark
is aligned with the stationary pointer 2 , the
piston is at top dead center TDC.

Note marks on flywheel to obtain correct
valve clearance measurements.

3 TDC for No.1 cylinder

4 TDC for No.2 cylinder

Measure the valve clearance using a Feeler

Gauge 5 .

Record the measured amount if the clear-
ance is incorrect.
Intake Valve (cold):
0.11
0.15 mm
(0.004
0.006 in)
Exhaust Valve (cold):
0.26
0.30 mm
(0.010
0.012 in)

2-4
 INSP
VALVE CLEARANCE ADJUSTMENT ADJ

A Crankshaft degree
B Cylinder
S Measure the valve clearance, in sequence,
for Nor.3, 4, and No.2 cylinders.
Out of specification
Adjust clearance.
1 Front

Firing Sequence:
1–3–4–2

2. Adjust:
S Valve clearance

Valve clearance adjustment steps:

S Position the valve lifter slots (intake and ex-
haust side) opposite each other.
S Install the Tappet Adjusting Tool 1
(90890-04105) onto the camshaft 2 .

S Turn the crankshaft until the lobe of the tool

1 depresses the valve lifters 3 .

4 Cylinder head
5 Pad

2-5
 INSP
VALVE CLEARANCE ADJUSTMENT ADJ
S Remove the pads 5 from the lifters. Use a
small screwdriver and a magnetic rod for re-
moval.
S Note pad numbers.
S Select the proper valve adjusting pad from
the chart below:

Pad Availability:
Pad range
25 increments
200 mm
(0.079 in) Pads stepped in
No. 200


0.05 mm (0.002 in)
No. 320
320 mm increments
(0.130 in)

NOTE:
The thickness of each pads is marked on the
pad face that contacts the valve lifter (not the
cam).

S Round off the hundredths digit of the original

pad number to the nearest 0.05 mm incre-
ment.
Hundredths digit Rounded valve
0 or 2 0
5 (NOT ROUNDED OFF)
8 10

EXAMPLE:
Original pad number = 258 (2.58 mm)
Rounded off digit = 260
NOTE:
Pads can only be selected in 0.05 mm (0.002
in) increments.

S Locate the “Installed Pad Number” on the

chart, and then find the measured valve
clearance. The point where these coordi-
nates intersect is the new pad number.
NOTE:
Use the new pad number as a guide only as
the number must be verified.

Pad number verification steps:

S Install the new pad with the number down.
S Remove the adjusting tool.
S Recheck the valve clearance.
S If the clearance is incorrect, repeat all of the
clearance adjustment steps until the proper
clearance is obtained.

2-6
 INSP
VALVE CLEARANCE ADJUSTMENT ADJ
INTAKE
B A INSTALLED PAD NUMBER
MEASURED
CLEARANCE 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.00
0.05 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310
0.06
0.10 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315
0.11
0.15
0.16
0.20 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.21
0.25 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.26
0.30 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.31
0.35 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.36
0.40 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.41
0.45 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.46
0.50 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.51
0.55 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.56
0.60 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.61
0.65 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.66
0.70 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.71
0.75 260 265 270 275 280 285 290 295 300 305 310 315 320
0.76
0.80 265 270 275 280 285 290 295 300 305 310 315 320 VALVE CLEARANCE (cold):
0.81
0.85 270 275 280 285 290 295 300 305 310 315 320
0.86
0.90 275 280 285 290 295 300 305 310 315 320 0.11
0.15 mm (0.004
0.006 in)
0.91
0.95 280 285 290 295 300 305 310 315 320 Example: Installed is 250
0.96
1.00 285 290 295 300 305 310 315 320 Measured clearance is 0.32 mm (0.013 in)
1.10
1.05 290 295 300 305 310 315 320
Replace 250 pad with 270 pad
1.06
1.10 295 300 305 310 315 320
1.11
1.15 300 305 310 315 320 *Pad number: (example)
1.16
1.20 305 310 315 320 Pad No.250 = 2.50 mm (0.098 in)
1.21
1.25 310 315 320
Pad No.255 = 2.55 mm (0.100 in)
1.26
1.30 315 320
1.31
1.35 320 Always install pad with number down.

EXHAUST
B A INSTALLED PAD NUMBER
MEASURED
CLEARANCE 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.00
0.05 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305
0.06
0.10 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310
0.11
0.15 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315
0.16
0.20
0.21
0.25 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.26
0.30 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.31
0.35 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.36
0.40 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.41
0.45 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.46
0.50 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.51
0.55 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.56
0.60 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.61
0.65 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.66
0.70 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.71
0.75 255 260 265 270 275 280 285 290 295 300 305 310 315 320
0.76
0.80 260 265 270 275 280 285 290 295 300 305 310 315 320
0.81
0.85 265 270 275 280 285 290 295 300 305 310 315 320 VALVE CLEARANCE (cold):
0.86
0.90 270 275 280 285 290 295 300 305 310 315 320
0.91
0.95 275 280 285 290 295 300 305 310 315 320 0.26
0.30 mm (0.010
0.012 in)
0.96
1.00 280 285 290 295 300 305 310 315 320 Example: Installed is 250
1.10
1.05 285 290 295 300 305 310 315 320 Measured clearance is 0.32 mm (0.013 in)
1.06
1.10 290 295 300 305 310 315 320
Replace 250 pad with 265 pad
1.11
1.15 295 300 305 310 315 320
1.16
1.20 300 305 310 315 320 *Pad number: (example)
1.21
1.25 305 310 315 320 Pad No.250 = 2.50 mm (0.098 in)
1.26
1.30 310 315 320
Pad No.255 = 2.55 mm (0.100 in)
1.31
1.35 315 320
1.36
1.40 320 Always install pad with number down.

2-7
CRANKCASE VENTILATION SYSTEM INSPECTION/ INSP
FUEL LINE INSPECTION ADJ
Assembly
When installing the top cover, reverse the re-
moval procedure. Note the following points.
1. Install:
S Cylinder head covers
NOTE:
S Be sure all cam caps are coverd with oil plug
1.
S Arrow mark 2 on the cover should face to-
ward the exhaust side.
S Inspect the head cover gasket and replace it if
damaged.

2. Tighten:
S Bolts (cylinder head cover)

Bolts (Cylinder Head Cover):

10 Nm (1.0 mSkg, 7.2 ftSlb)

3. Tighten:
S Bolts (radiator)

Bolts (Radiator):
7 Nm (0.7 mSkg, 5.1 ftSlb)

CRANKCASE VENTILATION SYSTEM IN-

SPECTION
1. Inspect:
S Crankcase ventilation hose 1
Cracks/Damage
Replace.

FUEL LINE INSPECTION

1. Inspect:
S Fuel hoses
S Vacuum lines
Cracks/Damage
Replace.

2-8
 FUEL FILTER REPLACEMENT /
INTAKE MANIFOLD INSPECTION / INSP
EXHAUST SYSTEM INSPECTION ADJ
FUEL FILTER REPLACEMENT
1. Remove:
S Seat
S Bracket
S Fuel filter 1
2. Inspect:
S Fuel filter
Dirty/Damage
Replace.
3. Install:
S Components in above list (step “1”)

INTAKE MANIFOLD INSPECTION

1. Tighten:
S Carburetor clamps
S Carburetor joint bolts
S Carburetor joint nuts
2. Inspect:
S Carburetor joint
S Gaskets
Cracks/Damage
Replace.

EXHAUST SYSTEM INSPECTION

1. Inspect:
S Exhaust pipe
S Muffler clamp gasket(s)
Damage
Replace.
2. Tighten:
S Exhaust pipe bolts
S Muffler bolts

Exhaust Pipe Joint:

7 Nm (0.7 mSkg, 5.1 ftSlb)
Exhaust Pipe Flange:
20 Nm (2.0 mSkg, 14 ftSlb)
Muffler Clamp:
20 Nm (2.0 mSkg, 14 ftSlb)

2-9
 INSP
CARBURETOR SYNCHRONIZATION ADJ
CARBURETOR SYNCHRONIZATION
NOTE:
Valve clearance must be set properly before
synchronizing the carburetors.

1 OPEN
2 CLOSE

2-10
 INSP
CARBURETOR SYNCHRONIZATION ADJ
1. Remove:
S Carburetor joint covers (left and right) 1
S Vacuum plugs (left and right) 2
S Vacuum hose 3

2. Attach:
S Vacuum Gauge 1 (90890-03094)
To the vacuum plugs.
3. Start the engine and let it warm up.

4. Adjust:
S Idle speed
Out of specification

Turn the throttle stop screw 1 to adjust.

Idle Speed:
950
1,050 r/min

5. Adjust:
S Carburetor synchronization

Carburetor synchronization adjustment

steps:
S Synchronize carburetor No.1 to carburetor
No.2 by turning synchronizing screw “A” un-
til both gauges read the same.
S Rev the engine for a fraction of a second,
two or three times, and check the synchro-
nization again.
2-11
 IDLING SPEED ADJUSTMENT/ INSP
THROTTLE CABLE ADJUSTMENT ADJ

Vacuum Pressure at Idle Speed:

22.61 kPa (170 mm Hg, 6.69 in Hg)
Vacuum Synchronous Difference:
2.66 kPa (30 mm Hg, 0.79 in Hg)

Repeat the above steps to synchronize car-
buretor No.3 to carburetor No.4 by turning
synchronizing screw “B” until both gauges
read the same.

Repeat the same steps to synchronize No.4
carburetor to No.2 carburetor, then turn syn-
chronizing screw “C” until both gauges read
the same.

IDLE SPEED ADJUSTMENT

1. Adjust

Idle speed
Warm up the engine and turn the throttle stop
screw 1 to adjust.

Idle Speed:
950
1,050 r/min

THROTTLE CABLE ADJUSTMENT

NOTE:
Before adjusting the throttle cable free play, the
engine idling speed should be adjusted.

1. Check:

Throttle cable free play a
Out of specification
Adjust.

Throttle Cable Free Play a :

4
7 mm (0.16
0.28 in)

2. Adjust:

Throttle cable free play

Throttle cable adjustment steps:

Loosen the locknut 1 .

Turn the adjuster 2 clockwise or counter-
clockwise until proper free play is attained.

Tighten the locknut.

2-12
ENGINE OIL LEVEL INSPECTION/ INSP
ENGINE OIL REPLACEMENT ADJ
ENGINE OIL LEVEL INSPECTION
1. Inspect:
S Oil level
Oil level low
Add sufficient oil.

Engine oil level visual inspection steps:

S Place the motorcycle on its centerstand and
warm up the engine for several minutes.
NOTE:
Position motorcycle straight up when check-
ing oil level, a slight tilt to the side can pro-
duce false readings.

S Stop the engine and visually check the oil

level through the level window 1 .
2 Maximum
3 Minimum

ENGINE OIL REPLACEMENT

Engine Oil Replacement (Without Oil Filter)
1. Warm up the engine for several minutes,
then place a receptacle under the engine.
2. Remove:
S Oil filler cap

3. Remove:
S Drain plug 1
Drain the engine oil.
4. Tighten:
S Drain plug 1

Drain Plug:
43 Nm (4.3 mSkg, 31 ftSlb)

5. Fill:
S Crankcase

Recommended Oil:
At 5_C (40_F) or Higher 1 :
SAE 20W40 Type SE Motor
Oil
At 15_C (60_F) or Lower 2 :
SAE 10W30 Type SE Motor
Oil
Periodic Oil Change:
3.5 L (3.1 Imp qt, 3.7 US qt)

2-13
 INSP
ENGINE OIL REPLACEMENT ADJ
CAUTION:
Do not allow foreign material to enter the
crankcase.

6. Install:
S Filler cap
7. Inspect:
S Oil leaks
S Oil level
Engine Oil Replacement (With Oil Filter)
1. Warm up the engine and place a receptacle
under the engine.
2. Remove:
S Oil filler cap
S Drain plug
Drain the engine oil.
3. Remove:
S Oil filter cover 1
4. Install:
S Drain plug

Drain Plug:
43 Nm (4.3 mSkg, 31 ftSlb)

S Oil filter (new)

S O-ring (new)
S Oil filter cover
NOTE:
Be sure the O-ring 1 is positioned properly.

5. Tighten:
S Bolt (oil filter)

Bolt (Oil Filter):

32 Nm (3.2 mSkg, 23 ftSlb)

6. Fill:
S Crankcase

Recommended Oil:
At 5_C (40_F) or Higher 1 :
SAE 20W40 Type SE Motor
Oil
At 15_C (60_F) or Lower 2 :
SAE 10W30 Type SE Motor
Oil
With Oil Filter Replacement:
3.8 L (3.3 Imp qt, 4.0 US qt)

CAUTION:
Do not allow foreign material to enter the
crankcase.
2-14
 INSP
COOLANT LEVEL INSPECTION/COOLING SYSTEM INSPECTION ADJ
7. Install:
S Oil filter cap
8. Inspect:
S Oil leaks
S Oil level

COOLANT LEVEL INSPECTION

1. Remove:
S Top cover
2. Inspect:
S Coolant level (reservoir tank)
Level low
Add tap water (soft water).
Change the Coolant every two years.
Refer to Chapter 4 “COOLING SYSTEM” for
more detail.
1 “FULL” level
2 “LOW” level

WARNING:
Do not remove the radiator cap when the en-
gine is hot.

CAUTION:
Hard water or salt water is harmful to the en-
gine parts; use boiled or distilled water if
you can’t get soft water.

Total Amount:
3.05 L (2.69 Imp qt, 3.22 US qt)
Reservoir Tank Capacity:
0.30 L (0.26 Imp qt, 0.32 US qt)
From LOW to FULL Level:
0.20 L (0.18 Imp qt, 0.21 US qt)

COOLING SYSTEM INSPECTION

1. Inspect:
S Hoses
Cranks/Damage
Replace.

2-15
 INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
COMPRESSION PRESSURE MEASURE-
MENT
NOTE:
Insufficient compression pressure will result in
performance loss.

1. Measure:
S Valve clearance
Out of specification
Adjust.
2. Warm up the engine.
3. Remove:
S Spark plugs
4. Measure:
S Compression pressure

Compression pressure measurement

steps:
S Install the Compression Gauge 1
(90890-03081) using an adapter.
S Crank over the engine with the electric start-
er (be sure the battery is fully charged) with
the throttle wide open until the compression
reading on the gauge stabilizes.
S Check redings with specified levels (See
chart)
Compression Pressure (at sea level):
Standard:
980 kPa (10 kg/cm2, 142 psi)
Minimum:
882 kPa (9 kg/cm2, 128 psi)
Maximum:
1,176.8 kPa (12 kg/cm2, 171 psi)

WARNING:
When cranking the engine, ground all of
the spark plug leads to prevent sparking.

S Repeat the previous steps for the other cyl-

inders.
S If pressure falls bellow the minimum level:
1) Squirt a few drops of oil into the affected
cylinder.
2) Measure the compression again.
Compression Pressure
(with oil introduced into cylinder)
Reading Diagnosis
Higher than without Worn or damaged
oil pistons

2-16
FINAL GEAR OIL LEVEL INSPECTION INSP
FINAL GEAR OIL REPLACEMENT ADJ
Defective ring(s),
valves, cylinder
Same as without oil
head gasket or
piston is possible.
Inspect cylinder
head, valve
Above maximum
surfaces, or piston
level
crown for carbon
deposits.
NOTE:
The difference between the highest and low-
est cylinder compression readings must not
vary more than the specified value.

Difference Between Each Cylinder:

Less than 98 kPa (1 kg/cm2, 14 psi)

CHASSIS
FINAL GEAR OIL LEVEL INSPECTION
1. Inspect:
S Final gear oil level
Oil level low
Add sufficient oil.

Final gear oil level visual inspection

steps:
S Position the motorcycle on a level area and
place on its centerstand.
S Remove the oil filler cap 1 .
S Visually check the oil level. Correct oil level
2 should be at the brim of the hole.
S If the oil level is low, add sufficient oil.
S Tighten the oil filler cap to specification.
Oil Filler Cap (Final Gear):
23 Nm (2.3 mSkg, 17 ftSlb)

FINAL GEAR OIL REPLACEMENT

1. Place a receptacle under the final gear case.
2. Remove:
S Oil filler cap
S Drain plug 1
Drain the oil.

2-17
 INSP
AIR FILTER CLEANING ADJ
3. Install:
S Drain plug

Drain Plug (Final Gear):

23 Nm (2.3 mSkg, 17 ftSlb)

4. Fill:
S Final gear case

Oil Capacity:
0.2 L (0.18 Imp qt, 0.21 US qt)
Final Gear Oil:
SAE 80 API “GL-4” Hypoid
Gear Oil
If desired, an SAE 80W90 Hypoid gear oil
may be used for all conditions.

WARNING:
Do not allow the gear oil to contact the tire or
wheel.

5. Install:
S Oil filler cap

Oil Filler Cap (Final Gear):

23 Nm (2.3 mSkg, 17 ftSlb)

AIR FILTER CLEANING

1. Remove:
S Top cover

2. Remove:
S Air filter case cover
S Air filter element
CAUTION:
The engine should never be run without the
air filter element installed; excessive piston
and/or cylinder wear may result.

2-18
 INSP
BRAKE FLUID LEVEL INSPECTION ADJ
3. Eliminate:

Dust
Use the compressed air.
Blow out dust in the element from the outer
surface.
4. Inspect:

Element
Damage
Replace.
5. Install:

Element

Air filter case cover

Top cover

BRAKE FLUID LEVEL INSPECTION

Brake Inspection
1. Inspect:

Brake fluid level (brake master cylinder)
Level low
Replenish fluid.

Brake Fluid:
DOT #3

1 Lower level
NOTE:
Be sure that:

Spilled fluid is cleaned up immediately to pre-
vent painted surfaces or plastic parts from
eroding.

WARNING:

Use only the designated quality brake
fluid, otherwise poor brake performance
will result.

Water does not enter the master cylinder
when refilling, otherwise poor brake per-
formance.

2-19
 INSP
FRONT AND REAR BRAKE PAD INSPECTION ADJ
Clutch Inspection
This motorcycle has a hydraulic clutch. There
are no adjustments to perform, but the clutch
system must be inspected periodically for fluid
level and leakage.
1. Inspect:
S Brake fluid level (clutch master cylinder)
Level low
Replenish fluid.

Brake Fluid:
DOT #3

1 Lower level
NOTE:
Be sure that:
S Use only the designated quality brake fluid.
S Water does not enter the master cylinder when
refilling.
S Spilled fluid is cleaned up immediately to pre-
vent painted surfaces or plastic parts from
eroding.

FRONT AND REAR BRAKE PAD INSPEC-

TION
1. Activate the brake lever or brake pedal.
2. Inspect:
S Wear indicator 1
Indicator almost contacts disc
Replace
pads.
Refer to “Chapter 5 CHASSIS” section.

2-20
 INSP
FRONT BRAKE ADJUSTMENT/REAR BRAKE ADJUSTMENT ADJ
FRONT BRAKE ADJUSTMENT
1. Loosen:

Lockunt 1
2. Adjust:

Free play a
Turn the adjuster 2 until the free play a is
within the specified limits.

Free play a :
2
5 mm (0.08
0.20 in)

CAUTION:
Proper lever free play is essential to avoid
excessive brake drag.

WARNING:
A soft or spongy feeling in the brake lever
can indicate the pressence of air in the brake
system. This air must be removed by bleed-
ing the brake system before the motorcycle
is operated. Air in the system will cause
greatly diminished braking capability and
can result in loss of control and an accident.
Inspect and bleed the system if necessary.

3. Tighten:

Locknut

REAR BRAKE ADJUSTMENT

1. Loosen:

Locknut 1
2. Adjust:

Brake pedal height a
Turn the adjuster 2 until the brake pedal
position is at the specified height.

Brake Pedal Height a :

20 mm (0.8 in)
Below the Top of the Footrest

WARNING:
After adjusting the brake pedal height, visu-
ally check the adjuster end through the hole
3 of the joint holder. The adjuster end must
appear within this hole.

2-21
 CABLE INSPECTION AND LUBRICATION/ BRAKE AND CHANGE
PEDALS/ BRAKE AND CLUTCH LEVERS LUBRICATION/ CENTER- INSP
STAND AND SIDESTAND LUBRICATION/ SWINGARM LUBRICATION ADJ
CABLE INSPECTION AND LUBRICATION

Cable inspection and lubrication steps:

Remove the screws that secure throttle
housing to handlebar.

Hold cable end high and apply several
drops of lubricant to cable.

Coas metal surface of disassembled
throttle twist grip with suitable all-purpose
grease to minimize friction.

Check for damage to cable insulation.
Replace any corroded or obstructed cables.

Lubricate any cables that do not operate
smoothly.

SAE 10W30 Motor Oil

BRAKE AND CHANGE PEDALS/BRAKE

AND CLUTCH LEVERS LUBRICATION
Lubricate pivoting parts of each lever and pedal.

SAE 10W30 Motor Oil

CENTERSTAND AND SIDESTAND LU-

BRICATION
Lubricate the centerstand and sidestand at their
pivot points.

SAE 10W30 Motor Oil

SWINGARM LUBRICATION
Lubricate the swingarm bearing.

Medium Weight Wheel

Bearing Grease

2-22
 INSP
FRONT FORK ADJUSTMENT ADJ
FRONT FORK OIL CHANGE

WARNING:

Fork oil leakage can cause loss of stability
and safe handling. Have any problem cor-
rected before operating the motorcycle.

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

1. Elevate the front wheel by placing a suitale

stand under the engine.
2. Remove:

Air valve cap (left)

Fork caps 1
NOTE:
Keep the valve open by pressing it for several
seconds so that the air can be let out of the inner
tube.

3. Loosen:

Pinch bolts (steering crown) 1
4. Remove:

Cap bolts 2
Use the Front Fork Cap Socket 3
(90890-01104).

Collars
5. Place a receptacles under the drain screws.

6. Remove:

Drain screws 1
Drain the fork oil.

WARNING:
Do not allow any oil to contact the disc brake
components. If oil is discovered, be sure to
remove it, otherwise diminished braking ca-
pacity and damage to the rubber compo-
nents of the brake assembly will occur.

7. Inspect:

O-rings (cap bolt) 1

Gaskets (drain screw)
Wear/Damage
Replace.

2-23
 INSP
FRONT FORK ADJUSTMENT ADJ
8. Install:

Drain screws

Collars
9. Fill:

Front forks

Each Fork:
451 cm3 (15.9 Imp oz, 15.3 US oz)
Fork Oil 10 wt or Equivalent
After filling, pump the forks slowly
up and down to distribute the oil.

10. Tighten:

Cap bolts
Use the Front Fork Cap Socket (90890-
01104).

Pinch bolts (steering crown)

Cap Bolt:
23 Nm (2.3 m
kg, 17 ft
lb)
Pinch Bolts (Steering Crown):
20 Nm (2.0 m
kg, 14 ft
lb)

11. Adjust:

Front fork air pressure
Refer to “FRONT FORK ADJUSTMENT”
section.

FRONT FORK ADJUSTMENT

1. Elevate the front wheel by placing a suitable
stand under the engine.
NOTE:
When checking and adjusting the air pressure,
there should be no weight on the front end of the
motorcycle.

2. Adjust:

Air pressure
NOTE:
The air pressure of the front forks can be ad-
justed to suit rider’s preference, weight, and the
course condition.

2-24
 INSP
REAR SHOCK ABSORBER ADJUSTMENT ADJ
Air pressure adjustment steps:

Remove the valve cap.

Using the air check gauge 1 , check and ad-
just the air pressure.
Stiffer
Increase the air pressure.
(Use an air pump or pressur-
ized air supply.)
Softer
Decrease the air pressure.
(Release the air by pushing the
valve.)
Standard Air Pressure:
39.2 kPa (0.4 kg/cm2, 5.7 psi)
Maximum Air Pressure:
98.1 kPa (1.0 kg/cm2, 14.2 psi)

CAUTION:
Never exceed the maximum pressure, or
oil seal damage may occur.

Install the valve cap securely.

REAR SHOCK ABSORBER ADJUSTMENT

1. Adjust:

Spring preload

Damping
NOTE:
The spring preload and damping of the rear
shock absorbers can be adjusted to suit rider’s
preference, weight, and the course condition.

WARNING:
Always adjust rear shock absorber preload
and damping to the same setting. Uneven
adjustment can cause poor handling and
loss of stability.

2-25
 INSP
REAR SHOCK ABSORBER ADJUSTMENT ADJ
Spring preload adjustment steps:

Using the screwdriver, adjust the spring pre-
load.
Stiffer a
Increase the spring preload.
(Turn the spring seat 1
clockwise.)
Softer b
Decrease the spring preload.
(Turn the spring seat 1
counter-clockwise.)
A Position: 5 (Maximum)
4
3
2
1 (Minimum / Standard)
Standard Position (Minimum Position):
1
Maximum Position:
5
CAUTION:
Never attempt to turn the spring seat be-
yond the maximum or minimum setting.

Damping adjustment steps:

Adjust the damping with the damping ad-
juster 1 .
Stiffer a
Increase the damping.
(Turn the adjuster 1 clock-
wise.)
Softer b
Decrease bhe damping
(Turn the adjuster 1 coun-
terclockwise.)
Standard Position (Minimum Position):
1
Maximum Position:
4

CAUTION:
Never attempt to turn the adjuster be-
yond the maximum or minimum setting.

2-26
 RECOMMENDED COMBINATIONS OF THE FRONT FORK
AND THE REAR SHOCK ABSORBER SETTINGS / INSP
STEERING HEAD INSPECTION / STEERING HEAD ADJUSTMENT ADJ
RECOMMENDED COMBINATIONS OF THE FRONT FORK AND THE REAR SHOCK ABSORBER
SETTINGS
Use this table as guidance to meet specific riding conditions and motorcycle load.
A Front fork C Rear shock absorber F Loading condition
B D E G H I J
Damping With accessory With accessory
Spring seat Solo rider With
Air pressure adjuster equipments equipments
passenger
and passenger
39.2
58.8 kPa
(0.4
0.6 kg / cm2, 1 or 2 1 or 2 
5.7
8.5 psi)
39.2
98.1 kPa
(0.4
1.0 kg / cm2, 3
5 2
4  
5.7
14.2 psi)
39.2
98.1 kPa
(0.4
1.0 kg / cm2, 5 4 
5.7
14.2 psi)

STEERING HEAD INSPECTION

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

1. Place the motorcycle on its centerstand,

then elevate the front wheel.
2. Check:

Steering assembly bearings
Grasp the bottom of the forks and gently rock
the fork assembly back and forth.
Looseness
Adjust steering head.

STEERING HEAD ADJUSTMENT

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

1. Elevate the front wheel by placing a suitable

stand under the engine.

2-27
 INSP
STEERING HEAD ADJUSTMENT ADJ
2. Remove:

Headlight lens unit 1
3. Disconnect:

All leads (in the headlight body)

4. Remove:

Bolt (headlight body bracket) 1

Emblem 2

5. Remove:

Flasher light bracket assembly 1

6. Remove:

Handlebar holder assembly 1

7. Loosen:

Pinch bolts (steering crown) 1
8. Remove:

Nut (steering stem) 2

Steering crown 3

2-28
 INSP
STEERING HEAD ADJUSTMENT ADJ
9. Remove:

Lock washer (ring nut) 1

Ring nut (upper) 2

Washer 3

Ring nut (lower) 4
WARNING:
Support the under bracket so that it may not
fall down.

10. Tighten:

Ring nuts (lower and upper)
Ring nuts tightening steps:
NOTE:
Set the Torque Wrench to the Ring Nut
Wrench so that they form a right angle.

Install the ring nut (lower) 6 .

NOTE:
The tapered side of ring nut must face down-
ward.

Tighten the ring nut 6 using the Ring Nut

Wrench (90890-01403).
Ring Nut 6 (Initial Tightening):
50 Nm (5.0 m
kg, 36 ft
lb)

Loosen the ring nut 6 completely and re-
tighten it to specification.
WARNING:
Do not over-tightening.

Ring Nut 6 (Final Tightening):

3 Nm (0.3 m
kg, 2.2 ft
lb)

Check the steering stem by turning it lock to
lock. If there is any binding, remove the
steering stem assembly and inspect the
steering barings 7 .
Refer to “CHAPTER 6. STEERING HEAD”
for more details.

Install the washer 5 .

Install the ring nut (upper) 4 .
NOTE:
The tapered side of ring nut must face down-
ward.

Finger tighten the ring nut 4 , then align the

slots of both ring nuts. If not aligned, hold the
lower ring nut 6 and tighten the other until
they are aligned.
2-29
 INSP
WHEEL BEARINGS CHECK/TIRES CHECK ADJ

Install the lock washer 3 .
NOTE:
Make sure the lock washer tab is placed in
the slots.

Install the steering crown 2 and tighten the

steering stem nut 1 to specification.

Nut (Steering Stem):

110 Nm (11.0 m
kg, 80 ft
lb)

Tighten the pinch bolts to specification.

Pinch Bolt (Steering Crown):

20 Nm (2.0 m
kg, 14 ft
lb)

11. Install:

Components in above list (steps “6
2”)

Handlebar Lower Holder:

40 Nm (4.0 m
kg, 29 ft
lb)

WHEEL BEARINGS CHECK

Front Wheel
1. Check:

Front wheel bearings
Raise the front end of the motorcycle, and
spin the wheel by hand. Touch the axle or
front fender while spinning the wheel.
Excessive vibration
Replace bearings.

Rear Wheel
1. Remove:

Rear wheel
2. Check:

Bearing movement
With the fingers.
Roughness/Wear
Replace.

TIRES CHECK

WARNING:
Do not attempt to use tubeless tires on a
wheel designed for tube type tires only. Tire
failure and personal injury may result from
sudden deflation.

Wheel Tire
Tube type Tube type only
Tubeless Tube type of tubeless

2-30
 INSP
TIRES CHECK ADJ
A B Be sure to install the correct tube when us-
ing tube type tires.

A Tire C Tubeless tire

B Wheel D Tube type tire
1 Air valve
2 Aluminum wheel (tubeless type)
3 Tube
4 Aluminum wheel (tube type)
C D WARNING:
This motorcycle is fitted with “V” range tires
(for super high speed running). The follow-
ing points must be observed in order for you
to make fully effective use of these tires.

Never fail to use “V” range tires in tire re-
placement. “S” or “H” tires may be in dan-
ger of bursting at super high-speeds.

New tires have a relatively poor adhesion
on the road surface so do not allow them to
be subjected to high speed load from maxi-
mum speed until after a break-in run of
approx. 100 km (60 mi).

Before any high-speed runs, remember to
allow a sufficient warm-up time for the
tires.

Always use the correct tire inflation pres-
sure according to the operation condi-
tions.

1. Measure:

Tire pressure
Out of specification
Adjust.
Basic weight:
281 kg (619 lb)
With oil and full fuel tank
Maximum load* 218 kg (481 lb)
Cold tire pressure Front Rear
235 kPa 255 kPa
Up to 90 kg (198 lb) load* (2.4 kg / cm2, (2.6 kg / cm2,
34 psi) 36 psi)
235 kPa 275 kPa
90 kg (198lb)

(2.4 kg / cm2, (2.8 kg / cm2,
Maximum load*
34 psi) 40 psi)
235 kPa 255 kPa
High speed riding (2.4 kg / cm2, (2.6 kg / cm2,
34 psi) 36 psi)

* Load is the total weight of cargo, rider, pas-

senger, and accessories.

2-31
 TIRES CHECK INSP
ADJ
WARNING:

Tire inflation pressure should be checked
and adjusted when the temperature of the
tire equals the ambient air temperature.
Tire inflation pressure must be adjusted
according to total weight of cargo, rider,
passenger, and accessories (fairing, sadd-
lebags, etc. if approved for this model), and
vehicle speed.

Proper loading of your motorcycle is im-
portant for the handling, braking, and other
performance and safety characteristics of
your motorcyle. Do not carry loosely
packed items that can shift. Securely pack
your heaviest items close to the center of
the motorcycle, and destribute the weight
evenly from side to side. Properly adjust
the suspension for your load, and check
the condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTORCYCLE.
Make sure the total weight of the cargo, rid-
er, passenger, and accessories (fairing,
saddlebags, etc. if approved for this mod-
el) does not exceed the maximum load of
the motorcycle. Operation of an over-
loaded motorcycle could cause tire dam-
age, an accident, or even injury.

2. Inspect:

Tire surfaces
Wear/Damage
Replace.

Minimum Tire Tread Depth: (Front

and Rear)
1.0 mm (0.04 in)

1 Tread depth
2 Side wall
3 Wear indicator

WARNING:

It is dangerous to ride with a wornout tire.
When a tire tread begins to show lines, re-
place the tire immediately.

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 replacement.
2-32
 INSP
WHEELS CHECK/IGNITION TIMING CHECK ADJ
WHEELS CHECK
1. Inspect:

Aluminum wheels
Damage/Bends
Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.

WARNING:
Never attempt even small repairs to the
wheel.

2. Tighten:

Valve stem locknut

Valve Stem Locknut:

1.5 Nm (0.15 m
kg, 1.1 ft
lb)

WARNING:
Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.

ELECTRICAL
IGNITION TIMING CHECK
1. Check:

Ignition timing
By the following steps.
Ignition timing check steps:

Remove the timing plug 1 .

Connect the Timing Light 2 (90890-03109)
to No.1 or No.2 cylinder spark plug lead.

Warm up the engine and let it idle at the spe-
cified idle speed of 1,000 r/min.

Visually check the stationary pointer 3 in
the timing window to vertify it is within the re-
quired firing range indicated on the fly-
wheel.
Incorrect firing range
Check flywheel
and/or pickup assembly (tightness dam-
age).
Refer to “CHAPTER 7, ELECTRICAL” for
further information.

4 Firing range for the No.1 cylinder

5 Firing range for the No.2 cylinder

2-33
 INSP
BATTERY INSPECTION ADJ
BATTERY INSPECTION
1. Inspect:

Battery fluid level
Battery fluid level low
Fill.
Fluid level should be between upper and
lower level marks.

1 Upper level
2 Lower level

CAUTION:
Refill with distilled water only; tap water
contains minerals harmful to a battery.

WARNING:
Battery electrolyte is dangerous; it contains
sulfuric acid and therefore is poisonous and
highly caustic.
Always follow these preventive measures:

Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.

Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):

SKIN – Flush with water.

EYES – Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):

Drink large quantities of water or milk fol-
low with milk of magnesia beaten egg, or
vegetable oil. Get immediate medical
attention.
Batteries also generate explosive hydrogen
gas, therefore you should always follow
these preventive measures:

Charge batteries in a well-ventilated area.

Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)

DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.

2-34
 INSP
BATTERY INSPECTION ADJ
2. Remove:
S Battery
3. Inspect:
S Battery fluid specific gravity
Out of specification
Charge.
CAUTION:
Always charge a new battery before using it
to ensure maximum performance.

Charging Current:
1.4 amps/10 hrs
Specific gravity:
1.280 at 20_C (68_F)

4. Install:
S Battery
5. Connect:
S Breather hose
Be sure the hose is properly attached and
routed.
CAUTION:
When inspecting the battery, be sure the
breather hose is routed correctly. If the
breather hose touches the frame or exits in
such a way as to cause battery electrolyte or
gas to exit onto the frame, structural and
cosmetic damage to the motorcycle can oc-
cur.

1 Battery
2 Pass through guide

6. Inspect:
S Breather hose
Obstruction
Remove.
Damage
Replace.

2-35
BRAKE LIGHT SWITCH ADJUSTMENT/ INSP
SPARK PLUG INSPECTION ADJ
BRAKE LIGHT SWITCH ADJUSTMENT
1. Adjust:

Brake light operating timing
Hold the main body 1 of the switch with your
hand so it does not rotate, and turn the ad-
juster 2 until the operating timing is correct.

SPARK PLUG INSPECTION

1. Inspect:

Electrode 1
Wear/Damage
Replace.

Insulator color 2
Normal condition is a medium to light tan col-
or.
Distinctly different color
Check the engine
condition.
3 Spark plug gap

2. Clean:

Spark plug
Clean the spark plug with a spark plug clean-
er or wire brush.
3. Inspect:

Spark plug type
Incorrect
Replace

Standard Spark Plug:

DPR8EA-9 (NGK)
X24EPR-U9 (N.D.)
4. Measure:

Spark plug gap
Out of specification
Regap.
Use a wire gauge.

Spark Plug Gap:

0.8
0.9 mm (0.031
0.035 in)

5. Tighten:

Spark Plug
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.

Spark Plug:
17.5 Nm (1.75 m
kg, 12.5 ft
lb)

2-36
 INSP
HEADLIGHT BULD REPLACEMENT ADJ
NOTE:
If a torque wrench is not available when you are
installing a spark plug, a good estimate of the
correct torque is 1/4 to 1/2 turns part finger
tight. Have the spark plug torqued to the correct
value as soon as possible with a torque wrench.

HEADLIGHT BULB REPLACEMENT

1. Remove:

Headlight lens unit 1
2. Disconnect:

Headlight lens unit leads

3. Remove:

Bulb
Turn the bulb holder 1 counterclockwise to
release bulb.

WARNING:
Do not touch headlight bulb when it is on as
the bulb generates enormous heat; keep
flammable objects away.

4. Install:

Bulb (new)
Secure the new bulb with the bulb holder.
CAUTION:
Avoid touching glass part of bulb. Also keep
it free from oil otherwise, transparency of
glass, bulb life and illuminous flux will be
adversely affected. If oil gets on bulb, clean
it with a cloth moistened thoroughly with al-
cohol or lacquer thinner.

1 Don’t touch

5. Install:

Headlight lens unit

2-37
 INSP
HEADLIGHT BEAM ADJUSTMENT/FUSE INSPECTION ADJ
HEADLIGHT BEAM ADJUSTMENT
1. Adjust:

Headlight beam (horizontally)

Horizontal Adjustment
Right Turn adjusting screw 1 clockwise
Turn adjusting screw 1 counter-
Left
clockwise

2. Adjust:

Headlight beam (vertically)

Vertical Adjustment
Turn the adjusting screw 1
Higher
clockwise.
Turn the adjusting screw 1
Lower
counterclockwise.

FUSE INSPECTION
The fuse panel is located under the top cover
and seat.
1. Inspect:

Fuses 1

Main fuse 2
Defective
Replace.
Blown fuse (new)
Inspect circuit.
CAUTION:
Do not use fuses of higher amperage rating
than those recommended.
Substitution of a fuse of improper rating can
cause extensive electrical system damage
and possible a fire.

3 Spare fuses

Description Amperage Quantity

Main 30 A 1
Headlight 15 A 1
Signal 15 A 1
Ignition 10 A 1
30 A 1
Reserve 15 A 1
10 A 1

2-38
 ENG

CHAPTER 3.
ENGINE OVERHAUL
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AIR BAFFLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
FOOTREST (RIGHT) AND BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . 3-4
FOOTREST (LEFT) AND CLUTCH RELEASE CYLINDER . . . . . . . 3-5
EXHAUST PIPE AND MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

CYLINDER HEAD AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
STARTER IDLE GEARS AND FLYWHEEL . . . . . . . . . . . . . . . . . . . . . 3-11
CLUTCH AND OIL PUMP DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . 3-12
WATER PUMP AND THERMOSTATIC VALVE . . . . . . . . . . . . . . . . . . 3-13
STARTER MOTOR AND BREATHER COVER . . . . . . . . . . . . . . . . . . 3-14
OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
UPPER CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
LOWER CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
VALVE, VALVE GUIDE, AND VALVE SEAT . . . . . . . . . . . . . . . . . . . . . 3-20
CAMSHAFT, CAM CHAIN, AND CAM SPROCKET . . . . . . . . . . . . . . 3-27
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
PISTON, PISTON RING, AND PISTON PIN . . . . . . . . . . . . . . . . . . . . 3-29
STARTER DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
PRIMARY GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
OIL GALLERY PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
BLANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
CIRCLIPS AND WASHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

MIDDLE GEAR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

DRIVE AXLE POSITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
MIDDLE DRIVEN GEAR BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
 ENG
ENGINE ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 3-55
LOWER CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
CRANKSHAFT/CONNECTING ROD/PISTON . . . . . . . . . . . . . . . . . . 3-56
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
UPPER CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
OIL PUMP AND OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
BREATHER COVER AND STARTER MOTOR . . . . . . . . . . . . . . . . . . 3-65
WATER PUMP AND THERMOSTATIC VALVE . . . . . . . . . . . . . . . . . . 3-65
CLUTCH AND OIL PUMP DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . 3-66
FLYWHEEL AND STARTER IDLE GEAR . . . . . . . . . . . . . . . . . . . . . . 3-69
CYLINDER HEAD AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
OIL DELIVERY PIPE AND CYLINDER HEAD COVER . . . . . . . . . . . 3-77
REMOUNTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
 ENGINE REMOVAL ENG

ENGINE OVERHAUL
ENGINE REMOVAL
NOTE:
It is not necessary to remove the engine in order
to remove the following components:

Clutch

Carburetor

Water pump

AC magneto

PREPARATION FOR REMOVAL

1. Remove all dirt, mud, dust, and foreign mate-
rial before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to “CHAPTER 1. SPECIAL TOOL”
section.
NOTE:
When disassembling the engine, keep mated
parts together. This includes gears, cylinders,
pistons, and other parts that have been “mated”
through normal wear. Mated parts must be re-
used as an assembly or replaced.

3. During engine disassembly, clean all parts

and place them in trays in the order of disas-
sembly. This will speed up assembly time
and help assure that all parts are correctly re-
installed in the engine.

4. Drain engine oil completely.

Refer to “CHAPTER 2. ENGINE OIL RE-
PLACEMENT” section.
5. Drain coolant completely.
Refer to “CHAPTER 4. COOLANT RE-
PLACEMENT” section.

3-1
 ENGINE REMOVAL ENG
CARBURETOR
1. Remove:

Top cover 1

Covers (left and right) 2

2. Remove:

Holders (carburetor overflow hose) 1
3. Loosen:

Screws (air cleaner joint) 2

4. Remove:

Ventilation hose (crankcase) 1

Air cleaner assembly 2

5. Disconnect:

Fuel hose 1

6. Disconnect:

Vacuum hose (ignition advance) 1
7. Loosen:

Screws (carburetor joint)
8. Remove:

Carburetor joint cover (left and right) 2

3-2
 ENGINE REMOVAL ENG
9. Remove:

Electrical components board 1

Throttle cable cylinder 2
10. Disconnect:

All leads and cables

11. Remove:

Carburetor assembly
NOTE:
Cover the carburetor with a clean rag to prevent
dirt or foreign matter into the carburetor.

RADIATOR
1. Remove:

Radiator covers

2. Remove:

Bolts (radiator)
3. Disconnect:

Upper hose 1

Lower hoses 2

4. Disconnect:

Fan motor coupler
5. Remove:

Radiator assembly

Horn

3-3
 ENGINE REMOVAL ENG
6. Disconnect:

All hoses and leads (conduit)
7. Remove:

Screws (conduit)

AIR BAFFLE PLATE

1. Disconnect:

Spark plug caps
2. Straighten:

Tabs (front baffle plate) 1

3. Remove:

Air baffle plate (front) 1

Air baffle plate (rear) 2

FOOTREST (RIGHT) AND BRAKE PEDAL

1. Remove:

Footrest (right) 1

Brake pedal assembly 2

Brake master cylinder 3

2. Disconnect:

Ground lead 1
3. Remove:

Rear brake switch 2

3-4
 ENGINE REMOVAL ENG
FOOTREST (LEFT) AND CLUTCH RELEASE
CYLINDER
1. Remove:

Footrest (left) 1

Change pedal assembly 2

Middle gear case cover 3

2. Remove:

Seat

Side cover (left)
3. Disconnect:

All leads (engine)
4. Remove:

Band 1

5. Remove:

Clutch release cylinder 1

6. Remove:

Spring 1
7. Disconnect:

Rubber boot 2

3-5
 ENGINE REMOVAL ENG
EXHAUST PIPE AND MUFFLER
1. Remove:

Flange bolts (front exhaust pipe)

2. Loosen:

Bolts (front exhaust pipe) 1
3. Remove:

Front exhaust pipes 2

4. Remove:

Bolt (muffler chamber) 1
5. Loosen:

Bolts (muffler) 2
6. Remove:

Bolts (muffler bracket) 3

Mufflers

7. Remove:

Screws (rear exhaust protector)

Covers (rear exhaust) 1

8. Remove:

Clamps (rear exhaust pipes) 1

Protector 2

Rear exhaust pipes 3

3-6
 ENGINE REMOVAL ENG
ENGINE REMOVAL
1. Place a suitable stand under the engine.
2. Remove:

Bolt (engine) 1

Bolts (down tube) 2

Down tube frame (right) 3

3. Remove:

Engine assembly
From right side.
NOTE:
Remove the rear cylinder head cover if difficul-
ties are encountered with any of the previous
steps.

3-7
ENGINE DISASSEMBLY ENG

ENGINE DISASSEMBLY
CYLINDER HEAD AND CAMSHAFT
Rear Cylinder Head
1. Remove:

Cylinder head covers (rear and front)

Gaskets

Spark plugs
1 Front
2 Front cylinder
3 Rear cylinder
2. Remove:

Crankcase cover plate 1

Special washer 2

Timing plug 3
NOTE:
Check for clog of oil passage 4 in the bolt.
If any, clean the oil passage.

3. Align:

Flywheel “T-1” mark 1 with stationary point-
er 2 on crankcase cover

4. Remove:

Cam chain tensioner (rear) 1

5. Remove:

Chain guides 1 , 2

Camshaft caps 3 , 4
They was marked “I-2” 3 and “E-2” 4 .

3-8
ENGINE DISASSEMBLY ENG
6. Remove:

Bolts (cam chain sprocket).
Use 22 mm wrench to hold camshaft.

7. Remove:

Camshaft caps 1 , 2 , 3 , 4 , 5 , 6
NOTE:
When loosing camshaft cap bolts, be sure cam-
shaft cam lobes do not touching valve lifters.

8. Remove:

Camshafts

Sprockets
Slip the sprockets from mounting boss on
camshaft.
NOTE:
Fasten a safety wire 1 to the cam chain.

9. Remove:

Lock pin 1

Water jacket joint 2

10. Remove:

Nuts (cylinder head)
Use 8 mm Wrench Adapter (90890-04076).
NOTE:
Follow numerical order shown in photo. Start by
loosening each nut 1/2 turn until all are loose.

3-9
ENGINE DISASSEMBLY ENG
11. Remove:
S Oil delivery pipe 1
NOTE:
When removing the pipe, be sure not to lose the
washers that may fall out.

S Cylinder head

12. Remove:
S Cam chain guide (rear) 1
S Gasket 2
S Dowel pins 3

Front Cylinder Head

When removing the front cylinder head, repeat
the rear cylinder head removal procedure.
However, note the following points.
1. Rotate:
S Crankshaft
Counterclockwise 360_ plus an added 70_
(430_ total) from the “T-1” mark.

2. Align:
S Flywheel “T-2” mark 1 with stationary point-
er 2 on crankcase cover

3. Mark:
S Pistons
With piston number designations as shown.

3-10
ENGINE DISASSEMBLY ENG
STARTER IDLE GEARS AND FLYWHEEL
1. Remove:

Crankcase cover (left) 1

Gasket

Dowel pins

2. Remove:

Starter idle gears 1

3. Remove:

Bolt (flywheel) 1

Plain washer 2

Pin 3
NOTE:
Check for clog of oil passage 4 in the bolt.
If any, clean the oil passage.

4. Remove:

Flywheel
Use the Flywheel Puller (90890-01362) 1
with the Puller Adapter (90890-04089) 2 .
NOTE:
When removing the flywheel, do not allow the oil
baffle plate 3 to touch the projections 4 on the
flywheel.

3-11
 ENGINE DISASSEMBLY ENG
5. Remove:

Woodruff key 1

Starter clutch gear 2

6. Remove:

Oil baffle plate 1

CLUTCH AND OIL PUMP DRIVE GEAR

1. Remove:

Crankcase cover (right) 1
NOTE:
Working in a crisscross pattern, loosen the bolts
1/4 turn each. Remove them after all are loos-
ened.

Gasket

Dowel pins
2. Remove:
6 8
Bolts (clutch spring) 1

Plate washer 2

Clutch spring 3

Spring seat 4

Pressure plate 5

Friction plate 6

Clutch plates 7

Friction plates 8

Push rod 9

3-12
ENGINE DISASSEMBLY ENG
3. Straighten the lock washer tabs.
4. Loosen:

Nut (clutch boss) 1
Use the Clutch Holder (90890-04086) 2 to
hold the clutch boss.

5. Remove:

Nut (clutch boss) 1

Lock washer 2

Clutch boss 3

Thrust washer 4

Clutch housing 5

6. Remove:

Circlip 1

Oil pump drive gear 2

WATER PUMP AND THERMOSTATIC VALVE

1. Remove:

Waster pump cover/Water pump cable 1

Gasket

Dowel pins

2. Remove:

Thermostat assembly 1

3-13
ENGINE DISASSEMBLY ENG
STARTER MOTOR AND BREATHER COVER
1. Remove:

Starter motor 1

2. Remove:

Breather cover 1

Breather cover spacer 2

Oil pipe 3

OIL PAN AND OIL PUMP

1. Remove:

Oil filter cover 1

2. Remove:

Oil pan 1

Gasket

Dowel pins

3. Remove:

Oil pump assembly 1

Dowel pins

3-14
ENGINE DISASSEMBLY ENG

NOTE:
At this stage it is possible to replace the piston,
connecting rod, and big-end bearing by simply
removing the connecting rod nut. None of the
steps below are necessary to replace the above
components.

4. Straighten the bracket tabs 1 .

5. Remove:

Oil pipe 2

Main oil gallery pipe 3

6. Remove:

Damper (oil pump pipe) 1

Oil pump pipe 2

CRANKCASE DISASSEMBLY
1. Remove:

Retainer (main axle bearing) 1

Retainers (middle gear bearing) 2
Use the #40 Torx Driver (90890-04049).

2. Remove:

Bolts (middle driven gear housing) 1

3-15
 ENGINE DISASSEMBLY ENG
A 3. Remove:

Bolts (crankcase)
NOTE:

Remove the bolts starting with the highest
numbered one.

The embossed numbers in the crankcase des-
ignate the crankcase tightening sequence.

With washer
A UPPER CASE
B LOWER CASE

4. Remove:

Crankcase (upper)
Use a soft hammer.
NOTE:
Pull out the crankcase (upper) while pulling up
the cam chain.

Dowel pins

UPPER CRANKCASE
1. Remove:

Connecting rod caps 1

Connecting rod/Piston assembly
CAUTION:
Do not hammer out the connecting bolts to
remove the connecting rod assembly.

3-16
ENGINE DISASSEMBLY ENG
2. Remove:

Crankshaft

Plane bearings (crankshaft/connecting
rods/balancer shaft)
NOTE:
Identify each plane bearing position very care-
fully so that it can be reinstalled in its original
place.

3. Remove:

Piston pin clip 1

Piston pin 2

Piston 3

TRANSMISSION
1. Remove:

Balancer shaft 1

Main axle assembly 2

Drive axle assembly 3

Middle driven gear assembly 4

Plane bearings (Crankshaft/balancer shaft)
NOTE:
Identify each plane bearing position very care-
fully so that it can be reinstalled in its original
place.

LOWER CRANKCASE
1. Remove:

Shift shaft assembly

1 Shift lever 1
2 Shift lever 2

3-17
ENGINE DISASSEMBLY ENG
2. Unhook:

Tension spring 1
3. Remove:

Shift cam stopper lever 2

4. Remove:

Bearing retainer (shift cam) 1

Guide bars 2

Shift forks 3

Shift cam 4
NOTE:
Note the position of each part. Pay particular
attention to the location and direction of shift
forks.

5. Remove:

Circlip 1

Oil pump idle gear 2

3-18
INSPECTION AND REPAIR ENG

INSPECTION AND REPAIR

CYLINDER HEAD
1. Remove:

Valve pads

Lifters

Spark plugs
NOTE:
Identify each lifter and pad position very careful-
ly so that it can be reinstalled in its original
place.

2. Attach:

Valve Spring Compressor (90890-04019) 1

3. Remove:

Valve retainers 1

Valve spring seat 2

Valve springs 3

Oil seal 4

Valve spring seat 5

Valve 6
NOTE:
Deburr any deformed valve stem end. Use an
oil stone to smooth the stem end.

1 Deburr
2 Valve stem
4. Eliminate:

Carbon deposit
Use rounded scraper.
NOTE:
Do not use a sharp instrument and avoid dam-
aging or scratching.

Spark plug threads

Valve seat

Cylinder head

3-19
INSPECTION AND REPAIR ENG
5. Measure:

Cylinder head warpage
Under specification
Resurface.
Over specification
Replace.

Cylinder Head Warp Limit:

Less than 0.03 mm (0.0012 in)

VALVE, VALVE GUIDE, AND VALVE SEAT

Intake and Exhaust Valve
1. Inspect:

Valve face

Stem end
Wear/Pitting/Out of specification

Replace.

Minimum Thickness (Service limit)

1 :0.7 mm (0.028 in)
Beveled 2 : 0.5 mm (0.020 in)
Minimum Length (Service limit) 3 :
4.0 mm (0.16 in)

2. Measure:

Valve stem clearance
Out of specification
Replace either valve
and/or guide.
Use the Micrometer and Bore Gauge.

Valve Stem Clearance Maximum

0.010
0.037 mm 0.08 mm

Intake
(0.0004
0.0015 in) (0.0031 in)
0.025
0.052 mm 0.10 mm
Exhaust
(0.0010
0.0020 in) (0.0039 in)

1 Valve
2 Bore Gauge A Valve stem outside diameter
3 Valve guide B Valve guide inside diameter

3-20
INSPECTION AND REPAIR ENG
3. Inspect:
S Valve stem end
Mushroom shape/Larger diameter than rest
of stem
Replace valve, valve guide, and
oil seal.

4. Measure:
S Valve stem runout
Out of specification
Replace.

Maximum Runout:
0.01 mm (0.0004 in)

Valve Guide
NOTE:
S Always replace valve guide if valve is re-
placed.
S Always replace oil seal if valve is removed.

1. Inspect:
S Valve guide
Wear/Oil leakage into cylinder
Replace.

2. Remove:
S Valve guide
Use the Valve Guide Remover
(90890-01122) 1 .
NOTE:
Heat the head in an oven to 100_C (212_F) to
ease guide removal and installation and to
maintain correct interference fit.

3. Install:
S Circlip (new)
S Valve guide (Oversize)
Use the Valve Guide Remover
(90890-01122) 1 with the Valve Guide In-
staller (90890-04015) 2 .

3-21
INSPECTION AND REPAIR ENG
NOTE:
After installing valve guide:
S Use the 5.5 mm Valve Guide Reamer
(90890-01196) 1 to obtain proper valve
guide/valve stem clearance.
S Recut the valve seat.

2 Circlip
3 Valve guide

Valve Seat
1. Inspect:
S Valve seat
Wear/Pitting/Valve replacement
Resur-
face seat at 45_ angle.
CAUTION:
Clean valve seat if pitted or worn using a 45_
Valve Seat Cutter (YM-91043) 1 . When
twisting cutter, keep an even downward
pressure to prevent chatter marks.

Cut sections as follows

Section Cutter
A 30_
B 45_
C 60_

2. Measure:
S Valve seat width
3. Apply:
S Mechanics bluing dye (Dykem)
To valve and seat.
S Fine grinding compound (small amount)
Ground surface of valve face.
4. Position:
S Valves
Into cylinder head.
Spin it rapidly back and forth, then lift valve
and clean off all grinding compound.
5. Inspect:
S Valve seat surface
Wherever valve seat and valve face made
contact, bluing will have been removed.

3-22
INSPECTION AND REPAIR ENG
6. Measure:
S Valve seat width
Out of specification/Remaining pitting/Vari-
ation of valve seat width
Cut valve further.
CAUTION:
Remove just enough material to achieve
satisfactory seat.

Seat Width:
Standard: 0.9
1.1 mm
(0.035
0.043 in)
Wear limit: 1.4 mm (0.055 in)

Valve seat recutting steps are necessary

if:
S Valve seat is uniform around perimeter of
valve face but too wide or not centered on
valve face.

Valve Seat Cutter Set Desired Result

30_ cutter
Use
U To center
T t th
the seatt or
45_ cutter
either to reduce its width
60_ cutter
S Valve face indicates that valve seat is cen-
tered on valve face but is too wide (see “a”
diagram).

Valve Seat Cutter Set Desired Result

30_ cutter To reduce valve seat
Use
width to 1.0
1 0 mm
lightly 60_ cutter (0.039 in)
S Valve seat is in the middle of the valve face
but too narrow (see “b” diagram).

Valve Seat Cutter Set Desired Result

To achieve a uniform
Use 45_ cutter valve seat width of
1.0 mm (0.039 in)
S Valve seat is too narrow and right up near
valve margin (see “c” diagram).

Valve Seat Cutter Set Desired Result

30_ cutter, first To center the seat
Use and to increase its
45_ cutter width

3-23
INSPECTION AND REPAIR ENG
S Valve seat is too narrow and is located down
near the bottom edge of the valve face (see
diagram “d”).

Valve Seat Cutter Set Desired Result

60_ cutter, first To center the seat
Use and to increase its
45_ cutter width

Valve/Valve Seat Assembly Lapping

1. Apply:
S Coarse lapping compound (small amount)
To valve face.
S Molybdenum disulfide oil
To valve stem.
2. Position:
S Valves
In cylinder head.
3. Rotate:
S Valve
Turn until valve and valve seat are evenly
polished, then clean off all compound.
4. Apply:
S Fine lapping compound (small amount)
To valve face.
5. Repeat steps 2 and 3.
NOTE:
Be sure to clean off all compound from valve
face after every lapping operation.

6. Inspect:
S Valve face
Not yet uniformly smooth
Repeat proce-
dure from step 1.
7. Apply:
S Mechanics bluing dye (Dykem)
To valve face and seat.
8. Rotate:
S Valve
9. Inspect:
S Valve face
Valve must make full seat contact indicated
by grey surface all around. The valve face
where bluing was removed.
Faulty contact
Replace.
(See procedure below)

3-24
INSPECTION AND REPAIR ENG
10. Apply:

Solvent
Into each intake and exhaust port.
NOTE:
Pour solvent into intake and exhaust ports only
after completion of all valve work and assembly
of all head parts.

11. Check:

Valve seals 1
Leakage past valve seat
Replace valve.
(See procedure below)

2 Valve guide

Relapping steps:

Disassemble head parts.

Repeat lapping steps using fine lapping
compound.

Clean all parts thoroughly.

Reassemble and check for leakage again
using solvent.

Repeat steps as often as necessary to ef-
fect a satisfactory seal.

Valve Spring
This engine uses two springs of different sizes
to prevent valve float or surging. Valve spring
specifications show the basic value character-
istics.

1 Outer spring
2 Inner spring

1. Measure:

Spring free length
Out of specification
Replace.

Minimum Free Length:

Outer: 38.90 mm (1.531 in)
Inner: 37.45 mm (1.474 in)

3-25
INSPECTION AND REPAIR ENG
2. Measure:

Spring force (installed length)
Out of specification
Replace.

Valve Compressed Force:

Outer: 13.3
15.7 kg (29.3
34.6 lb)
at 33.8 mm (1.331 in)
Inner: 6.29
7.39 kg (13.9
16.3 lb)
at 31.8 mm (1.75 in)

Valve Lifter
1. Inspect:

Valve lifter wall
Scratches/Damage
Replace both lifter
and cylinder head.

Valve Installation
1. Lubricate:

Valve stem

Oil seal

High-Quality Molybdenum Disulfide

Motor Oil or Molybdenum Disulfide
Grease

2. Install:

Valve 1

Valve spring seat 2

Oil seal 3

Valve springs 4

Valve spring seat 5

Valve retainers 6

NOTE:
Install springs with wider-gapped coils facing
upwards, as shown.

1 Larger pitch
2 Smaller pitch

3-26
INSPECTION AND REPAIR ENG
CAMSHAFT, CAM CHAIN, AND CAM
SPROCKET
Camshaft
1. Inspect:

Cam lobes
Pitting/Scratches/Blue discoloration
Re-
place.
2. Measure:

Cam lobes
Use the Micrometer.
Out of specification
Replace.

Cam Lobe Cam Lobe

“A” (Limit) ”B” (Limit)
35.65 mm 26.95 mm
Intake
(1.404 in) (1.061 in)
35.65 mm 26.95 mm
Exhaust
(1.404 in) (1.061 in)

Camshaft/Cap Clearance Measurement

1. Install:

Camshaft
2. Attach:

Plastigage (YU-33210)
Onto camshaft.

A For Exhaust
B For Intake

3. Attach:

Camshaft cap (“1-3” or “E-3”)
4. Install:

Camshaft caps (others)
5. Tighten:

Camshaft cap bolts
CAUTION:
First Tighten the Nos.2, 4, and 1 cap bolts in
that order, then the No.3 cap bolts; other-
wise, the No.3 caps may be damaged or
bent.

Camshaft Cap:
10 Nm (1.0 m
kg, 7.2 ft
lb)

NOTE:
Do not turn the camshaft when measuring
clearance with Plastigage.

3-27
INSPECTION AND REPAIR ENG
6. Remove:

Camshaft caps
7. Measure:

Width of Plastigage 1
Out of specification
Follow step 8.

Camshaft-to-cap Clearance:
Standard: 0.020
0.054 mm
(0.0008
0.0021 in)
Maximum: 0.160 mm (0.006 in)

8. Measure:

Camshaft outside diameter
Use a micrometer.
Out of specification
Replace camshaft.
Within specification
Replace cylinder
head.

Camshaft Outside Diameter:

Standard: 24.967
24.980 mm
(0.9830
0.9835 in)
Cam Cap Inside Diameter:
Standard: 25.000
25.021 mm
(0.9843
0.9851 in)

Cam Chains
1. Inspect:

Cam chains
Chain stretch/Cracks
Replace.

Cam Sprockets
1. Inspect:

Cam sprockets
Wear/Damge
Replace.

Chain Dampers
1. Inspect:

Upper damper 1

Front damper 2

Rear damper 3
Wear
Replace.

3-28
INSPECTION AND REPAIR ENG
Cam Chain Tensioner
1. Check:

One-way cam operation
Unsmooth operation
Replace.
2. Inspect:

All parts
Damage/Wear
Replace.
1 End plug 4 Tensioner body
2 Washer 5 One way cam
3 Spring 6 Tensioner rod
CYLINDER
1. Inspect:

Cylinder wall
Wear/Scratches
Rebore or replace.
2. Measure:

Cylinder bore “C”
Use the Cylinder Bore Gauge.
Measure the cylinder bore “C” horizontally
and laterally at 40 mm (1.57 in) from cylinder
top.
Then, find the coverage of the measure-
ments.
Out of specification
Rebore.

Standard Wear Limit

Cylinder 75.967
76.016 mm 76.1 mm

Bore C: (2.991
2.993 in) (2.996 in)
X+Y
C=
2

PISTON, PISTON RING, AND PISTON PIN

Piston
1. Inspect:

Piston wall
Wear/Scratches/Damage
Replace.
2. Measure:

Piston outside diameter “P”
Use a Micrometer.
Out of specification
Replace.

3-29
INSPECTION AND REPAIR ENG
NOTE:
Measurement should be made at point 6.2 mm
(0.244 in) above the bottom edge of the piston.

Size “P”

75.905
75.955 mm
Standard
(2.9884
2.9903 in)
Oversize 1 76.25 mm (3.002 in)
Oversize 2 76.50 mm (3.012 in)

3. Measure:

Piston clearance
Out of specification
Rebore cylinder or re-
place piston.

Piston Clearance = C – P:
0.055
0.075 mm
(0.0022
0.0030 in)

C: Cylinder bore P: Piston outside diameter

Piston Ring
1. Measure:

Side clearance
Use the Feeler Gauge 1 .
Out of specification
Replace piston
and/or rings.
Side Clearance
Standard Limit
0.03
0.07 mm 0.12 mm
Top Ring
(0.0012
0.0028 in) (0.0047 in)
0.02
0.06 mm 0.12 mm
2nd Ring
(0.0008
0.0024 in) (0.0047 in)

3-30
INSPECTION AND REPAIR ENG
2. Position:

Piston ring
Into cylinder.
Push the ring with the piston crown.
3. Measure:

End gap
Use the Feeler Gauge 1 .
Out of specification
Replace rings as set.

End Gap
Standard Limit
0.35
0.50 mm 0.75 mm
Top Ring
(0.0138
0.0197 in) (0.0295 in)
0.35
0.50 mm 0.75 mm
2nd Ring
(0.0138
0.0197 in) (0.0295 in)

0.2
0.8 mm
Oil Ring –
(0.0080
0.032 in)

Oversize Piston Rings

The oversize top and middle ring sizes are
stamped on top of the ring.

Oversize 1 0.25 mm (0.0098 in)

Oversize 2 0.50 mm (0.0197 in)

The expander spacer of the bottom ring (oil

control ring) is color-coded to identify sizes.
The color mark is painted on the expander
spacer.

Size Color
Oversize 1 Blue (Two)
Oversize 2 Red (One)

Piston Pin
1. Lubricate:

Piston pin (lightly)
2. Install:

Piston pin
Into small end of connecting rod.

3-31
INSPECTION AND REPAIR ENG
3. Check:

Free play
Free play
Inspect connecting rod for wear.
Wear
Inspect connecting rod and piston
pin.
4. Position:

Piston pin
Into piston.
5. Check:

Free play
When pin is in place in piston.
Free play
Replace piston pin and/or pis-
ton.

STARTER DRIVES
Electric Starter Clutch
1. Check:

Ball 1 operation

Spring cap 2 operation

Spring 3 operation
Unsmooth operation
Replace one-way
clutch.

2. Check:

Damper housing 4

Rubber dampers 5
Cracks/Wear/Damage
Replace.
3. Install:

Rubber damper

Damper housing

One-way clutch
4. Tighten:

Bolts (one-way clutch)

Bolts (Starter One-way Clutch):

24 Nm (2.4 m
kg, 17 ft
lb)
LOCTITE
Stake Over the End of the Bolt

3-32
INSPECTION AND REPAIR ENG
Starter Gears
1. Inspect:

Idle gear surfaces
Pitting/Wear/Damage
Replace.

PRIMARY GEARS
The drive gear is mounted on the crankshaft;
the driven gear is mounted on the transmission
and is intergrated with the clutch assembly.
1. Inspect:

Drive gear
Scratches/Wear/Damage
Replace
crankshaft.

Driven gear 1
Scratches/Wear/Damage
Replace
clutch housing assembly.

CLUTCH
Clutch Housing
1. Inspect:

Dogs on the housing
Cracks/Wear/Damage
Deburr or re-
place.

Clutch housing bearing
Chafing/Wear/Damage
Replace.

Clutch Boss
The clutch boss contains a built-in damper be-
neath the friction plate 1 and clutch plate 2 . It
is not necessary to remove the wire circlip 3
and disassemble the built-in damper unless
there is serious clutch chattering.

3-33
INSPECTION AND REPAIR ENG
1. Inspect:

Clutch boss splines
Scoring/Wear/Damage
Replace clutch
boss assembly.
NOTE:
Scoring on the clutch plate splines will cause er-
ratic operation.

Friction Plates
1. Inspect:

Friction plate 1
Damage/Wear
Replace friction plate as a
set.
2. Measure:

Friction plate thickness
Measure at all four points.
Out of specification
Replace friction plate
as a set.

Wear Limit:
2.8 mm (0.11 in)

Clutch Plates
1. Measure:

Clutch plate warpage
Use the surface plate and the Feeler Gauge
1.
Out of specification
Replace.

Warp Limit:
0.2 mm (0.008 in)

Push Rod
1. Measure:

Push rod runout 1
Use V–Blocks and the Dial Gauge
(90890-03097).
Out of specification
Replace.

Bending Limit:
0.5 mm (0.02 in)

3-34
INSPECTION AND REPAIR ENG
Clutch Bearing
1. Inspect:

Bearing
Pitting/Damage
Replace.

Clutch Spring
1. Inspect:

Clutch spring 1
Wear/Bends/Cracks
Replace.
2. Measure:

Clutch spring free height a
Out of specification
Replace.

Clutch Spring Minimum Height:

6.5 mm (0.26 in)

3. Measure:

Clutch spring warpage
Use a surface plate and the Feeler Gauge 1
Out of specification
Replace.

Warp Limit:
0.1 mm (0.004 in)

Clutch Spring Seat

1. Inspect:

Clutch spring seat 1
Wear/Bends/Damage
Replace.

OIL PUMP
1. Measure:

Housing 1 /Outer rotor 2 clearance a Use
the Feeler Gauge.
Out of specification
Replace oil pump as-
sembly.

Side Clearance Limit:

0.08 mm (0.0031 in)

3-35
INSPECTION AND REPAIR ENG
2. Measure:

Outer rotor 1 /Inner rotor 2 clearance b
Use the Feeler Gauge.
Out of specification
Replace oil pump as-
sembly.

Tip Clearance Limit:

0.17 mm (0.0067 in)

OIL GALLERY PIPE

1. Inspect:

O-rings 1
Wear/Cracks/Damage
Replace.

Gallery pipe 2
Cracks/Damage
Replace.

CRANKSHAFT
Crankshaft
1. Measure:

Runout
Use the V–Blocks and Dial Gauge 1
(90890-03097).
Out of specification
Replace.

Runout Limit:
0.03 mm (0.0012 in)

2. Inspect:

Crankshaft bearing surfaces
Wear/Scratches
Replace.

Crankshaft Main Bearing Clearance Mea-

surement
1. Clean all parts.
2. Position:

Crankcase half (upper)
Place on a bench in an upside down position.
3. Install:

Bearings
Into the upper crankcase.

Crankshaft

3-36
INSPECTION AND REPAIR ENG
4. Attach:

Plastigage (YU-33210)
Onto the crankshaft journal surface.
NOTE:
Do not turn the crankshaft until clearance mea-
surement has been completed.

5. Install:

Bearings
Into lower crankcase.
6. Tighten:

Bolts
CAUTION:
Tighten to full torque in torque sequence as
shown.

10 mm Bolts (Crankcase):
40 Nm (4.0 m
kg, 29 ft
lb)

With a washer

7. Remove:

Bolts
Reverse assembly order.

Crankcase (lower)
Use care in removing.
8. Measure:

Width of Plastigage 1
Out of specification
Replace bearings; re-
place crankshaft if necessary.

Main Bearing Oil Clearance:

0.020
0.038 mm
(0.0008
0.0015 in)

3-37
INSPECTION AND REPAIR ENG
Connecting Rod Bearing Clearance Mea-
surement
1. Clean all parts.
2. Install:

Connecting rod bearings
Into connecting rod and cap.
3. Attach:

Plastigage (YU-33210)
Onto the crank pin.
4. Install:

Connecting rod

Connecting rod cap
NOTE:
Be sure the letter on both components align to
form perfect character.

5. Lubricate:

Bolt threads (connecting rod)

Molybdenum Disulfide Grease

6. Tighten:

Nuts (connecting rod cap)
NOTE:
Do not turn connecting rod until clearance mea-
surement has been completed.

CAUTION:
Tighten to full torque specification without
pausing. Apply continuous torque between
3.0 and 3.8 m
kg. Once you reach 3.0 m
kg,
DO NOT STOP TIGHTENING until final
torque is reached. If tightening is inter-
rupted between 3.0 and 3.8 m
kg, loosen nut
to less than 3.0 m
kg and start again.

Connecting Rod Cap:

36 Nm (3.6 m
kg, 25 ft
lb)

3-38
INSPECTION AND REPAIR ENG
7. Remove:

Connecting rod cap
Use care in removing.
8. Measure:

Width of Plastigage 1
Out of specification
Replace bearings
and/or replace crankshaft if necessary.

Connecting Rod Bearing Clea-

rance:
0.021
0.039 mm
(0.0008
0.0015 in)

Crankshaft Main and Connecting Rod Bear-

ing Selection

Numbers used to indicate crankshaft journal
sizes are stamped on the crankweb. The first
two (2) A are rod bearing journal numbers,
starting with the left journal. The four (4) B
main bearing journal numbers follow in the
same sequence.

The lower crankcase half is numbered J1, J2,

J3, and J4 on the front left boss as shown.

The numbers 1 are stamped in ink on the rod.

3-39
INSPECTION AND REPAIR ENG

Example 1: Selection of the crankshaft

main bearings;

If the crankcase J1 and crankshaft J1 sizes
are No.4 and No.1, respectively, the bearing
size No. is:

Bearing Size No. =

Crankcase No. – Crankshaft No. =
4 – 1 = 3 (Brown)

BEARING COLOR CODE

No.1 Blue
No.2 Black
No.3 Brown
No.4 Green
No.5 Yellow
No.6 Pink
Example 2: Selection of the connecting
rod bearing;

If the connecting rod P1 and crankshaft P1
sizes are No.5 and No.1, respectively, the
bearing size No. is:

Bearing Size No. =

Connecting Rod No. – Crankshaft No. =
5 – 1 = 4 (Green)

BEARING COLOR CODE

No.1 Blue
No.2 Black
No.3 Brown
No.4 Green
No.5 Yellow
No.6 Pink
No.7 Red

BALANCER SHAFT
Balancer Shaft Bearing Clearance Measure-
ment
1. Clean surfaces of balancer shaft and crak-
case journal.
2. Position:

Crankcase half (upper)
Place on a bench in an upside down position.

3-40
INSPECTION AND REPAIR ENG
3. Install:

Bearings
Into the upper crankcase.
4. Install:

Balancer shaft
Into the upper crankcase.
5. Attach:

Plasticage (YU-33210)
Onto the balancer shaft journal surface.

NOTE:
Do not move balancer shaft until clearance
measurement has been completed.

6. Install:

Bearings
Into lower crankcase.
7. Tighten:

Bolts (crankcase)
CAUTION:
Tighten to full torque in torque sequence
cast on the crankcase.

8 mm Bolt (Crankcase):
24 Nm (2.4 m
kg, 17 ft
lb)

8. Remove:

Bolts
Reverse assembly order.

Crankcase (lower)
Use care in removing.
9. Measure:

Plastigage width 1
Out of specification
Replace bearings; re-
place balancer shaft in necessary.

Balancer Shaft Bearing Oil Clea-

rance:
0.020
0.048 mm
(0.0008
0.002 in)

3-41
INSPECTION AND REPAIR ENG
Balancer Shaft Bearing Selection

Numbers used to indicate balancer shaft jour-
nal sizes are stamped on the RH balancer web
corner, starting with the left journal.

1 Left balancer shaft journal size number

2 Right balancer shaft journal size number

The lower crankcase half is numbered J5, and

J6 as shown.

Example: Selection of the balancer shaft

bearings;

If the crankcase J5 and left balancer shaft
sizes are No.4 and No.1, respectively, the
left balancer bearing size No. is:

Bearing Size No. =

Crankcase No. – Balancer Shaft No. =
4 – 1 = 3 (Brown)

BEARING COLOR CODE

No.1 Blue
No.2 Black
No.3 Brown
No.4 Green
No.5 Yellow
No.6 Pink
TRANSMISSION
Shift Fork
1. Inspect:

Shift forks
On the gear and shift cam contact surfaces.
Wear/Chafing/Bends/Damage
Replace.
2. Check:

Shift fork movement
On its guide bar.
Unsmooth operation
Replace fork and/or
guide bar.

3-42
INSPECTION AND REPAIR ENG
Shift Cam
1. Inspect:

Shift cam grooves
Wear/Damage/Scratches
Replace.

Shift cam segment
Damage/Wear
Replace.

Shift cam bearing
Pitting/Damage
Replace.

Main and Drive Axles

1. Measure:

Axle runout 1
Use the centering device and Dial Gauge
(90890-03097) 2 .
Out of specification
Replace.

Runout Limit: 0.08 mm (0.0031 in)

Gears
1. Inspect:

Gears
Damage/Wear
Replace.
2. Check:

Gear movement
Unsmooth operation
Replace.
3. Inspect:

Mating dogs
Cracks/Wear/Damage
Replace.

BEARINGS
1. Inspect:

Axle bearings

Shift cam bearing
Pitting/Damage
Replace.

CIRCLIPS AND WASHERS

1. Inspect:

Circlips

Washers
Damage/Looseness/Bends
Replace.

3-43
 MIDDLE GEAR SERVICE ENG

MIDDLE GEAR SERVICE

1 Universal joint 13 Middle drive pinion gear
2 Dust seal 14 Thrust washer
3 Housing 15 Retainer
4 O-ring
5 Bearing
6 Collapsible collar
7 Bearing
8 Middle drive shaft
9 Middle driven pinion gear
10 Spring seat
11 Damper spring
12 Damper cam

90 Nm (9.0 m
kg, 65 ft
lb)

30 Nm (3.0 m
kg, 22 ft
lb)

SHIMS:
A 0.10 mm (0.004 in)
0.15 mm (0.006 in)
0.30 mm (0.012 in)

B Always use a new one

GEAR LASH:
C 0.05
0.12 mm
(0.002
0.005 in)

SHIMS:
0.15 mm (0.006 in)
A 0.30 mm (0.012 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in) D 110 Nm (11.0 m
kg, 80 ft
lb)
STAKE
3-44
 MIDDLE GEAR SERVICE ENG
1 Drive axle 10 Oil seal
2 Drive pinion gear shim 11 Bearing retainer
3 Bearing 12 Bearing housing
4 Middle drive pinion gear 13 Driven pinion gear shim
5 Collapsible collar 14 Nut (drive pinion gear)
(Always use a new one) 15 Nut (driven pinion gear)
6 Spacer 16 Bearing stopper
7 Middle driven pinion gear
8 O-ring
9 Universal joint

A STAKE
25 Nm (2.5 m
kg, 18 ft
lb)

A STAKE
110 Nm
(11.0 m
kg, 80 ft
lb)

B GEAR LASH
0.05
0.12 mm
(0.002
0.005 in)

30 Nm (3.0 m
kg, 22 ft
lb)

90 Nm (9.0 m
kg, 65 ft
lb)

C STARTING TORQUE:
0.4
0.5 Nm (0.04
0.05 m
kg,
0.28
0.35 ft
lb)

3-45
MIDDLE GEAR SERVICE ENG
DRIVE AXLE POSITIONING
When the crankcase assembly and/or the drive
axle are replaced, you must position the drive
axle in place.
Refer to “Drive Pinion Gear Shim Selection and
Middle Gear Lash Adjustment” section.
1 Drive pinion gear
2 Driven pinion gear
A Drive pinion gear shim
B Driven pinion gear shim

Drive Pinion Gear Shim Selection

“A” = 54.5 plus or minus the number stamped
on the drive pinon gear.

“B” = 53 plus the number stamped on the left-

side rear of the upper crankcase.

3-46
MIDDLE GEAR SERVICE ENG

Example: Selection of the drive pinion

gear shim;
Shim Thickness =
Distance “A” – Distance “B”

If the drive pinion gear is stamped “03” (plus
(+03) is implied here since only the minus
(–) designations are stamped alongside the
numbers), then:
“A” = 54.5 + 0.03
= 54.53
NOTE:
All stamped numbers are in hundredths of a
mm.

If the left-side-rear of the upper crankcase is

stamped “95”, then:
“B” = 53 + 0.95
= 53.95
Therefore:
T=A–B
= 54.53 – 53.95
= 0.58 mm

The calculated shim thickness is 0.58 mm.
Because shim can only be selected in 0.05
mm increments, use the following chart to
round off the hundredths digit of the calcu-
lated thickness and selest the appropriate
shim.

Hundredths Digit Rounded Value

0, 1, 2 0
3, 4, 5, 6 5
7, 8, 9 10

Using the above example, the calculated

shim thickness of 0.58 mm is rounded off to
0.60 mm. Therefore, you may choose either
4 – 0.15 mm shims, 2 – 0.30 mm shims, or 1
– 0.30 mm and 2 – 0.15 mm shims as se-
lected from the shim thickness chart below.
Shim size are supplied in the following thick-
nesses:

Drive Pinion Gear Shim

0.15 0.30
Thickness (mm)
0.40 0.50

3-47
MIDDLE GEAR SERVICE ENG
Middle Gear Lash Adjustment
1. Attach:

Middle Drive Gear Holder 1 (90890-
04080)
This tool will prevent the drive axle from turn-
ing.
2. Install:

Bolts (three)
On driven bearing housing.
Finger-tighten the bolts.
NOTE:
Clearance between the crankcase and driven
bearing housing should be about 2 mm.
Measure gap with Feeler Gauge 2 .

3. Position:

Dial Gauge 3 (90890-03097)
On the outside edge of U-joint.
NOTE:
Be sure the gauge is positioned over the center-
line of the yoke bearing hole.

4. Rotate:

U-joint
Move it gently back and forth.
5. Measure:

Gear lash
Over specification
Follow next steps.
Under or same specification
Incorrect;
check for faulty parts and/or reassemble
bearing housing.

Middle Gear Lash:

0.05
0.12 mm
(0.002
0.005 in)

CAUTION:
Do not hammer the U-joint or the collapsible
collar of the driven pinion gear may be dis-
torted.
This will result in a change in the standard
starting torque, requiring replacement of
the collapsible collar and reassembly of the
driven gear assembly.

NOTE:
Check the gear lash at four positions. Rotate the
U-joint 90 degrees each time and repeat the
gear lash check.

3-48
MIDDLE GEAR SERVICE ENG
6. Tighten:

Bolt (Three)
Tighten carefully one-thread turn only. Push
in bearing housing and hold in position while
tightening bearing housing bolts.
CAUTION:
Do not overtighten bearing housing bolts or
you may obtain too little gear lash and cause
damage to gears. If over tightened, loosen
the 3 bolts so that crankcase/bearing hous-
ing clearance is about 2 mm (0.08 in) and re-
peat all previous steps.

7. Repeat steps 4 and 5 until correct gear lash

is achieved.

Middle Gear Lash:

0.05
0.12 mm
(0.002
0.005 in)

8. Measure:

Crankcase/bearing housing clearance
Use a Feeler Gauge.
9. Select:

Shim(s) 1
Example: Selection of the driven pinion
gear shim;

If the clearance is 0.46 mm.

The shim can only be selected in 0.05 mm
increments, round off hundredths digit and
select appropriate shim(s).

Hundredths Round Value

0, 1, 2 0
3, 4, 5, 6 5
7, 8, 9 10

In the example above, the measured shim

thickness is 0.46 mm. The chart instructs
you, however, to round off the 6 to 5. Thus
you should use 0.15 mm and 0.30 mm
shims.

Shim sizes are supplied in the following
thickness.

Driven Pinion Gear Shim

0.10 0.15 0.30

Thickness (mm)
0.40 0.50 0.60

3-49
MIDDLE GEAR SERVICE ENG
10. Tighten:

Bolts (bearing housing)

Bolts (Bearing Housing):

30 Nm (3.0 m
kg, 22 ft
lb)

NOTE:
Before tightening the bolts, make sure that the
arrow on the bearing housing points to the up-
per crankcase.

11. Measure:

Gear lash

REMOVAL
1. Remove:

Drive axle assembly 1

2. Attach:

Damper Spring Compressor (90890-04090) 1
Onto drive pinion.
3. Position:

Drive axle shaft assembly
Onto a Hydraulic Press.
4. Compress the damper spring on the drive
axle shaft assembly.

5. Remove:

Retainers 1

Washer 2

Drive pinon gear 3

Damper cam 4

Damper spring 5

Spring seat 6

Bearing 7

3-50
MIDDLE GEAR SERVICE ENG
6. Remove:

Nut (drive gear)
Use the Offset Wrench 1 (90890-04054).

Bearing

Shim(s)

INSPECTION
1. Inspect:

Damper cam surfaces
Wear/Scratches
Replace damper and
drive pinion gear as a set.
2. Inspect:

Damper spring
Damage/Cracks
Replace.

ASSEMBLY
1. Install:

Shim(s)

Bearing

Nut (drive gear)
Use the Offset Wrench 1 (90890-04054).

Nut (Drive Gear):

110 Nm (11 m
kg, 80 ft
lb)
LOCTITE

2. Lock the threads with center punch 1 as

shown.

3. Install:

Bearing 1

Spring seat 2

Damper Spring 3

Damper cam 4

Drive gear assembly 5

Washer 6

3-51
MIDDLE GEAR SERVICE ENG
4. Attach:

Damper Spring Compressor (90890-04090)
1
5. Position:

Drive axle shaft assembly
Onto a Hydraulic Press.
6. Compress the damper spring on the drive
axle assembly.
7. Install:

Retainers
Into drive axle shaft groove.

Drive axle shaft assembly
Onto the crankcase.
MIDDLE DRIVEN GEAR BEARINGS
The following procedures should be performed
only if the middle driven gear or middle drive
shaft bearing(s) must be replaced.

Universal Joint Removal

1. Remove:

Universal joint
Universal joint removal steps:

Remove the circlips 1 .

Place the U-joint in a press.

With a suitable diameter pipe beneath the
yoke, press the bearing into the pipe as
shown.
NOTE:
It may be necessary to lightly tap the yoke
with a punch.

Repeat the steps for the opposite bearing.

Remove the yoke.
NOTE:
It may be necessary to lightly tap the yoke
with a punch.

2. Attach:

Universal Joint Holder 1 (90890-04062)
Onto the universal joint yoke.

3-52
MIDDLE GEAR SERVICE ENG
3. Remove:

Nut (driven pinion gear)

Washer

Yoke

Bearing

Bearing housing

Collapsible collar

Spacer

Inspection
1. Inspect:

Gear teeth
Pitting/Galling/Wear
Replace middle
gear as a set.

Bearings
Pitting/Damage
Replace.
2. Check:

U-joint movement
Roughness
Replace U-joint.

Assembly
1. Install:

Bearing outer race
Into the bearing housing.
CAUTION:
Do not press the bearing outer race. Always
press the inner race with care when instal-
ling.

2. Install:

Inner bearing 1

Spacer 2

Collapsible collar 3 (new)

Bearing housing 4

Outer bearing 5

Dust seal 6

Yoke 7

Washer 8

Nut (driven pinion gear) 9
3. Attach:

Universal Joint Holder (90890-04062)
Onto the universal joint yoke.
4. Tighten:

Nut (driven pinion gear)
Torque nut carefully, little by little.

Nut (Driven Pinion Gear):

90 Nm (9.0 m
kg, 65 ft
lb)
LOCTITE

3-53
MIDDLE GEAR SERVICE ENG
5. Measure:

Starting torque (driven pinion gear)
Under specification
Repeat steps from 4.

Starting Torque (Driven Pinion

Gear):
0.4
0.5 Nm (0.04
0.05 m
kg,
0.29
0.36 ft
lb)

CAUTION:

Never exceed the standard starting torque.

Be sure to tighten the driven pinion gear
nut slowly, carefully checking measure-
ments each time. Exceeding the standard
starting torque may depress the collaps-
ible collar, requiring reassembly.

To reassemble, you must replace the col-
lapsible collar and repeat the steps in 4 and
5 to obtain the standard starting torque.

6. Position:

Yoke
Into the U-joint.
7. Lubricate:

Bearings

Wheel Bearing Grease

8. Install:

Bearings
Onto the yoke.
CAUTION:
Check each bearing. The needles can easily
fall out of their races. Slide the yoke back
and forth on the bearings; the yoke will not
go all the way onto a bearing if a needle is
out of palce.

9. Press each bearing into U-joint using a suit-

able socket.
NOTE:
Bearing must be inserted far enough into U-joint
so that circlip can be installed.

10. Install:

Circlips 1
Into groove of each bearing.
3-54
ENGINE ASSEMBLY AND ADJUSTMENT ENG

ENGINE ASSEMBLY AND AD-

JUSTMENT
LOWER CRANKCASE
1. Install:

Oil pump idle gear 2

Circlip 1

2. Install:

Shift cam

Shift forks (No.1, 2, 3)

Guide bars
NOTE:
All numbers should face the left side and be in
sequence (1, 2, 3), begining from the left.

3. Install:

Bearing retainer (shift cam)
4. Tighten:

Screws (bearing retainer)

Screws (Bearing Retainer):

7 Nm (0.7 m
kg, 5.1 ft
lb)
LOCTITE

5. Rotate the shift cam to neutral position.

6. Install:

Shift cam stopper lever 1

tension spring 2

Washer 3

Bolt (shift cam stopper lever) 4
7. Tighten:

Bolt (shift cam stopper lever)

Bolt (Shift Cam Stopper Lever):

8 Nm (0.8 m
kg, 5.8 ft
lb)
LOCTITE

NOTE:
Check for smooth operation after tightening the
stopper lever.

3-55
 ENGINE ASSEMBLY AND ADJUSTMENT ENG

CRANKSHAFT/CONNECTING ROD/PISTON
1 Piston ring
2 “Y” mark
3 Matching mark
4 Connecting rod bearing size
5 Projection
6 Washer
7 Journal bearing size
8 Crank pin size
9 Balancer matching mark

B END GAP LIMIT:

C Top: 0.75 mm (0.0295 in)
D 2nd: 0.75 mm (0.0295 in)

A PISTON TO CYLINDER CLEARANCE:

0.055
0.075 mm(0.0022
0.0030 in)

36 Nm (3.6 m
kg, 25 ft
lb) CONNECTING ROD

E BEARING CLEARANCE:
0.021
0.039 mm
(0.0008
0.0015 in)

CRANKSHAFT JOURNAL
F CLEARANCE:
0.020
0.038 mm
(0.0008
0.0015 in)
130 Nm (13.0 m
kg, 94 ft
lb)

3-56
 ENGINE ASSEMBLY AND ADJUSTMENT ENG

TRANSMISSION
1 Circlip 10 2nd wheel gear (39T) 19 Circlip
2 Bearing 11 Washer 20 2nd, 3rd pinion gear (22 / 23T)
3 1st wheel gear (43T) 12 Circlip 21 5th pinion gear (28T)
4 4th wheel gear (28T) 13 5th wheel gear (26T) 22 Washer
5 Circlip 14 Bearing 23 Circlip
6 Washer 15 Bearing 24 Bearing
7 3rd wheel gear (31T) 16 Main axle 25 Circlip
8 Drive axle 17 4th pinion gear (26T)
9 Plug 18 Washer

DEFLECTION LIMIT:
A 0.08 mm (0.0031 in)

3-57
ENGINE ASSEMBLY AND ADJUSTMENT ENG
8. Install:

Shift shaft assembly

1 Shift lever 1
2 Shift lever 2

TRANSMISSION
1. Install:

Plane bearings (crankshaft/balancer shaft)
NOTE:
Identify each plane bearing position very carfuly
so that it can be reinstalled in its original palce.

2. Install:

Main axle assembly 1

Drive axle assembly 2
NOTE:

Insert the bearing circlips 3 completely into
lower crankcase positioning grooves.

Position the bearing pin 4 as shown.

3. Install:

Middle driven pinion gear assembly 1
NOTE:

Be careful not to damage the O-ring 2 during
installation.

The arrow mark 3 on the bearing housing
points to the upper crankcase.

4. Install:

Push rod support bearing 1
NOTE:

Insert the bearing pin 2 into the crankcase
hole.

Position the oil seal 3 snugly against the
bearing.

Lightly apply grease to the oil seal lips.

3-58
ENGINE ASSEMBLY AND ADJUSTMENT ENG
5. Check:

Transmission and shifter operation
Unsmooth operation
Repair.
NOTE:
Oil each gear and bearing thoroughly.

6. Install:

Crankshaft with cam chains 1

Balancer shaft 2
NOTE:
Align the mark 3 on the balancer shaft gear
with the mark 4 on the crankshaft gear.

UPPER CRANKCASE
1. Install:

Plane bearings (crankshaft/balancer gear)
NOTE:
Identify each plane bearing position very care-
fuly so that it can be reinstalled in its original
place.

2. Install:

Piston rings
NOTE:
Be sure to install rings so that Manufacturer’s
marks or numbers are located on the top side of
the rings.

3. Oil liberally:

Pistons

Rings

Cylinders
4. Set:

Piston ring ends
CAUTION:
Make sure the ends of the oil ring expanders
do not overlap.

1 TOP 2 OIL RING (LOWER RAIL)

3 OIL RING (UPPER RAIL) 4 2ND
3-59
 ENGINE ASSEMBLY AND ADJUSTMENT ENG
5. Install:

Piston 3

Piston pin 2

Piston pin clip 1
NOTE:

Be sure the piston is positioned correctly as
shown.

Always install new piston pin clips.

Plane bearings (connecting rods) 7

Onto the connecting rod and cap.

4 “Y” Mark
5 “EX” Exhaust side
6 “IN” Intake side
8 Projection

6. Install:

Piston/Connecting rod assembly (#1
#4)
Into the upper crankcase.
Piston/Connecting rod assembly instal-
lation steps:

Attach the Piston Ring Compressor 1
(90890-05158) to the piston.

Install the piston to the cylinder.
NOTE:

The stamped “Y” mark 2 on the No.2 and
A No.4 connecting rods should face towards
the RIGHT side of the crankcase.

The stamped “Y” mar 2 on the No.1 and
No.3 connecting rods should face towards
the LEFT side of the crankcase.

A Top view
3 Front
4 “Y”-mark facing direction
5 Piston exhaust mark
6 Piston intake mark

3-60
ENGINE ASSEMBLY AND ADJUSTMENT ENG
CRANKCASE ASSEMBLY
1. Apply:

Yamaha Bond No.1215
(90890-85505)
To the mating surfaces of both case halves.
NOTE:
DO NOT ALLOW any sealant to come in con-
tact with the oil gallery O-ring, or crankshaft
bearings. Do not apply sealant to within 2
3
mm (0.08
0.12 in) of the bearings.

2. Set shift cam and transmission gears in

NEUTRAL position.
3. Install:

Upper crankcase

Dowel pins
To the lower crankcase.
NOTE:
Attach wire to each cam chain and place cam
chains on timing gear sprockets.

CAUTION:
Before tightening the crankcase bolts,
check the following points:

Be sure the gear shifts correctly while
handturning the shift cam.

Be sure the balancer shaft gear is aligned
so that the dot mark lines up between the
triangular timing marks on the upper
crankcase when the No.1 piston is at TDC.

1 Balancer shaft mark

2 Triangular timing marks

4. Finger-tighten the several crankcase bolts,

preferably wide apart. Then, turn the crank-
case assembly upside down.
NOTE:
Be careful not to let pistons fall out of the cylin-
ders.

5. Install:

Rod caps
NOTE:
Be sure the letters on both components align to
form a perfect character.

3-61
 ENGINE ASSEMBLY AND ADJUSTMENT ENG
6. Tighten:

Nuts (connecting rod cap)

Nut (Connecting Rod):

36 Nm (3.6 m
kg, 25 ft
lb)

NOTE:

Apply Molybdenum disulfide grease to the rod
cap bolt threads and nut surfaces.

The projection 1 on the connecting rod cap
should faces the crankshaft web.

CAUTION:
When tightening the rod cap, apply continu-
ous torque between 3.0 and 3.8 m
kg. Once
you reach 3.0 m
kg of torque, DO NOT STOP
TIGHTENING until final torque is reached. If
tightening is interrupted between 3.0 and
3.8 m
kg, loosen the nut to less than 3.0
m
kg, and start again. Tighten to full-torque
A
specification without pausing.

7. Tighten:

Bolts (crankcase)
NOTE:
Tighten the bolts starting with the lowest num-
bered one.

With washer
A LOWER CASE
B UPPER CASE

6 mm Bolt:
12 Nm (1.2 m
kg, 8.7 ft
lb)
8 mm Bolt:
B
24 Nm (2.4 m
kg, 17 ft
lb)
10 mm Bolt:
40 Nm (4.0 m
kg, 29 ft
lb)

NOTE:

Install the oil pipe bracket on Bolt Nos.1 and 3.

Install the lead wire bracket on Bolt No.22.

Install the battery ground lead on Bolt No.36.

Install the copper washers on Bolt Nos.28 and
30.

3-62
ENGINE ASSEMBLY AND ADJUSTMENT ENG
8. Check:

Crankshaft operation
Unsmooth operation
Repair.
9. Install:

Bolts (middle driven gear housing)
NOTE:
The arrow mark 1 on the bearing housing
points to the upper crankcase.

10. Install:

Retainer (main axle bearing) 1
NOTE:
Be sure that the groove in the shaft mesh with
the slot in the retainer.

Retainer (Main Axle Bearing):

7 Nm (0.7 m
kg, 5.1 ft
lb)
LOCTITE

11. Install:

Retainers (middle gear bearing) 1
Use the #40 Torx Drive (90890-04049).
Stake screw head with center punch to lock.

Retainers (Middle Gear Bearing):

25 Nm (2.5 m
kg, 18 ft
lb)

OIL PUMP AND OIL PAN

1. Install:

Damper (oil pump pipe) 1

Oil pump pipe 2

3-63
ENGINE ASSEMBLY AND ADJUSTMENT ENG
2. Install:

Main oil gallery pipe 1

Oil pipe 2
NOTE:
Make sure the correct O-rings 3 are installed
on gallery pipe.

3. Tighten:

Bolts (main oil gallery pipe) 1 , 2

6 mm Flange Bolt 1 :
12 Nm (1.2 m
kg, 8.7 ft
lb)
8 mm Union Bolt 2 :
18 Nm (1.8 m
kg, 13 ft
lb)

4. Bend the bracket tabs 3

5. Install:

Dowel pins

Oil pump assembly
NOTE:

Make sure the correct O-ring 1 is installed on
oil pump pipe.

The arrow mark 2 on the oil pump should face
toward the rear.

Oil Pump:
10 Nm (1.0 m
kg, 7.2 ft
lb)

6. Install:

Gasket

dowel pins

Oil pan 1

Oil Pan:
10 Nm (1.0 m
kg, 7.2 ft
lb)

7. Clamp the oil level gauge lead.

3-64
ENGINE ASSEMBLY AND ADJUSTMENT ENG
8. Install:

Oil filter cover 1
NOTE:
Be sure that the projections 2 on the filter cover
mesh with the slots 3 on the crankcase.

Oil Filter Cover:

32 Nm (3.2 m
kg, 23 ft
lb)

BREATHER COVER AND STARTER MOTOR

1. Install:

Oil pipe 1

Breather cover spacer 3

Breather cover 4

Bolt (Breather Cover):

10 Nm (1.0 m
kg, 7.2 ft
lb)

2 O-ring

2. Install:

Starter motor 1

Bolts (Starter Motor):

10 Nm (1.0 m
kg, 7.2 ft
lb)

WATER PUMP AND THERMOSTATIC VALVE

1. Install:

Thermostat assembly 1

Thermostatic Valve Housing:

10 Nm (1.0 m
kg, 7.2 ft
lb)

2. Install:

Dowel pins

Gasket

Water pump case/Water pump cover 1

Water Pump Case and Housing:

10 Nm (1.0 m
kg,7.2 ft
lb)

3-65
 ENGINE ASSEMBLY AND ADJUSTMENT ENG
CLUTCH AND OIL PUMP DRIVE GEAR
1. Install:

Oil pump drive gear 1

Circlip 2

2. Install:

Clutch housing 1

Thrust washer 2

Clutch boss 3

Lock washer (new) 4

Nut (clutch boss) 5

3. Tighten:

Nut (clutch boss) 1
Use the Clutch Holder (90890-04086) 2 to
hold the clutch boss.

Nut (Clutch Boss):

70 Nm (7.0 m
kg, 50 ft
lb)

2 4 4. Bend the lock washer tabs along the nut flat.

5. Install:

Push rod 1

Friction plates 2 , 4

Clutch plates 3
NOTE:
Install the friction plates and clutch plates alter-
nately on the clutch boss, starting with a friction
plate and ending with a friction plate.

3-66
 ENGINE ASSEMBLY AND ADJUSTMENT ENG

CLUTCH
1 Washer 9 Wire circlip 17 Push rod (No.2)
2 Clutch spring 10 Washer 18 Push rod support bearing
3 Spring seat 11 Circuit 19 Oil seal
4 Pressure plate 12 Push rod (No.1) 20 Clutch release cylinder
5 Friction plate (2 pcs) 13 Clutch boss 21 Special washer
6 Clutch plate (7 pcs) 14 Thrust washer 22 Clutch pipe
7 Friction plate (6 pcs) 15 Clutch housing
8 Bearing 16 Ball

A FRICTION PLATE THICKNESS: CLUTCH SPRING MINIMUM HEIGHT:

D
B WEAR LIMIT: 2.8 mm (0.11 in) 6.5 mm (0.26 in)
CLUTCH PLATE WARP LIMIT:
C E CLUTCH SPRING WARP LIMIT:
0.2 mm (0.008 in) 0.1 mm (0.004 in)

8 Nm (0.8 m
kg, 5.8 ft
lb)

70 Nm (7.0 m
kg, 50 ft
lb)

F USE NEW ONE

PUSH ROD BENDING LIMIT:

G 0.5 mm (0.02 in)

12 Nm (1.2 m
kg, 8.7 ft
lb)

25 Nm (2.5 m
kg, 18 ft
lb)

3-67
ENGINE ASSEMBLY AND ADJUSTMENT ENG

Friction plates and clutch plates installa-

tion steps:

Install the six friction plates (with the double
semi-circular slots) and the six clutch
plates.
NOTE:
Be sure the double semi-circular slots 1 on
the friction plate is aligned with the clutch
housing embossed match marks 2 .

Install the clutch plate and the friction plate

(with the wide square slot).
NOTE:
Be sure the wide square slot 3 on the friction
plate is aligned with the clutch housing em-
bossed match marks 2 .

If the clutch does not release due to hard

meshing between the friction plates and the
clutch housing, check to see if any of the
friction plates fit too snugly into the clutch
housing. Any tight-fitting friction plates must
be repositioned as follows.
1) Remove the friction plates and the clutch
plates.
2) Install the six friction plate (with the
double semi-circular slots) and the six
clutch plates.
NOTE:

Invert the friction plates.

Be sure the single semi-circular slot 4 on
the friction plate is aligned with the clutch
housing embossed match marks 2 .
3) Install the clutch plate and the friction plate
(with the wide square slot).
NOTE:

Invert the friction plates.

Be sure the narrow square slot 5 on the
friction plate is aligned with the clutch hous-
ing embossed match marks 2 .

3-68
ENGINE ASSEMBLY AND ADJUSTMENT ENG
6. Install:

Pressure plate
NOTE:
Be sure the match mark 1 on the clutch boss is
aligned with the match mark 2 on the pressure
plate.

7. Install:

Spring seat

Clutch spring

Plate washer

Bolts (clutch spring)

Bolt (Clutch Spring):

8 Nm (0.8 m
kg, 5.8 ft
lb)

8. Install:

Dowel pins

Gasket

Crankcase cover (right) 1
NOTE:
Tighten the bolts in a crisscross pattern.

Crankcase Cover (Right):

10 Nm (1.0 m
kg, 7.2 ft
lb)

FLYWHEEL AND STARTER IDLE GEAR

1. Install:

Oil baffler plate 1

Oil Baffle Plate:

7 Nm (0.7 m
kg, 5.1 ft
lb)

3-69
ENGINE ASSEMBLY AND ADJUSTMENT ENG
2. Install:

Starter clutch gear 2

Woodruff key 1
CAUTION:
Be sure to remove any oil and or grease from
the tapered portion of the crankshaft and ro-
tor with a thinner.

3. Install:

Flywheel
NOTE:
When installing the flywheel, do not allow the oil
baffle plate 1 to touch the projections 2 on the
flywheel.

4. Install:

Pin 1

Plain washer 2

Bolt (flywheel) 3
NOTE:
Check for clog of oil passage 4 in the bolt.If
any, clean the oil passage.

Bolt (Flywheel):
130 Nm (13.0 m
kg, 94 ft
lb)

5. Install:

Starter idle gears 1

6. Install:

Dowel pins

Gasket

Crankcase cover (left) 1
NOTE:
Tighten the bolts in a crisscross pattern.

Crankcase Cover (Left):

10 Nm (1.0 m
kg, 7.2 ft
lb)
3-70
ENGINE ASSEMBLY AND ADJUSTMENT ENG
CYLINDER HEAD AND CAMSHAFT
Rear Cylinder Head
1. Install:

Dowel pins 1

Gasket 2

Rear cam chain guide 4
NOTE:

The gasket “HEAD” mark 3 should the up-
ward.

The lower end of chain guide must rest in the
cam chain guide slot in the crankcase.

Cylinder head
Pass cam chain through cam chain cavity.
2. Install:

Nuts (cylinder head)
Use 8 mm Wrench Adapter (90890-04076).
NOTE:

In sequence as shown and torque nuts in two
stages.

Never lubricate the bolt threads with engine
oil.

Nuts (Cylinder Head):

43 Nm (4.3 m
kg, 31 ft
lb)

3. Install:

Water jacket joints 1
NOTE:
Be sure each joint passes through its corre-
sponding cam chain.

Lock pin 3
2 O-ring

3-71
 ENGINE ASSEMBLY AND ADJUSTMENT ENG

CYLINDER HEAD AND CAMSHAFT

1 Washer 10 Oil seal
2 Rubber washer 11 Valve
3 Pad 12 Gasket
4 Valve lifter 13 Sprak plug
5 Valve retainer 14 Joint
6 Spring seat 15 O-ring
7 Inner spring 16 Oil plug
8 Outer spring 17 Valve guide
9 Spring seat 18 Circlip

A VALVE CLEARANCE (COLD):

10 Nm (1.0 m
kg, 7.2 ft
lb) B Intake: 0.11
0.15 mm
(0.004
0.006 in)
C Exhaust: 0.26
0.30 mm
(0.010
0.0012 in)

D TYPE / GAP:
DPR8EA-9 / NGK
X24EPR-U9 / NIPPONDENSO
0.8
0.9 mm (0.031
0.035 in)

10 Nm (1.0 m
kg, 7.2 ft
lb)

43 Nm (4.3 m
kg, 31 ft
lb)

17.5 Nm (1.75 m
kg, 12.5 ft
lb)

CYLINDER HEAD WARP LIMIT:

E 0.03 mm (0.0012 in)

15 Nm (1.5 m
kg, 11 ft
lb)

3-72
ENGINE ASSEMBLY AND ADJUSTMENT ENG
4. Install:
S Camshafts
Camshaft installation steps:
S Align the “T-1” mark 1 on the flywheel with
the stationary pointer 2 on the crankcase
cover use 32 mm wrench.
CAUTION:
S Never turn the flywheel installing bolt.
Rotating the bolt may loosen it, causing
the rotor to fall out.
S Do not turn the crankshaft during the
camshafts installation.

S Install the cam chain sprockets onto the

camshafts.
NOTE:
Make sure the “REAR” mark 3 on the cam
chain sprockets face away from the “IN” mark
4 and “EX” mark 5 on the camshafts.

S Apply engine oil to the camshaft bearing

surfaces.
S Install the “IN” marked camshaft onto the in-
take side and “EX” marked camshaft onto
the exhaust side.
S Turn the camshafts by hand so that the tim-
ing markes 6 (f: small hole) on the cam-
shaft face upward.
S Install the dowel pins into the cam caps.
S Install the cam caps (Nos.3, 1 and 4) onto
the camshaft.
NOTE:
S Do not install No.2 intake and No.2 exhaust
cam caps at this stage.
S The numbers are punched on the camshaft
caps in increments from right to left.

3-73
ENGINE ASSEMBLY AND ADJUSTMENT ENG

Tighten the cap bolts.

NOTE:
First tighten the No.3, 1 and 4 cap bolts in that
order, then the No.2 cap bolts.

Camshaft Cap:
10 Nm (1.0 m
kg, 7.2 ft
lb)

5. Install:

Cam chain sprockets
Cam chain sprockets installation steps:

Align the “T-1” mark 1 on the flywheel with
the stationary pointer 2 on the crankcase
cover use 32 mm wrench.
CAUTION:

Never turn the flywheel installing bolt.
Rotating the bolt may loosen it, causing
the rotor to fall out.

Do not turn the crankshaft during the
sprocket installation.

Place the cam chain onto the intake sprock-

et.

Install the sprocket with the punched mark
“REAR” facing outward and finger-tighten
the sprocket bolts.
NOTE:
Align the “IN” mark 3 hole on the sprocket
with the thread hole on the camshaft.

Rotate the intake camshaft to align the tim-

ing mark 4 (: small hole) on the camshaft
with the embossed match mark 5 on the
camshaft cap (I-4).

3-74
ENGINE ASSEMBLY AND ADJUSTMENT ENG

Force the intake camshaft counterclock-

wise to remove the cam chain slack.

Place the cam chain onto the exhaust
sprocket.

Install the sprocket with the punched mark
“REAR” facing outward and finger-tighten
the sprocket bolt.
NOTE:
Align the “EX” mark hole on the sprocket with
the thread hole on the camshaft.

Rotate the exhaust camshaft to align the

timing mark (: small hole) on the camshaft
with the embossed match mark on the cam-
shaft cap (E-4).

Force the exhaust camshaft clockwise to re-
move all the cam chain slack.

Insert your finger into the cam chain ten-
sioner hole, and push the cam chain guide
inward.

While pushing the cam chain guide, be sure
camshaft embossed match marks align with
the timing marks on the camshaft.

If marks do not align, change the meshing
position of sprocket and cam chain.

6. Install:

Cam chain tensioner
Cam chain tensioner installation steps:

Remove the tensioner end cap bolt and
spring.

Release the cam chain tensioner one-way
cam 1 .

Install the tensioner with a new gasket into
the cylinder.

Cam Chain Tensioner Body:

12 Nm (1.2 m
kg, 8.7 ft
lb)

Install the tensioner spring 2 , copper wash-

er 3 and end cap bolt 4 .

End Bolt (Cam Chain Tensioner):

20 Nm (2.0 m
kg, 14 ft
lb)

3-75
ENGINE ASSEMBLY AND ADJUSTMENT ENG
7. Turn the crankshaft and tighten the cam
sprocket bolts.

Camshaft Sprocket:
24 Nm (2.4 mSkg, 17 ftSlb)

CAUTION:
Be sure to attain the specified torque value
to avoid the possibility of these bolts com-
ing loose and causing damage to the en-
gine.

8. Install:
S Cam caps (“I-2” and “E-2”) 1 , 2

Camshaft Cap:
10 Nm (1.0 mSkg, 7.2 ftSlb)

S Cam chain guides 3 , 4

9. Apply:
S Engine oil
To the cam chain, sprockets, camshaft and
valves.

Front Cylinder Head

When installing the front cylinder head, repeat
the rear cylinder head installation procedure.
However, note the following points.
1. Install:
S Camshafts
1) Rotate the crankshaft counterclockwise
360_ plus and added 70_ (430_ total) from
the “T-1” mark.
2) Align the “T-2” 1 mark on the flywheel with
the stationary pointer 2 on the crankcase
cover use 32 mm wrench.
3) Install the cam chain sprockets onto the
camshafts.
NOTE:
Make sure the “FRONT” mark 1 on the cam
chain sprockets face away from the “IN” mark
2 and “EX” mark 3 on the camshaft.

4) Turn the camshafts by hand so that the tim-

ing marks (f: big hole) on the camshaft
face upward.

3-76
ENGINE ASSEMBLY AND ADJUSTMENT ENG
2. Install:
S Cam chain sprocket
1) Align the “T-2” mark on the flywheel with the
stationary pointer on the crankcase cover
use 32 mm wrench.
2) Install the sprocket with the punched mark
“FRONT” facing outward and finger-tighten
the sprocket bolts.
3) Rotate the intake and exhaust camshafts to
align the timing mark (f: big hole) on the
camshaft with the embossed match mark-
son the camshaft caps (I-4 and E-4).
3. Measure:
S Valve clearance
Out of specification
Adjust.
Refer to “CHAPTER 2. VALVE CLEARANCE
ADJUSTMENT” section.

Valve Clearance (Cold):

Intake: 0.11
0.15 mm
(0.004
0.006 in)
Exhaust: 0.26
0.30 mm
(0.010
0.012 in)

OIL DELIVERY PIPE AND CYLINDER HEAD

COVER
1. Install:
S Oil delivery pipe 1
NOTE:
Tighten the three unin bolts evenly, then torque
them to specification.

Oil Delivery Pipe:

8 mm Bolt:
18 Nm (1.8 mSkg, 13 ftSlb)
10 mm Bolt:
20 Nm (2.0 mSkg, 14 ftSlb)

2. Install:
S Gasket
S Cylinder head covers (rear and front)

3-77
ENGINE ASSEMBLY AND ADJUSTMENT ENG
NOTE:

Be sure all cam caps are covered with oil plugs
1.

Arrow mark 2 on the cover should face to-
ward the exhaust side.

Inspect the head cover gasket and replace it if
damaged.

3. Tighten:

Bolts (cylinder head cover)

Spark plugs

Cylinder Head Cover:

10 Nm (1.0 m
kg, 7.2 ft
lb)
Spark Plug:
17.5 Nm (1.75 m
kg, 12.5 ft
lb)

4. Install:

Timing plug 3

Special washer 2

Crankcase cover plate 1
NOTE:
Check for clog of oil passage 4 in the bolt. If
any, clean the oil passage.

3-78
 ENGINE ASSEMBLY AND ADJUSTMENT ENG
REMOUNTING ENGINE
When remounting the engine, reverse the re-
moval procedure. Note the following points.
1. Install:

Down tube frame (right)

Bolts (down tube) 1 , 2 , 3 , 4 , 7 , 8

Bolts (engine) 5 , 6 , 9
NOTE:
Tighten the bolts (#1
#9) in that order.

Engine Mounting:
Bolts (Down Tube) 1 , 2 , 3 , 4 :
45 Nm (4.5 m
kg, 32 ft
lb)
Bolts (Engine) 5 :
70 Nm (7.0 m
kg, 50 ft
lb)
Bolts (Engine) 6 , 9 :
40 Nm (4.0 m
kg, 29 ft
lb)
Bolts (Down Tube) 7 , 8 :
15 Nm (1.5 m
kg, 11 ft
lb)

2. Tighten:

Exhaust pipes

Muffler

1 Exhaust pipe
2 Muffler
3 Clamp

25 Nm (2.5 m
kg, 18 ft
lb)

10 Nm (1.0 m
kg, 7.2 ft
lb)

7 Nm (0.7 m
kg, 5.1 ft
lb)

7 Nm (0.7 m
kg, 5.1 ft
lb)

20 Nm (2.0 m
kg, 14 ft
lb)

7 Nm (0.7 m
kg, 5.1 ft
lb)

20 Nm (2.0 m
kg, 14 ft
lb)

3-79
ENGINE ASSEMBLY AND ADJUSTMENT ENG
3. Tighten:

All nuts or bolts
By the following specification torque.

Clutch Release Cylinder:

12 Nm (1.2 m
kg, 8.7 ft
lb)
Middle Gear Case Cover:
10 Nm (1.0 m
kg, 7.2 ft
lb)
Change Pedal:
10 Nm (1.0 m
kg, 7.2 ft
lb)
Footrest (Left):
40 Nm (4.0 m
kg, 29 ft
lb)
Footrest (Right):
23 Nm (2.3 m
kg, 17 ft
lb)
Rear Brake Master Cylinder:
23 Nm (2.3 m
kg, 17 ft
lb)

4. Adjust:

Rear brake switch
Refer to “CHAPTER 2. REAR BRAKE
SWITCH ADJUSTMENT” section.
5. Bend the tabs 1 on the air baffle plate (front)
as shown.

6. Tighten:

All nuts or bolts.
By the following specification torque.

Conduit:
7 Nm (0.7 m
kg, 5.1 ft
lb)
Radiator:
7 Nm (0.7 m
kg, 5.1 ft
lb)
Radiator Cover:
4 Nm (0.4 m
kg, 2.9 ft
lb)
Carburetor Joint:
10 Nm (1.0m
kg, 7.2 ft
lb)

3-80
ENGINE ASSEMBLY AND ADJUSTMENT ENG
7. Connect:

All hoses and lead (conduit)
Refer to “CHAPTER 4. COOLING SYSTEM,
RADIATOR AND CONDUIT” section.
8. Adjust:

Throttle calbe free play
Refer to “CHAPTER 5. CARBURETION,
THROTTLE CABLE CYLINDER” seciton.
9. Add:

Engien oil
Refer to “CHAPTER 2. ENGINE OIL RE-
PLACEMENT” section.
10. Add:

Coolant
Refer to “CHAPTER 4. COOLING SYSTEM
COOLANT” section.

3-81
ENG
 COOL

CHAPTER 4.
COOLING SYSTEM
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
COOLANT FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
BEARING AND SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 4-5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

THERMOSTATIC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
INSPECTION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

COOLANT DRAIN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

CYLINDER HEAD WATER JACKET JOINT . . . . . . . . . . . . . . . . . . . . . . . 4-10

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

RADIATOR AND CONDUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
COOL
 COOLANT COOL

COOLING SYSTEM
COOLANT
COOLANT FLOW
1 Radiator
2 Coolant drain valve
3 Bypass pipe to the coolant drain valve
4 Bypass pipe to the thermostatic valve
5 Thermostatic valve
6 Water pump
7 To the reservoir tank
8 Thermostat housing
9 Conduit

A : HOT COOLANT
B : COOL COOLANT

4-1
 COOLANT COOL
COOLANT REPLACEMENT

WARNING:
Do not remove the radiator cap when the en-
gine and radiator are hot. Scalding hot fluid
and steam may be blown out under pres-
sure, which could cause serious injury.
When the engine has cooled, open the radia-
tor cap by the following procedure:
Place a thick rag, like a towel, over the radia-
tor cap, slowly rotate the cap counterclock-
wise to the detent. This procedure allows
any residual pressure to escape. When the
hissing sound has stopped, press down on
the cap while turning counterclockwise and
remove it.

1. Place a receptacle under the coolant drain

bolt.

2. Remove:

Cover (right)

To cover

Radiator cap 1

Feed hose (reservoir tank) 2

3. Align:

Coolant drain valve “ON” 1 mark with match
mark 2 on drain valve housing

4. Remove:

Drain bolt 1
Drain the coolant.

4-2
 COOLANT COOL
5. Remove:

Side covers (cylinder) 1

6. Remove:

Rubber plugs 1
Drain the coolant.

NOTE:
To facilitate removal of the rubber plug’s, screw
a spark plug into the threaded hole and hand-
pull the spark plug firmly.

7. Drain:

Coolant (completely)
NOTE:
Thoroughly flush the cooling system with clean
tap water.

8. Inspect:

Rubber plugs
Damage
Replace.
9. Tighten:

Drain bolt

Drain Bolt:
43 Nm (4.3 m
kg, 31 ft
lb)

10. Fill:

Cooling system

Recommended Coolant:
High Quality Ethylene Glycol
Anti-Freeze containing Anti-
Corrosion for Aluminum Engine
Inhibitors
Coolant and Water Mixed Ratio:
50%/50%
Total Amount:
3.05 L (2.69 Imp qt, 3.22 US qt)

4-3
 COOLANT COOL

Reservoir Tank capacity:

0.30 L (0.26 Imp qt, 0.32 US qt)
From “LOW” to “FULL” Level:
0.20 L (0.18 Imp qt, 0.21 US qt)

CAUTION:

Hard water or salt water is harmful to the
engine. You may use distilled water if you
can’t get soft water.

Do not mix more than one type of ethlen
glycol antifreeze containing corrosion for
aluminum engine inhabitors.

Coolant filling steps:

Fill the coolant into the conduit until the con-
duit is full.

Start the engine (coolant level decreases.)
CAUTION:
Always check coolant level, and check for
coolant leakage before starting engine.

Add the coolant while engine is running.

Stop the engine when coolant level stabi-
lizes.

Add the coolant again to specified level 1 .

Install the radiator cap.

Align the coolant drain valve “OFF” mark 2
with the match mark 3 on drain valve hous-
ing.

11. Connect:

Feed hose (reservoir tank)
12. Fill:

Reservoir tank
Add the coolant until liquid reaches “FULL”
level mark.
1 “FULL” level
2 “LOW” level

4-4
 WATER PUMP COOL

WATER PUMP
DISASSEMBLY
NOTE:

Be sure to drain the coolant before disassem-
bly of the cooling system components.

Refer to Engine Disassembly for water pump
disassembly.

1. Remove:

Circlip 1

Drive gear 2

Gear stopper pin 3

Circlip 4

Impeller shaft 5
2. Eliminate:

Deposits
From the impeller and water pump housing.

INSPECTION
1. Inspect:

Bearing
Wear/Damage
Replace.

Oil seal
Wear/Damage
Replace.

Impeller
Cracks/Wear/Damage
Replace.

Water pump seal set 1
Wear/Damage
Replace.

BEARING AND SEAL REPLACEMENT

1. Remove:

Bearing 1

Oil seal 2
Tap off both components from water pump
seal side.
3 Crankcase cover

2. Remove:

Water pump seal (crankcase side) 1
Tap it off from the cover 2 .

4-5
 WATER PUMP COOL
3. Install:

Water pump seal 1
Use Water Pump Seal Installer
2
(90890-04058 , 90890-04078 ) 3
Apply Yamaha Bond No.4 to crankcase cov-
er 4 before installing seal.

A PRESS
B APPLY YAMAHA BOND No.4

4. Remove:

Seal No.2 1
From impeller.
Pry out with a small screwdriver.
NOTE:
Be careful not to scratch or bend the impeller
shaft.

2 Damper rubber

5. Apply:

Water or coolant
To outer surface of damper rubber 2 and im-
peller hub.
CAUTION:
Never apply oil or grease to water pump seal
surfaces.

6. Assemble:

Seal No.2/Damper rubber 2
To impeller hub.
1 Slip ring
3 Impeller
A APPLICATION OF WATER OR COOLANT
7. Measure:

Tilt
Out of specification
Repeat the above
steps “4
6”.
NOTE:
Be sure seal No.2 fits squarely.

Tilt Limit: 0.15 mm (0.006 in)

1 Straight edge
2 Seal No.2
3 Impeller
4-6
 WATER PUMP COOL
ASSEMBLY

1 Impeller
2 Mechanical seal
3 Oil seal
4 Bearing
5 Circlip
6 Gear stopper pin
7 Driven gear
8 Drive gear
9 Water pump cover
10 O-ring
11 Crankcase cover
A FRONT
B FRONT RADIATOR
C TO CYLINDER
1. Install:

Impeller shaft 5

Circlip 4

Gear stopper pin 3

Drive gear 2

Circlip 1
CAUTION:

Be sure not to scratch the water pump me-
chanical seal while installing.

Replace any scratched seal.

4-7
 THERMOSTATIC VALVE COOL

THERMOSTATIC VALVE
12Nm (1.2 mSkg, 8.7 ftS16) REMOVAL
1. Remove:
S Thermostat cover 1
S Thermostatic valve 2
3 Thermostat housing

12Nm (1.2 mSkg, 8.7 ftS16)

INSPECTION AND ASSEMBLY

1. Inspect:
S Thermostatic valve
Valve does not open at 80
84_C (176

183_F)
Replace.
Thermostatic valve inspection steps:
S Suspend thermostatic valve in a vessel or
water.
S Place reliable thermometer in water.
S Heat water slowly.
S Observe thermometer, while stirring water
continually

1 Thermometer 4 Water
2 Full open 5 Thermostatic valve
3 Opening sequence begins 6 Vessel
A OPEN B CLOSE
NOTE:
Thermostat is sealed and its setting is special-
ized work. If its accuracy is in doubt, always re-
place it. A faulty unit could cause serious over-
heating or overcooling.

4-8
COOLANT DRAIN VALVE COOL
2. Inspect:

O-ring 1
Wear/Damage
Replace.

3. Install:

Thermostatic valve 1
NOTE:
Line up the valve breather hole 2 with the
housing projection 3 .

Thermostat cover

Thermostat housing

COOLANT DRAIN VALVE

DISASSEMBLY
1. Remove:

Retaining screw 1

Valve assembly

INSPECTION
1. Inspect:

O-ring 1
Wear/Damage
Replace.

Spring 2
Damage
Replace.

Stopper ball 3
Wear/Damage
Replace.

ASSEMBLY
1. Install:

Valve assembly
Be sure stopper ball falls into body cavity.
2. Secure valve assembly with retaining screw.

4-9
CYLINDER HEAD WATER JACKET JOINT/
RADIATOR AND CONDUIT COOL

CYLINDER HEAD WATER JACKET

JOINT
CAUTION:

Be sure to drain the coolant before you dis-
assemble the water jacket joints otherwise
the coolant will flow into the crankcase.

Do not remove the water jacket joints un-
less absolutely essential; e.g., when over-
hauling the engine.

REMOVAL
1. Remove:

Stopper pins 1

Water jacket joints 2

INSPECTION
1. Inspect:

Water jacket joint 1
Clogging
Clean.

O-rings 2
Wear/Damage
Replace.

Stopper pin 3
Wear/Bends
Replace.

ASSEMBLY
1. Install:

Water jacket joints 1

Stopper pins 2

RADIATOR AND CONDUIT

DISASSEMBLY
1. Drain:

Coolant (completely)
Refer to “COOLANT REPLACEMENT” sec-
tion.

4-10
RADIATOR AND CONDUIT COOL
2. Remove:

Bolts (radiator)
3. Disconnect:

Upper hose 1

Lower hoses 2

4. Disconnect:

Fan motor coupler
5. Remove:

Radiator assembly

6. Disconnect:

All hoses and leads (conduit)
7. Remove:

Screws (conduit)

8. Remove:

Fan motor assembly

INSPECTION
1. Inspect:

Radiator
Obstruction
Blow out with compressed air
through rear of radiator.
Flattened fins
Repair.

Coolant hoses
Cracks/Damage
Replace.

4-11
RADIATOR AND CONDUIT COOL
2. Inspect:

Vacuum valve spring
Fatigue
Replace.

Vacuum valve seating condition
Poor condition
Replace.
3. Measure:

Valve opening pressure
Valve opening pressure measurement
steps:

Measure the radiator cap pressure using
the Radiator Cap Tester 1 (90890-01325).
Valve opens at pressure below specified
valve or defective
Replace.
Valve Opening Pressure:
73.6
103.0 kPa (0.75
1.05 kg/cm2,
10.7
14.9 lb/in2)

ASSEMBLY
When installing the radiator and conduit, re-
verse the removal procedure. Note the follow-
ing points.
1. Install:

Conduit

Screws (Conduit):
7 Nm (0.7 m
kg, 5.1 ft
lb)

2. Connect:

All hoses and leads (conduit)
NOTE:
Align the hose match marks 1 with the match
marks 2 on the conduit.

3. Install:

Radiator assembly

Bolts (Radiator):
7 Nm (0.7 m
kg, 5.1 ft
lb)

4. Fill:

Cooling system
Refer to “COOLANT REPLACEMENT” sec-
tion.

4-12
RADIATOR AND CONDUIT COOL
5. Inspect

Cooling system
Cooling system inspection steps:

Connect Radiator Cap Tester (90890-
01325) 1 .

Apply 98 kPa (1.0 kg/cm2, 14 psi) pressure.

Measure pressure with gauge.
Decrease of pressure (leaks)
Repair at re-
quired.

4-13
COOL
 CARB

CHAPTER 5.
CARBURETION
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SECTION VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

THROTTLE CABLE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

AIR CLEANER AND CRANKCASE VENTILATION SYSTEM . . . . . . . . 5-14

CARB
 CARBURETOR CARB

CARBURETION
CARBURETOR
1 Throttle cable (Close side) 15 Starter lever shaft SPECIFICATIONS
2 Throttle cable (Open side) 16 Fuel overflow hose
Main jet #1& #3:# 152.5
3 Fuel overflow hose 17 Fuel feed hose #2& #4:# 150
4 Fuel feed hose 18 Pilot air jet No.1 Main air jet
2.0
5 Syncronization rod 19 Coasting enrichment Jeet needle 5EZ47-3
Needle jet Y-0
6 Float needle valve valve assembly pilot jet #37.5
7 Needle jet screw 20 Pilot air jet No.2 Fuel level 15.5  16.5 mm
8 Float 21 Piston valve assembly (0.61  0.65 in)
Pilot screw 2
9 Main jet 22 Starter plunger assembly Float valve seat 1.5
10 Main bleed pipe 23 Starter body Engine idle speed 950  1,050 r / min
11 Rubber plug 24 Piston valve center mark
12 Fuel drain hose 25 Throttle stop screw set
13 Pilot jet 26 Syncronization screw
14 Jet block 27 Pilot screw set

A FUEL LEVEL: 15.5  16.5mm (0.61  0.65 in)

5-1
 CARBURETOR CARB

SECTION VIEW
1 Air vent 10 Pilot screw
2 Pilot air jet No.1 11 Bypass hole
3 Main air jet 12 Pilot outlet
4 Jet needle 13 Purge hole
5 Pilot air jet No.2 14 Throttle valve
6 Piston valve 15 Pilot jet
7 Diaphragm 16 Main jet
8 Purge jet No.2 17 Main bleed pipe
9 Purge jet No.1 18 Needle jet

A AIR

B MIXTURE
C FUEL

5-2
 CARBURETOR CARB
REMOVAL
1. Remove:

Carburetor assembly
Refer to engine removal section.
NOTE:
The following parts can be cleaned and in-
spected without disassembly.

Piston valve

Starter plunger

Coasting enrichment valve

DISASSEMBLY
CAUTION:
The plastic piston valve is fragile and highly
susceptible to damage. Be sure to handle
with extreme care. Do not drop the valve or
subject it to undue abuse as this can cause
cracks that could severely weaken the pis-
ton valve.

1. Remove:

Fuel lines
2. Number each carburetor before removing it
from carburetor bracket.
3. Remove:

Upper brackets 1

A FRONT

4. Remove:

Lower brackets 1

5-3
 CARBURETOR CARB
5. Remove:

Side brackets 1

6. Remove:

Starter lever shafts 1

7. Remove:

Synchronization screws 1

Synchronization rod 2
NOTE:
When separating the carburetors be sure not to
lose the small spring that may fall out. This
spring connects the throttle levers.

8. Remove:

Starter plunger 1

Starter plunger body 2

3 Nut
4 Spring

9. Remove:

Vacuum chamber cover 1
Use the special Torx Driver (90890-05349).

2 Tamperproof screw

5-4
 CARBURETOR CARB
10. Remove:

Spring 1

Vacuum piston 2

O-ring 3

Pilot air jet No.2 4

11. Remove:

Coasting enrichment cover 1

Spring 2

Diaphragm 3

12. Remove:

Float chamber cover

Float 1

Needle valve 2

13. Remove:

Main jet 1

Jet block 2

14. Remove:

Gasket 1

O-ring 2

Needle jet 3
NOTE:
Move the needle jet toward the vacuum piston.

5-5
 CARBURETOR CARB
15. Remove:

Rubber caps 1

Pilot jet 2

Main bleed pipe 3

16. Remove:

Pilot air jet No.1 1

INSPECTION
1. Inspect:

Carburetor body
Contamination
Clean.
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with compressed
air.

2. Inspect:

Float
Damage
Replace.

Needle valve
Wear/Contamination
Replace.

3. Inspect:

Vacuum piston 1
Cracks
Replace.
NOTE:
If you suspect the piston valve has been dam-
aged, check the component for cracks by pour-
ing gasoline into the valve. If it leaks, replace
with a new piston valve.

5-6
 CARBURETOR CARB
4. Inspect:

Jet needle
Bends/Wear
Replace.

5. Inspect:

Diaphragm 1
Tears
Replace.

6. Inspect:

Starter plunger
Damage/Wear
Replace.
7. Inspect

O-ring,

Gasket
Damage
Replace.

ASSEMBLY
To assemble the carburetors, reverse the disas-
sembly procedures. Note the following points.
CAUTION:

Before reassembling, wash all parts in
clean gasoline.

Always use a new gasket.

1. Install:

Needle jet 3

O-ring 2

Gasket 1
NOTE:
Make sure the projections on the carburetor
body are meshed with the holes on the gasket.

5-7
 CARBURETOR CARB
2. Install:

Jet block
NOTE:
Make sure the projection 1 on the jet block is
meshed with the groove 2 on the needle jet.

3. Install:

Coasting enricher 1

Vacuum piston 2

O-ring 3
NOTE:
There is a tab on the rubber diaphragm and a
matching recess in the carburetor body to ac-
cept the diaphragm tab.

4. Install:

Starter lever shafts 1
Apply LOCTITE to the starter plunger lever
securing screws.

5. Install:

Mounting brackets
Apply LOCTITE to the bracket securing
screws.
NOTE:
When reassembling, the surface plate 1
should be used for proper carburetor alignment.

Screws (Mounting Brackets):

5 Nm (0.5 m
kg, 3.6 ft
lb)

INSTALLATION
1. Install:

Carburetors
Reverse the removal steps

5-8
 CARBURETOR CARB
ADJUSTMENT
1. Measure:

Fuel level
Out of specification
Adjust.

Fuel Level:
15.5
16.5 mm (0.61
0.65 in)
Below the Carburetor Piston
Valve Center

Fuel level measurement steps:

Place the motorcycle on a level surface.

Use a garage jack under the engine to en-
sure that the carburetor is positioned verti-
cally.

Connect the Fuel Level Gauge 1
(90890-01312) to the drain pipe 2 using a
level gauge adapter 3 .

Loosen the drain screw 4 and warm up the
engine for several minutes.

Measure the fuel level a with the gauge.
5 Piston valve center mark

Repeat the above procedure for other car-
buretors.

If the fuel level(s) is incorrect, adjust the fuel
level(s).

2. Adjust:

Fuel level

Fuel level adjustment steps:

Remove the carburetors.

Inspect the needle valve.

If it is worn, replace it.

If it is fine, adjust float level by bending the
float tang 1 slightly.

Repeat the procedure for the other carbure-
tors.

5-9
THROTTLE CABLE CYLINDER CARB

THROTTLE CABLE CYLINDER

1 Cable cylinder 7 Throttle stop screw
2 Slider 8 Silver tape
3 Cable adjustment 9 Cable adjustment
mark (Open side) mark (Close side)
4 Standard adjuster 10 Cable adjuster
distance (Throttle grip side)
5 Cable adjuster 11 Turning direction
(Carburetor side) 12 Free play
6 Locknut (Carburetor side) (Throttle grip)

ADJUSTMENT
1. Loosen:

Throttle stop screw 1
To set the throttle valve to full closed.

2. Adjust:

Distance a
Between the threaded end of the tubular
control cable guide and the adjuster.

Standard Carburetor Side

Adjuster Distance:
15 mm (0.59 in)

5-10
THROTTLE CABLE CYLINDER CARB
3. Measure:

Free play (throttle grip) a
Out of specification
Adjust.

Throttle Grip Free Play:

4
7 mm (0.16
0.28 in)

4. Check:

No.2 carburetor throttle valve operation

No.2 carburetor throttle valve operation

checking steps:

Loosen the locknut (carburetor side) 1 .

Turn throttle grip back and forth.

Check No.2 carburetor to see if the throttle
valve operates at full open and full closed.
Operation of throttle valve normal
Tight-
en locknut 1 .
Throttle valve fails to operate at full closed

Adjust.
A THROTTLE VALVE FULLY OPEN
B THROTTLE VALVE FULLY CLOSED

5. Adjust:

No.2 carburetor throttle valve operation

No.2 carburetor throttle valve operation

adjustment steps:
First step:
a. Loosen the locknut (carburetor side).
b. Turn the adjuster (carburetor side) clock-
wise a little.
c. Turn the adjuster (throttle grip side) coun-
terclockwise and adjust free play (throttle
grip) to within 4
7 mm (0.16
0.28 in).
d. Check to see if throttle valve operates at
full closed.
If not, repeat steps a
d.
e. Set the throttle valve at full closed and
tighten locknut (carburetor side).
f. Check to see if throttle valve operates at
full open.
Throttle valve fails to operate at full open

Perform the next step.
5-11
THROTTLE CABLE CYLINDER CARB
Second step:
a. Loosen the locknut (carburetor side).
b. Turn the adjuster (carburetor side) coun-
terclockwise a little.
c. Turn adjuster (throttle grip side) clockwise
so that the free play (throttle grip) is within
4
7 mm (0.16
0.28 in).
d. Check to see if throttle valve operates at
full open.
If not, repeat steps a
d.
e. Tighten locknut (carburetor side).
f. Check to see if throttle valve operates at
full open or full closed.
Throttle valve fails to operate at full open
or full closed
Perform the next step.
Third step:

Check to see if throttle cable installation is
correct.
NOTE:
Be sure that the silver throttle cable 3 is
positioned opposite the adjusters.

Check the position of the control cable slid-

ers in the throttle cable cylinder.
NOTE:

Be sure the open side slider (silver cable
side) falls between the three adjustment
marks on the carburetor side.

Be sure the closed side slider falls between
the two adjustment marks on the throttle
grip side.

If the slider(s) fall outside the adjustment

marks then the throttle cable(s) must be re-
place.
1 Cable adjustment mark (Open side)
2 Cable adjustment mark (Closed side)

5-12
THROTTLE CABLE CYLINDER CARB
6. Install:

Air cleaner
7. Set engine idle speed.

Idle Speed: 950
1,050 r/min

5-13
 AIR CLEANER AND CRANKCASE VENTILATION SYSTEM CARB

AIR CLEANER AND CRANKCASE VENTILATION SYSTEM

Refer to “CHAPTER 2” for the air cleaner maintenance.
1 Air cleaner
2 Carburetor
3 Blind plug

A FRESH AIR

B BLOW BY GAS

5-14
 CHAS

CHAPTER 6.
CHASSIS
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

FRONT AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

CALIPER PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
MASTER CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
BRAKE INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
BRAKE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
BRAKE DISC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

CLUTCH RELEASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
MASTER CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
CLUTCH INSPECITON AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
CLUTCH REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
 CHAS
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
FREE PLAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

SHAFT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
FINAL DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
 FRONT WHEEL CHAS

CHASSIS
FRONT WHEEL TIRE PRESSURE (COLD TIRE)

1 Collar 6 Searing Basic weight:

With Oil and Full 281 kg (619 lb)
2 Oil seal 7 Meter clutch Fuel Tank
3 Bearing 8 Clutch retainer
Maximum Load* 218 kg (481 lb)
4 Spacer 9 Oil seal
5 Spacer flange 10 Gear unit assembly Cold Tire Pressure: FRONT REAR
235 kPa 255 kPa
Up to 90 kg (198 lb) (2.4 kg / cm2, (2.6 kg / cm2,
Load* 34 psi) 36 psi)
235 kPa 275 kPa
90 kg (198 lb)*  (2.4 kg / cm2, (2.8 kg / cm2
Maximum Load* 34 psi) 40 psi)

235 kPa 255 kPa

High Speed Riding (2.4 kg / cm2, (2.6 kg / cm2
34 psi) 36 psi)

* Load is the total weight of cargo, rider, pas-

senger, and accessories.

B6303 TIRE SIZE:

A 110 / 90 V-18
WEAR LIMIT:
B 1.0 mm (0.04 in)

MINIMUM DISC THICKNESS:

C 7.0 mm (0.28 in)
D MAXIMUM DIFLECTION:
0.15 mm (0.006 in)

RIM SIZE:
E MT2.50
18
RIM RUNOUT LIMIT:
RADIAL
F 2.0 mm (0.08 in)
LATERAL:
2.0 mm (0.08 in)
20 Nm (2.0 m
kg, 14 ft
lb)

B6303
60 Nm (6.0 m
kg, 43 ft
lb)

6-1
 FRONT WHEEL CHAS
REMOVAL

WARNING:
Securely support the motorcycle so it won’t
fall over when the front wheel.

1. Place the motorcycle on its centerstand.

2. Remove:

Speedometer cable 1

3. Remove:

Fork brace 1

Front fender 2

4. Loosen:

Pinch bolt (front axle) 1

Front axle 2
5. Elevate the front wheel by placing a suitable
stand under the engine.
6. Remove:

Front axle

Front wheel
Lower the wheel until the brake discs come
off the calipers. Turn the brake calipers out-
ward so they do not obstruct the wheel.
NOTE:
Do not squeeze the brake lever while the wheel
is off the motorcycle.

INSPECTION
1. Inspect:

Tire
Tire tread shows crosswise lines (minimum
tread depth)/Cracks
Replace.

Minimum Tire Tread Depth:

1.0 mm (0.04 in)

1 Tread depth 2 Side wall 3 Wear indicator

6-2
 FRONT WHEEL CHAS
2. Inspect:

Front axle
Bends
Replace.
Roll the axle on a flat surface.

WARNING:
Do not attempt to straighten a dent axle.

3. Inspect:

Wheel
Cracks/Bends/Warpage
Replace.
4. Measure:

Wheel runout
Over specified limit
Replace.

Rim Runout Limits:

Radial 1 : 2.0 mm (0.08 in)
Lateral 2 : 2.0 mm (0.08 in)

5. Check:

Wheel balance
Out of balance
Adjust.
NOTE:
Balance wheels with the brake discs installed.

CAUTION:
Be sure the valve stem locknut is tightened
securely after repairing or replacing a tire
and/or wheel.

WARNING:
Ride conservatively after installing a tire to
allow the tire to seat itself correctly on the
rim.

6. Inspect:

Wheel bearings
Bearings allow play in the wheel hub or
wheel turns roughly
Replace.

Wheel bearing replacement steps:

Clean the outside of the wheel hub.

Drive out the bearing.

6-3
 FRONT WHEEL CHAS

WARNING:
Eye protection is recommended when us-
ing striking tools.

Install the new bearing by reversing the pre-

vious steps.
NOTE:
Use a socket that matches the outside diam-
eter of the race of the bearing.

CAUTION:
Do not strike the center race or balls of the
bearing. Contact should be made only
with the outer race.

7. Inspect:

Brake disc
Wear/Over specified limit
Replace.

Maximum Deflection
(Front and Rear):
0.15 mm (0.006 in)
Minimum Disc Thickness
(Front and Rear):
7.0 mm (0.28 in)

INSTALLATION
When installing the front wheel, reverse the re-
moval procedure. Note the following points.
1. Apply:

Lithium base grease
Lightly grease to the oil seal and gear unit.
2. Install:

Gear unit assembly
NOTE:
Be sure that the two projections inside the
wheel hub mesh with the two slots in the gear
unit assembly.

6-4
 FRONT WHEEL CHAS
3. Install:

Front wheel
NOTE:
Be sure that the projecting portion (torque stop-
per) 1 of the gear unit housing is positioned
correctly.

4. Tighten:

Front axle

Front Axle:
60 Nm (6.0 m
kg, 43 ft
lb)

5. Tighten:

Pinch bolt (front axle)

Fork brace

Front fender

Pinch Bolt (Front Axle):

20 Nm (2.0 m
kg, 14 ft
lb)
Nuts (Fork Brace):
9 Nm (0.9 m
kg, 6.5 ft
lb)

6-5
 REAR WHEEL CHAS

REAR WHEEL
1 Oil seal 7 Cylindrical bearing
2 Circlip 8 Oil seal
3 Bearing 9 Clutch hub
4 Spacer flange 10 Damper
5 Spacer 11 Hub dust seal
6 Collar 12 Circlip

MINIMUM DISC
E THICKNESS:
7.0 mm (0.28 in)

F MAXIMUM DEFLECTION:
0.15 mm (0.006 in)

B6304RS

TIRE SIZE:
A
150/90 V15
WEAR LIMIT:
B
1.0 mm (0.04 in)
RIM SIZE:
C
MT 3.50
15
RIM RUNOUT LIMIT:
RADIAL:
D 2.0mm (0.08 in)
LATERAL:
2.0mm (0.08in)

120 Nm (12.0 m
kg, 85 ft
lb)

G USE A NEW ONE

6-6
 REAR WHEEL CHAS
REMOVAL
1. Place the motorcycle on its centerstand.
2. Remove:

Cotter pin 1

Axle nut 2

Washer

3. Remove:

Rear caliper

Tension bar
NOTE:
Do not depress the brake pedal when the wheel
is off the motorcycle as the brake pads will be
forced.

4. Loosen:

Pinch bolt (rear axle) 1
5. Remove:

Rear axle
While supporting the brake caliper, pull out
the rear axle.

Rear wheel
Move the wheel to the right side to separate it
from the final gear case.

INSPECTION
1. Inspect:

Tire

Rear axle

Wheel

Wheel bearings

Brake disc
Refer to “FRONT WHEEL – INSPECTION”
section.
2. Measure:

Wheel runout
Refer to “FRONT WHEEL – INSPECTION”
section.
3. Check:

Wheel balance
Refer to “FRONT WHEEL – INSPECTION”
section.

6-7
 REAR WHEEL CHAS
INSTALLATION
When installing the rear wheel, reverse the re-
moval procedure. Note the following points.
1. Apply:

Lithium base grease
Lightly grease to the final gear case splines.
2. Install:

Rear wheel assembly
NOTE:
Be sure the splines on the wheel hub fit into final
gear case.

3. Tighten:

Wheel axle

Axle Nut:
120 Nm (12.0 m
kg, 85 ft
lb)
Pinch Bolt (Rear Wheel):
20 Nm (2.0 m
kg, 14 ft
lb)

CAUTION:
Always use a new cotter pin on the rear axle
nut.

4. Tighten:

Tension bar

Rear caliper

Rear Caliper:
45 Nm (4.5 m
kg, 32 ft
lb)

6-8
 FRONT AND REAR BRAKE CHAS

FRONT AND REAR BRAKE

1 Air bleed screw F – a :Install the pad spring with its longer tangs a in the
2 Retaining pin disc rotating direction.
3 Dust seal
4 Piston seal
5 Piston
6 Circlip

A FRONT CALIPER

5 Nm (0.5 m
kg, 3.6 ft
lb)

PAD MEAR LIMIT:
C
0.5 mm (0.02 in)

B REPLACE AS A SET

45 Nm (4.5 m
kg, 32 ft
lb) B REPLACE AS A SET

MINIMUM DISC THICKNESS:

D
7.0 mm (0.28 in)
MAXIMUM DEFLECTION:
E 0.15 mm (0.006 in)

45 Nm (4.5 m
kg, 32 ft
lb)

20 Nm (2.0 m
kg, 14 ft
lb)

F PAD SPRING

6-9
 FRONT AND REAR BRAKE CHAS
1 Air bleed screw G– a :
2 Retaining pin Install the pad spring with its longer tangs a in the disc
3 Dust seal rotating direction.
4 Piston seal H– a :
5 Piston Be sure to position the shim 1 so that its arrow mark a
6 Clirlip points in the rotating direction b of the disc plate rota-
7 Shim tion.
A FRONT CALIPER
H SHIM

5 Nm (0.5 m
kg, 3.6 ft
lb)

B REPLACE AS A SET
B REPLACE AS A SET

PAD MEAR LIMIT:

C
0.5 mm (0.02 in)

45 Nm (4.5 m
kg, 32 ft
lb)

F USE A NEW ONE

20 Nm (2.0 m
kg, 32 ft
lb)

G PAD SPRING

MINIMUM DISC THICKNESS:

D
7.0 mm (0.28 in)
MAXIMUM DEFLECTION:
E
0.15 mm (0.06 in)

6-10
FRONT AND REAR BRAKE CHAS
CALIPER PAD REPLACEMENT
It is not necessary to disassemble the brake cal-
iper and brake hose to replace the brake pads.
1. Remove:

Cover 1

2. Remove:

Retaining clips 1

Retaining pins 2

Pad spring 3

3. Remove:

Pads
NOTE:

Replace the pad spring if pad replacement is
required.

Replace the pads as a set if either is found to
be worn to the wear limit.

Wear Limit a :
0.5 mm (0.02 in)

4. Install:

Components in above list (steps “3
1”)
NOTE:

FRONT AND REAR BRAKE:
Install the pad spring with its longer tangs a
facing towards the disc rotating direction.

6-11
FRONT AND REAR BRAKE CHAS

REAR BRAKE ONLY:
Be sure to position the shim 1 so that its arrow
mark a points in the rotating direction b of
the disc plate rotation.

CALIPER DISASSEMBLY
1. Remove:

Pads
Refer to “CALIPER PAD REPLACEMENT”
section.
2. Remove:

Brake hose 1
Place the open hose end into a container and
pump the old fluid out carefully.

3. Remove:

Caliper
CAUTION:
Never loosen the bridge bolts 1 on either
side of the caliper.

4. Remove:

Dust seals 1

Piston seals 2

Pistons 3

Caliper piston removal steps:

Insert a plece of wooden board 4 into the
caliper to lock the right side piston.

Blow compressed air into the tube joint
opening to force out the left side piston from
the caliper body.

Repeat previous step to force out the right
side piston from the caliper body.

6-12
 FRONT AND REAR BRAKE CHAS

MASTER CYLINDER DISASSEMBLY

1 Master cylinder cap
2 Rubber seal
3 Master cylinder kit
4 Copper washer
5 Brake joint

A FRONT MASTER SYLINDER

1 Nm (0.1 m
kg, 0.7 ft
lb) B BRAKE FLUID TYPE: DOT#3

9 Nm (0.9 m
kg, 6.5 ft
lb)

25 Nm (2.5 m
kg, 18 ft
lb)

25 Nm (2.5 m
kg, 18 ft
lb)

25 Nm (2.5 m
kg, 18 ft
lb)

25 Nm (2.5 m
kg, 18 ft
lb)

25 Nm (2.5 m
kg, 18 ft
lb)

6-13
 FRONT AND REAR BRAKE CHAS
1 Reservoir tank D BRAKE HOSE ROUNTING:
2 Band When installing the rear brake hose,
3 Copper washer align the brake pipe 1 with the front
4 Master cylinder kit projection 2 on the master cylinder.

A REAR MASTER CYLINDER

B BRAKE FLUIC TYPE: DOT #3

25 Nm (2.5 m
kg, 18 ft
lb)

23 Nm (2.3 m
kg, 17 ft
lb)

C BRAKE PEDAL HEIGHT: D BRAKE HOSE ROUTING

6-14
FRONT AND REAR BRAKE CHAS
Front Brake Master Cylinder Disassembly
NOTE:
Drain the brake fluid before removing master
cylinder.

1 Dust boot
2 Circlip
3 Piston
4 Piston cups
5 Return spring
6 Washer
7 Seat
A MASTER CYLINDER KIT (Replace as a set)

1. Remove:

Brake light switch leads 1

Brake lever 2

Lever spring
2. Disconnect:

Brake hose 3
Drain the fluid.

3. Remove:

Master cylinder 1

Master cylinder cap 2

4. Remove:

Dust boot 1

Circlip 2

Master cylinder kit 3

6-15
FRONT AND REAR BRAKE CHAS
Rear Brake Master Cylinder Disassembly
NOTE:
Drain the brake fluid before removing master
cylinder.

1. Remove:

Side cover (right)
2. Disconnect:

Brake hose

1 Spring
2 Piston cup
3 Piston
4 Adjusting rod
5 Circlip
6 Dust boot
A MASTER CYLINDER KIT (Replace as a set)

3. Remove:

Master cylinder 1

Fluid reservoir tank 2
Drain the fluid.
4. Disconnect:

Tank hose 3

5. Remove:

Dust boot 1

Circlip 2

Adjusting rod 3

Master cylinder kit 4
Drain the excess fluid.

BRAKE INSPECTION AND REPAIR

Recommended Brake Component Replacement
Schedule:
Brake pads As required
Piston seal, dust seal Every two years
Brake hoses Every four years
Replace only when
Brake fluid
brakes are disassembled

6-16
FRONT AND REAR BRAKE CHAS

WARNING:
All internal parts should be cleaned in new
brake fluid only. Do not use solvents will
cause seals to swell and distort.

1. Inspect:

Brake pads
Over specified limit
Replace.

Wear Limit a :
0.5 mm (0.02 in)

2. Inspect:

Caliper piston
Rust/Wear/Damage
Replace.

Dust seal/Piston seal
Damage
Replace.

WARNING:
Replace the piston and dust seals whenever
a caliper is disassembled.

Master cylinder kit

Master cylinder body
Scratches/Wear
Replace.
NOTE:
Clean all passages with new brake fluid.

1 Oil baffle plate

Brake hose
Cracks/Wear/Damage
Replace.

BRAKE REASSEMBLY

WARNING:

All internal parts should be cleaned in new
brake fluid only.

Internal parts should be lubricated with
brake fluid when installed.

Brake Fluid:
DOT #3

6-17
FRONT AND REAR BRAKE CHAS
Caliper Reassembly
When assembling the caliper, reverse the dis-
assembly procedure. Note the following points.
1. Install:

Brake calipers

Brake hoses

Brake Caliper:
45 Nm (4.5 m
kg, 32 ft
lb)
Brake Hose:
25 Nm (2.5 m
kg, 18 ft
lb)

2. Bleed the air completely from the brake sys-

tem.

Master Cylinder Reassembly

When assembling the master cylinder, reverse
the disassembly procedure. Note the following
points.
1. Install:

Master cylinder kit

WARNING:
Internal parts should be lubricated with
brake fluid when installed.

2. Install:

Master cylinders (front and rear)

Brake hoses

Front Master Cylinder:

9 Nm (0.9 m
kg, 6.5 ft
lb)
Rear Master Cylinder:
23 Nm (2.3 m
kg, 17 ft
lb)
Brake Hose:
25 Nm (2.5 m
kg, 18 ft
lb)

CAUTION:
When installing the rear brake hose, align
the brake pipe 1 with the front projection 2
on the master cylinder.

6-18
FRONT AND REAR BRAKE CHAS
3. Fill:

Master cylinders

Brake Fluid:
DOT #3

4. Bleed the air completely from the brake sys-

tem.

AIR BLEEDING

WARNING:
Bleed the brake system it:

The system has been disassembled.

A brake hose has been loosened or re-
moved.

The brake fluid is very low.

The brake operation is faulty.
A dangerous loss of braking performance
may occur if the brake system is not proper-
ly bled.

1. Bleed:

Brake fluid

Air bleeding steps:

a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to over-
flow.
c. Connect the clear plastic tube 1 tightly to
the caliper bleed screws.
d. Place the other end of the tube into a con-
tainer.
e. Slowly apply the brake lever or pedal sev-
eral times.
f. Pull the lever in or push down on the pedal.
Hold the lever or pedal in position.
g. Loosen the bleed screw and allow the le-
ver or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever or
pedal limit has been reached; then re-
lease the lever or pedal.

Bleed Screw:
6 Nm (0.6 m
kg, 4.3 ft
lb)

i Repeat steps (e) to (h) until of the air

bubbles have been removed from the sys-
tem.

6-19
FRONT AND REAR BRAKE CHAS

NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have disap-
pered.

j.Add brake fluid to the level line on the reser-

voir.

BRAKE DISC INSTALLATION

1. Install:

Brake disc(s)
NOTE:

The brake disc should be installed with the ar-
row mark 1 face outward.

The arrow mark 1 on the disc must point to-
ward the rotating direction A of the wheel.

2. Tighten:

Bolts (disc)

Bolts (Brake Disc):

20 Nm (2.0 m
kg, 14 ft
lb)
LOCTITE

6-20
 HYDRAULIC CLUTCH CHAS

HYDRAULIC CLUTCH
1 Copper washer
2 Master cylinder kit
(Replace as a set)

1 Nm (0.1 m
kg, 0.7 ft
lb)

9 Nm (0.9 m
kg, 6.5 ft
lb)

25 Nm (2.5 m
kg, 18 ft
lb)

A CLUTCH FLUID TYPE: DOT #3

6-21
HYDRAULIC CLUTCH CHAS
CLUTCH RELEASE DISASSEMBLY
1. Remove:

Footrest

Change pedal

Middle gear case cover
NOTE:
When removing the middle gear case cover, be
sure oil does not leak out of the case.

2. Remove:

Clamp 1

Clutch hose 2
Drain the fluid.

Clutch release assembly 3

3. Remove:

Dust seal 1

Piston assembly 2

Spring 3

MASTER CYLINDER DISASSEMBLY

NOTE:
Drain the clutch fluid before removing master
cylinder.

1 Bush
2 Push rod
3 Dust boot
4 Spring
5 Circlip
6 Washer
7 Piston cup
8 Piston
9 Seat
10 Return spring
A Master cylinder kit (Replace as a set)

6-22
HYDRAULIC CLUTCH CHAS
1. Remove:

Clutch switch leads 1

Clutch lever 2

Clutch hose 3
Drain the fluid.

2. Remove:

Master cylinder 1

Cap 2
Drain the excess fluid.

3. Remove:

Dust boot 1

Push rod 2

Spring 3

Circlip 4

Master cylinder kit 5

CLUTCH INSPECTION AND REPAIR

Recommended Clutch Component Replacement
Schedule:
Piston seal, dust sel Every two years
Clutch hoses Every four years
Replace only when
Clutch fluid
clutch is disassembled
1. Inspect:

Cylinder body
Scratches/Wear
Replace.
NOTE:
Clean all passages with new brake fluid.

Clutch hoses
Cracks/Wear/Damage
Replace.

6-23
HYDRAULIC CLUTCH CHAS
2. Inspect:

Piston 1
Scratches/Wear
Replace.

Piston seal 2
Wear
Replace.

CLUTCH REASSEMBLY

WARNING:

All internal parts should be cleaned in new
brake fluid only.

Internal parts should be lubricated with
brake fluid when installed.

Brake Fluid:
DOT #3

Clutch Release Reassembly

When assembling the clutch release, reverse
the disassembly procedure. Note the following
points.
1. Install:

Clutch release assembly

Clutch hose

Clutch Release Assembly:

12 Nm (1.2 m
kg, 8.7 ft
lb)
Clutch Hose:
25 Nm (2.5 m
kg, 18 ft
lb)

Master Cylinder Reassembly

When assembling the master cylinder, reverse
the disassembly procedure. Note the following
points.
1. Install:

Master cylinder

Clutch hose

6-24
HYDRAULIC CLUTCH CHAS

Master Cylinder:
9 Nm (0.9 m
kg, 6.5 ft
lb)
Clutch Hose:
25 Nm (2.5 m
kg, 18 ft
lb)

2. Install:

Push rod

Lever
NOTE:
Grease the pivot point 1 .

3. Fill:

Master cylinder

Brake Fluid:
DOT #3

4. Bleed the air completely from the clutch sys-

tem.
AIR BLEEDING

WARNING:
Bleed the clutch system it:

The system has been disassembled.

A clutch hose has been loosened or re-
moved.

The clutch fluid is very low.

The clutch operation is faulty.

1. Bleed:

Clutch fluid (brake fluid)

Air bleeding steps:

a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to over
flow.
c. Connect the clear plastic hose 1 to the
bleed screw.
d. Place the other end of the tube into a con-
tainer.
e. Slowly apply the clutch lever several
times.
f. Pull in the lever and hold it in position.
g. Loosen the bleed screw and allow the le-
ver to travel slowly toward its limit.
h. Tighten the bleed screw when the lever has
reached its limit, then release the lever.

Bleed Screw:
6 Nm (0.6 m
kg, 4.3 ft
lb)

6-25
HYDRAULIC CLUTCH CHAS
i. Repeat steps (e) to (h) until allow of the air
bubbles have been removed from the sys-
tem.
NOTE:
If bleeding is difficult, it may be necessary to
let the clutch fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have disap-
peared.

j. Add brake fluid to the level line on the res-

ervoir.

6-26
 FRONT FORK CHAS

FRONT FORK
1 Damper 13 Cylinder complete
2 Air joint 14 Oil lock piece
3 O-ring 15 Inner fork tube
4 Circlip 16 Guide bush
5 Air valve 17 Dust cover
6 Fork cap 18 Retaining clip
7 O-ring 19 Oil seal
8 Cap bolt 20 Seal spacer
9 Collar 21 Slide bush
10 Spring seat 22 Outer fork tube
11 Fork spring 23 Drain screw
12 Rebound spring

A FORK OIL (EACH):

CAPACITY:
B 451 Cm3 (15.9 lmp oz,15.3 US oz)
GRADE:
C Fork Oil 10wt or equivalent
STD AIR PRESSURE:
D 39.2 KPa (0.4 kg/cm2, 5.7 psi)
MIN. TO MAX. AIR PRESSURE:
E 39.2  98.1 kpa
FORK SPRING FREE (0.4  1.0 kg/cm2, 5.7  14.2 psi)
F LENGTH (LIMIT):
487.5 mm (19.2 in)

23 Nm (2.3 m
kg, 17 ft
lb)

23 Nm (2.3 m
kg, 17 ft
lb)

20 Nm (2.0 m
kg, 14 ft
lb)

40 Nm (4.0 m
kg, 29 ft
lb)

6-27
 FRONT FORK CHAS
REMOVAL

WARNING:
Securely support the motorcycle so it won’t
fall over when the front wheel and front forks
are removed.

1. Remove:

Front wheel
Refer to “FRONT WHEEL” section.

Brake calipers

Cable holders
2. Remove:

Air valve cap (left)

Fork cap 1
Depress the valve until all of the air has been
released.

3. Loosen:

Pinch bolt (steering crown) 1

Cap bolt 2
Use the Front Fork Cap Socket 3
(90890-01104).

4. Loosen:

Pinch bolts (under bracket) 1

5. Remove:

Rubber damper 1

Air joint bracket 2

Circlip 3

Front fork(s) 4

6-28
 FRONT FORK CHAS
DISASSEMBLY
1. Remove:

Cap bolt 1
Use the Front Fork Cap Socket
(90890-01104).

Collar 2

Spring seat 3

Fork spring 4
5 Inner fork tube

2. Remove:

Dust cover 1

Retaining clip 2
Use a thin screwdriver, and be careful not to
scratch the inner fork tube.

3. Remove:

Bolt (cylinder complete)
Use the Damper Rod Holder 1
(90890-01328) and the T-Handle 2
(90890-01326) to lock the damper rod.

4. Remove:

Damper rod (cylinder complete) 1

Rebound spring 2

5. Remove:

Inner fork tube

Inner fork tube removal steps:

Hold fork leg horizontally.

Clamp the caliper mounting boss of the out-
er tube securely in a vise with soft jaws.

Pull out the inner fork tube from the outer
tube by forcefully, but carefully, with drawing
the inner tube.

6-29
 FRONT FORK CHAS
NOTE:

Excessive force will damage the oil seal
and/or the bushes. Damaged oil seal and
bushing must be repalced.

Avoid bottoming the inner tube in the outer
tube during the above procedure, as the oil
lock piece will be damaged.

6. Remove:

Oil seal 1

Seal spacer 2

Slide bush 3

Guide bush 4

Oil lock piece 5

INSPECTION
1. Inspect:

Inner fork tube
Scratches/Bends
Replace.

WARNING:
Do not attempt to straighten a bent inner
fork tube as this may dangerously weaken
the tube.

Outer fork tube

Scratches/Bends/Damage
Replace.

Fork spring
Over specified limit
Replace.

Fork Spring Free Length (limit):

487.5 mm (19.2 in)

2. Inspect:

Air joint bracket

Air hose
Cracks/Damage
Replace.

O-ring 1
Damage
Replace.

6-30
 FRONT FORK CHAS
3. Inspect:

Damper rod
Wear/Damage
Replace.
Contamination
Blow out all oil passages
with compressed air.

4. Inspect:

O-ring (cap bolt) 1

Oil lock piece 2
Damage
Replace.

Seals
Wear/Damage
Replace.

ASSEMBLY
Before assembling, clean and inspect all parts
and replace when necessary.
NOTE:
In front fork assembly, be sure to use following
new parts. Do not reuse them.

Slide bush

Guide bush

Oil seal

Dust seal

1. Install:

Rebound spring 1

Damper rod 2
Allow the rod to slide slowly down the tube
until the it protrudes from the bottom.

Oil lock piece 3
Fit oil lock piece over damper rod sticking out
of the inner fork tube.
2. Install:

Inner fork tube
Into outer tube.

6-31
 FRONT FORK CHAS
3. Tighten:

Bolt (cylinder complete)
Use the Damper Rod Holder (90890-01328)
and the T-Handle (90890-01326).

Bolt (Cylinder Complete):

40 Nm (4.0 m
kg, 29 ft
lb)
LOCTITE

4. Install:

Slide bush 1
Into outer tube.
Use the Fork Seal Driver Weight 3
(90890-01367) and the Adapter 2
(90890-01373).

4 Inner tube
5 Outer tube

5. Install:

Seal spacer 1
On top of the slide bush 2 .

Oil seal 3
Use the Fork Seal Driver Weight 5
(90890-01367) and the Adapter 4
(90890-01373), and install with numbered
side up.
6 Inner tube
7 Outer tube
6. Install:

Retaining clip 1

Dust seal 2
Use the Special Tools 3
(90890-01367, 90890-01373)

4 Inner tube
5 Outer tube

7. Fill:

Front fork

Each Fork:
451 cm3 (15.9 Imp oz, 15.3 US oz)
Fork Oil 10 wt or equivalent
After filling, slowly pump the
fork up and down to distribute oil.

6-32
 FRONT FORK CHAS
8. Install:

Fork spring 4
With smaller pitch side up.

Spring seat 3

Collar 2

Cap bolt 1
Temporarily tighten the cap bolt.

INSTALLATION
1. Install:

Front fork(s)
Into underbracket.

Circlip
Onto inner tube.
Apply a light coat of lithium base grease to
the O-rings in the air joint bracket.

Air joint bracket

Rubber damper
Over inner fork tube.
2. Tighten:

Pinch bolts (under bracket)
Temporarily tighten the pinch bolts.
NOTE:
Position the inner tube end so that it is flush a
with the top of the steering crown.

3. Tighten:

Pinch bolts (under bracket)

Pinch Bolts (Under Bracket):

23 Nm (2.3 m
kg, 17 ft
lb)

NOTE:
Do not tighten the pinch bolt (steering crown) in
this stage.

4. Tighten:

Cap bolt 2
Use the Front Fork Cap Socket 3
(90890-01104).

Pinch bolt (steering crown) 1

Cap Bolt:
23 Nm (2.3 m
kg, 17 ft
lb)
Pinch Bolts (Steering Crown):
20 Nm (2.0 m
kg, 14 ft
lb)

6-33
 FRONT FORK CHAS
5. Adjust:

Front fork air pressure
Refer to “CHAPTER 2. FRONT FORK AD-
JUSTMENT” section.
6. Install:

Air valve cap

Fork cap

Brake calipers

Cable holders
Refer to “FRONT AND REAR BRAKE” sec-
tion.

Front wheel
Refer to “FRONT WHEEL” section.

6-34
 STEERING HEAD CHAS

STEERING HEAD
1 Steering stem nut 5 Ring nut (Lower)
2 Lock washer 6 Bearing cover
3 Ring nut (Upper) 7 Bearing (Upper)
4 Washer 8 Bearing (Lower)

20 Nm (2.0 m
kg, 14 ft
lb)

1 110 Nm (11 m
kg, 80 ft
lb)

20 Nm (2.0 m
kg, 14 ft
lb)

40 Nm (4.0 m
kg, 29 ft
lb)

3
A FINGER TIGHTEN

5 1. TIGHTEN RING NUT 5 :

B 50 Nm (5.0 m
kg 36 ft
lb)
2. LOOSEN IT COMPLETY:
3. RETIGHTEN IT:
3 Nm (0.3 m
kg, 2.2 ft
lb)

6-35
 STEERING HEAD CHAS
REMOVAL

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

1. Remove:

Front wheel

Front forks
2. Remove:

Headlight lens unit 1
3. Disconnect:

All leads (in the headlight body)

4. Remove:

Bolt (headlight body bracket) 1

Emblem 2

5. Remove:

Flasher light bracket assembly 1

6. Remove:

Handlebar holder assembly 1

6-36
 STEERING HEAD CHAS
7. Remove:

Brake hose joint 1

8. Remove:

Nut (steering crown) 1

Steering crown 2

9. Remove:

Lock washer (ring nut) 1

Ring nut (upper) 2

Washer 3

Ring nut (lower) 4

WARNING:
Support the under bracket so that it may not
fall down.

10. Remove:

Steering stem

Bearing cover 1

Bearing (upper) 2

Bearing (lower) 3

6-37
 STEERING HEAD CHAS
INSPECTION
1. Wash the bearing in a solvent.
2. Inspect:

Bearings

Bearing race
Pitting/Damage
Replace.
NOTE:
Always replace bearing and race as a set.

INSTALLATION
1. Lubricute:

Bearing and races

Wheel bearing grease

2. Install:

Bearing (lower) 1
Onto steering stem.

Steering stem 2
CAUTION:
Hold the steering stem until it is secured.

Bearing (upper) 3

Ball race cover 4

Ring nut (lower) 5
3. Tighten:

Ring nuts (lower and upper)

Ring nuts tightening steps:

NOTE:
Set the Torque Wrench to the Ring Nut
Wrench so that they form a right angle.

Install the ring nut (lower) 5 .

NOTE:
The tapered side of ring nut must face down-
ward.

Tighten the ring nut 5 using the Ring Nut

Wrench (90890-01403).

Ring Nut 5 (Initial Tightening):

50 Nm (5.0 m
kg, 36 ft
lb)

Loosen the ring nut 5 completely and re-
tighten it to specification.
WARNING:
Do not over-tightening.

Ring Nut 5 (Final Tightening):

3 Nm (0.3 m
kg, 2.2 ft
lb)

6-38
 STEERING HEAD CHAS

Check the steering stem by turning it lock to
lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings 1 , 3 .

Install the washer 6 .

Install the ring nut (upper) 7 .
NOTE:
The tapered side of ring nut must face down-
ward.

Finger tighten the ring nut 7 , then align the

slots of both ring nuts. If not aligned, hold the
lower ring nut 5 and tighten the other until
they are aligned.

Install the lock washer 8 .
NOTE:
Make sure the lock washer tab is placed in
the slots.

Install the steering crown 9 and tighten the

steering stem nut 10 to specification.

Nut (Steering Stem):

110 Nm (11.0 m
kg, 80 ft
lb)

Tighten the pinch bolts to specification.

Pinch Bolt (Steering Crown):

20 Nm (2.0 m
kg, 14 ft
lb)

5. Install:

Components in aforementioned list (steps “7

1”)

Handlebar Lower Holder:

40 Nm (4.0 m
kg, 29 ft
lb)

6-39
 REAR SHOCK ABSORBER CHAS

REAR SHOCK ABSORBER

1 Rear shock absorber assembly

A SPRING PRELOAD POSITION

20 Nm (2.0 m
kg, 14 ft
lb) (STANDARD): 1

B DAMPING POSITION
(STANDARD): 1

20 Nm (2.0 m
kg, 14 ft
lb)

30 Nm (3.0 m
kg, 22 ft
lb)

30 Nm (3.0 m
kg, 22 ft
lb)

6-40
REAR SHOCK ABSORBER CHAS
REMOVAL
1. Remove:

Bolt (shock absorber top) 1

Special washer 2

Nut (shock absorber bottom) 3

Plain washer 4

2. Pull out the shock absorber top, and turn the

shock absorber clockwise.
3. Remove:

Rear shock absorber

INSPECTION
1. Inspect:

Shock absorber rod
Bends/Damage
Replace the shock ab-
sorber assembly.

Shock absorber
Oil leakes
Replace the shock absorber
assembly.

Spring
Fatigue
Replace the shock absorber as-
sembly.
Move the spring up and down.

INSTALLATION
When installing the rear shock absorber, re-
verse the removal procedure. Note the follow-
ing points.
1. Apply:

Lithium base grease
To the pivot points.

6-41
REAR SHOCK ABSORBER CHAS
2. Install:

Rear shock absorber
NOTE:
The rear shock absorber should be installed so
that the damping match mark 1 on the shock
absorber faces outward 2 .

3. Tighten:

Bolt (shock absorber top)

Nut (shock absorber bottom)

Bolt (Shock Absorber Top):

20 Nm (2.0 m
kg, 14 ft
lb)
Nut (Shock Absorber Bottom):
30 Nm (3.0 m
kg, 22 ft
lb)

4. Adjust:

Spring preload

Damping force
Refer to “CHAPTER 2. REAR SHOCK AB-
SORBER ADJUSTMENT” section.

6-42
 SWINGARM CHAS

SWINGARM
1 Locknut
2 Pivot shaft (right)
3 Collar
4 Oil seal
5 Taper roller bearing
6 Pivot shaft (left)
7 Lock washer
8 Collar
9 Oil seal
10 Taper roller bearing
11 Rubber boot

20 Nm (2.0 m
kg, 14 ft
lb)

6 Nm (0.6 m
kg, 4.3 ft
lb)

100 Nm (10.0 m
kg, 72 ft
lb)

100 Nm (10.0 m
kg, 72 ft
lb)

6-43
 SWINGARM CHAS
FREE PLAY INSPECTION
1. Remove:

Rear wheel

Rear shock absorbers
2. Check:

Swingarm (side play)
Side play
Replace taper roller bearings
and collars.
Move the swingarm from side to side.
There should be no noticeable side play.
3. Check:

Swingarm (vertical movement)
Tightness/Binding/Rough spots
Replace
bearings.
Move the swingarm up and down.

REMOVAL
1. Remove:

Rear wheel

Rear shock absorbers

Pivot shaft caps
2. Flatten:

Lock washer tab
Use a blunt chisel.

3. Remove:

Pivot shaft (left) 1

Lock washer 2

4. Remove:

Nut 1

Pivot shaft (right) 2

6-44
 SWINGARM CHAS
5. Remove:

Rubber boot

Bolts (muffler) 1

6. Remove:

Swingarm 1
Push down the muffler.

7. Remove:

Final gear assembly

INSPECTION
1. Wash the bearings in a solvent.
2. Inspect:

Bearings (race/rollers) 1
Pitting/Damage
Replace.

Oil seals 2

Collars 3
Damage
Replace.

3. Inspect:

Rubber boot
Damage
Replace.

6-45
 SWINGARM CHAS
INSTALLATION
When installing the swingarm, reverse the re-
moval steps. Note the following points.
1. Lubricate:

Bearing

Oil seals

Lithium Base Waterproof Wheel

Bearing Grease

2. Install:

Swingarm

Pivot shafts
3. Tighten:

Pivot shafts

Pivot shaft tightening steps:

Tighten the pivot shaft (left) 1 to specifica-
tion.

Pivot Shaft (Left):

100 Nm (10.0 m
kg, 72 ft
lb)

Tighten the pivot shaft (right) 3 until it con-

tacts the collar 5 .

Pivot Shaft (Right):

6 Nm (0.6 m
kg, 4.3 ft
lb)

Tighten nut (right pivot shaft) 4 to specifi-

cation.

Nut (Right Pivot Shaft):

100 Nm (10.0 m
kg, 72 ft
lb)

Bend the lock washer tab 2 along the nut

flat.

4. Apply:

Yamaha Bond No.1215
(90890-85505)
To the mating surfaces of both case halves.
5. Install:

Final gear assembly

Nuts (Final Gear Case):

42 Nm (4.2 m
kg, 30 ft
lb)

6. Check:

Swingarm (side play)

Swingarm (vertical movement)
Refer to “FREE PLAY INSPECTION” sec-
tion.

6-46
 SHAFT DRIVE CHAS

SHAFT DRIVE
1 Dust cover 15 Bearing 29 Bearing
2 Bearing housing 16 Drive pinion gear 30 Circlip
3 Ring gear stopper shim 17 Final drive gear shim 31 Universal joint
4 Ring gear stopper 18 Bearing
5 O-ring 19 Bearing retainer
6 Oil seal 20 O-ring
7 Ring gear shim 21 Oil seal
8 Bearing 22 Coupling gear
9 Ring gear 23 Spring
10 Thrust washer 24 Circlip
11 Bearing 25 Drive shaft
12 Oil seal 26 Oil seal
13 Collar 27 Washer
14 Bearing 28 Circlip

23 Nm (2.3 m
kg, 17 ft
lb)

40 Nm (4.0 m
kg, 29 ft
lb)

E KINDS: 6

9 Nm (0.9 m
kg, 6.5 ft
lb)

E KINDS: 6
23 Nm
A FINAL GEAR OIL: (2.3 m
kg, 17 ft
lb)

B CAPACITY:
0.2 L (0.18 Imp qt, 0.21 US qt)
TYPE:
C SAE 80 API GL-4 HYPOID
GEAR OIL E KINDS: 10
D GEAR LASH:
0.1
0.2 mm (0.004
0.008 in)
110 Nm (11.0 m
kg, 80 ft
lb)

23 Nm (2.3 m
kg, 17 ft
lb)

E KINDS: 5

110 Nm
(11.0 m
kg, 80 ft
lb)

42 Nm (4.2 m
kg, 30 ft
lb)

6-47
 SHAFT DRIVE CHAS
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:

A Symptoms B Possible Causes

1. A pronounced hesitation or “jerky” movement A. Bearing damage.
during acceleration, deceleration, or sus- B. Improper gear lash.
tained speed. (This must not be confused with C. Gear tooth damage.
engine surging or transmission characteris- D. Broken drive shaft.
tics.) E. Broken gear teeth.
2. A “rolling rumble” noticeable at low speed; a F. Seizure due to lack of lubrication.
high-piched whine; a “clunk” from a shaft drive G. Small foreign object lodged between moving
component or area. parts.
3. A locked-up condition of the shaft drive mech-
anism; no power transmitted from engine to
rear wheel.

NOTE:
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal motorcycle operating noise. If there is reason to believe these com-
ponents are damaged, remove the components for specific inspection.

6-48
 SHAFT DRIVE CHAS
Inspection Notes
1. Inrestigate any unusual noises

The following “Noises” may indicate a

mechanical defect:
a. A “rolling rumble” noise during coasting,
acceleration, or deceleration. The noise
increases with rear wheel speed, but it
does not increase with higher engine or
transmission speeds.
Diagnosis: Possible wheel bearing dam-
age.
b. A “whining” noise that varies with accel-
eration and deceleration.
Diagnosis: Possible incorrect reassembly,
too-little gear lash.
CAUTION:
Too-little gear lash is extremely destruc-
tive to the gear teeth. If a test ride follow-
ing reassembly indicates this condition,
stop riding immediately to minimize gear
damage.

c. A slight “thunk” evident at low speed op-

eration. This noise must be distinguished
from normal motorcycle operation.
Diagnosis: Possible broken gear teeth.

WARNING:
Stop riding immediately if broken gear
teeth are suspected. This condition could
result in a locking-up of the shaft drive as-
sembly, causing loss of control of the dike
and possible injury to the rider.

2. Inspect:

Drained oil
Drain plug shows large amount of metal.
Particles
Check bearing fur seizure.
NOTE:
A small amount of metal particles in the oil is
normal.

6-49
 SHAFT DRIVE CHAS
3. Inspect:

Oil leakage

Oil leakage inspection steps:

Clean the entire motorcycle thoroughly,
then dry it.

Apply a leak-localizing compound or dry
powder spray to the shaft drive.

Road test the motorcycle for the distance
necessary to locate the leak.
Leakage

Inspect component housing, gas-
ket,and/or seal for damage.
Damage

Replace component.
1 Oil seal
2 O-ring
3 Forward
NOTE:

An apparent oil leak on a new or nearly new
motorcycle may be the result of a rest-pre-
ventative coating or excessive seal lubrica-
tion.

Always clean the motorcycle and recheck
the suspected location of an apparent leak-
age.

6-50
 SHAFT DRIVE CHAS
Troubleshooting Chart
When basic conditions “a” and “b” above exist, check the following points:
YES
Elevate and spin the front wheel. Feel for Replace the wheel bearing.
wheel bearing damage. (Refer to “CHAPTER 5. FRONT WHEEL”)

NO

NO Rear wheel bearings and shaft drive bear-

Check the rear wheel. Feel for bearing dam-
age. ings probably not damaged. Repeat test or
remove individual components.

YES

YES Replace the rear wheel bearing.

Remove the rear wheel. Check for wheel
(Refer to “CHAPTER 5. REAR WHEEL”
bearing damage.
section).

NO

Remove the drive shaft components.

6-51
 SHAFT DRIVE CHAS
FINAL DRIVE GEAR
Gear Lash Measurement
1. Secure the gear case in a vise or other sup-
port.
2. Remove:
S Drain plug
Drain the oil.
3. Install:
S A bolt of the specified size 1
Into the drain plug hole.
4. Finger tighten the bolt until it holds the ring
gear.
NOTE:
Do not over tighten the bolt; finger-tight is suffi-
cient.

5. Attach:
S Gear Lash Measurement Tool 1
(90890-01230)
S Dial Gauge 2 (90890-03097)
3 Position mark
6. Measure:
S Gear lash
Gently rotate the gear coupling from engage-
ment to engagement.
Over specified limit
Adjust.

Final Gear Lash:

0.10
0.20 mm
(0.004
0.008 in)
NOTE:
Measure the gear lash at 4 positions., Rotate
the shaft 90_ each time.

Gear Lash Adjustment

1. Remove:
S Nuts (bearing housing)
S Bolts (bearing housing)
NOTE:
Working in a crisscross pattern, loosen nut 1/4
turn each. Remove them after all are loosened.

6-52
 SHAFT DRIVE CHAS
2. Remove:

Bearing housing 1

Dust cover 2

Rig gear

Shim(s) 3

Thrust washer 4
3. Adjust:

Gear lash

Gear lash adjustment steps:

Select the suitable shims and thrust washer
by the following chart.

Too-little gear lash
Reduce shim

thickness.
Too-large gear lash
Increase shim
thickness.

To Add or Reduce Ring Gear Shim Thickness

Increase by more Reduce by more

than 0.1 mm (0.004 in) than 0.1 mm (0.004 in)

Reduce thrust washer

thickness by 0.1 mm Reverse
(0.004 in) for every 0.1 mm procedure
of ring gear shim increase.

Ring Gear Shim

0.25 0.30 0.35

Thickness (mm)
0.40 0.45 0.50

Thrust Washer

1.4 1.5 1.6

1.7 1.8 1.9
Thickness (mm)
2.0 2.1 2.2
2.3

Ring Gear Stopper Clearance Measurement

1. Remove:

Bearing housing with ring gear
Refer to “Gear Lash Adjustment” section.

6-53
 SHAFT DRIVE CHAS
2. Measure:

Ring gear stopper clearance a
Use the Feeler Gauge 1 .
Out of specification
Adjust.

Ring Gear Stopper Clearance a :

0.30
0.60 mm (0.012
0.024 in)

2 Ring gear stopper

3 Ring gear
3. Install:

Bearing housing with ring gear

Ring Gear Stopper Clearance Adjustment

1. Remove:

Ring gear 1

Rig gear stopper 2

Shim(s) 3
4 Bearing housing
A Left-hand-threads
2. Select:

Suitable shim(s)
By the following chart.

Shim

0.100.100.150.15
Thickness (mm) 0.200.200.300.30
0.400.400.500.50

3. Install:

Components in above list (step “1”)

Ring Gear Stopper:

9 Nm (0.9 m
kg, 6.5 ft
lb)
LOCTITE

4. Measure:

Ring gear stopper clearance

6-54
 SHAFT DRIVE CHAS
Final Drive Gear Disassembly
1. Remove:

Nuts (bearing housing)

Bolts (bearing housing)
NOTE:
Working in a crisscross pattern, loosen nut 1/4
turn each. Remove them after all loosened.

2. Remove:

Bearing housing 1

Dust cover 2

Shim(s)

Thrust washer

3. Remove:

Self-locking nut (coupling gear)
Use a Final Drive Shaft Holder 1
(90890-01229).

Coupling gear

4. Remove:

Bearing retainer (final drive shaft)
Use a Final Drive Shaft Bearing Retainer 1
(90890-04050).
CAUTION:
Final-drive-shaft-bearing-retainer has left-
hand threads. Turn retainer clockwise to
loosen it.

Final drive shaft assembly

Tap lightly on the final drive shaft end with a
soft hammer.
CAUTION:
Final drive shaft removal should be per-
formed only if gearing replacement is nec-
essary. Do not reuse bearings or races after
removal.

6-55
 SHAFT DRIVE CHAS
Bearing Removal and Reassembly
1. Remove:
S Guide collar 1
S Oil seal 2
S Roller bearing 3
Use a suitable press tool 4 and an appropri-
ate support for the main housing.
2. Inspect:
S Roller bearing
Damage
Replace.
NOTE:
Reuse of roller bearing OK, but Yamaha recom-
mends installation of new bearing. Do not reuse
the oil seal.

3. Remove:
S Final drive shaft roller bearing 5

Final drive shaft roller bearing removal

steps:
S Heat the bare housing to 150_C (302_F)
S Remove the roller bearing outer race with
an appropriately shaped punch 6 .
S Remove the inner race from the final drive
shaft.
NOTE:
The removal of the final drive shaft roller
bearing is difficult and seldom necessary.

4. Install:
S Rear final drive shaft roller bearing (new)

Final drive shaft roller bearing installation

steps:
S Heat the bare bearing to 150_C (320_F)
S Install the roller bearing outer race using the
proper adapted.
S Install the inner race onto the drive shaft.

6-56
 SHAFT DRIVE CHAS
5. Install:

Guide collar 1

Oil seal (new) 2

Roller bearing (outer race) 3
Use a suitable press tool 4 and a press to
install the above components into the main
housing.

Final Drive/Ring Gear Positioning

NOTE:
Gear Positioning is necessary when any of the
following parts are replaced:

Final gear case

Ring gear bearing housing

Bearing(s)

1. Select:

Final drive gear shim 1

Ring gear shim 2

Final drive/ring gear shim selection

steps:

Position final drive shaft gear and ring gear
by using shims 1 and 2 with their respec-
tive thicknesses calculated from informa-
tion marked on final gear case and drive
gear end.
1 Shim thickness “A”
2 Shim thickness “B”
3 Thrust washer

To find shim thickness “A” use following for-
mula:

Final Drive Gear Shim Thickness:

A=a–b

6-57
 SHAFT DRIVE CHAS
Where:
a = a numeral (usually a decimal number)
on the gear is either added to or sub-
tracted from “84”.
b = a numeral on the gear case (i.e. 83.50)
Example:
1) If final drive shaft gear is marked “+01” . . .
“a” is 84.01.
2) If the gear case is marked “83.50” . . . “b” is
83.50.
A = 84.01 – 83.50
= 0.51
3) Therefore, shim thickness is 0.51 mm.
Shim sizes are supplied in following thick-
nesses:

Final Drive Gear Shim

0.150.150.300.30
Thickness
0.400.400.500.50
(mm)
0.60

Because shims can only be selected in 0.05

mm increments, round off hundredths digit
and select appropriate shim(s).

Hundredths Round value

0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
In the example above, the calculated shim
thickness is 0.51 mm. The chart instructs
you, however, to round off the 1 to 0. Thus
you should use a 0.50 mm shim.

To find shim thickness “B”, use following for-
mula:

Ring Gear Shim Thickness:

B = c + d – (e + f)

6-58
 SHAFT DRIVE CHAS
Where:
c = numeral on gear case (i.e. 45.52)
d = numeral (usually a decimal number) on
outside of ring gear bearing housing and
added to 3.
e = numeral (usually a decimal number) on
inside of ring gear either added to or
subtracted from 35.40.
f = bearing thickness (considered constant).

Bearing Thickness “f” = 13.00 mm

Example:
1) If gear case is marked “45.52” . . . “c” is
45.52.
2) If ring gear bearing housing is marked “35”
. . . “d” is 0.35 + 3 = 3.35.
3) If ring gear is marked “+01” . . . “e” is 35.40
+ 0.01 = 35.41.
4) “f” is 13.00.
B = c + d – (e + f)
= 45.52 + 3.35 – (35.41 + 13.00) = 48.87
– (48.41)
= 0.46
5) Therefore, shim thickness is 0.46 mm.
Shim sizes are supplied in following thick-
ness:

Ring Gear Shim

0.25 0.30 0.35

Thickness (mm)
0.40 0.45 0.50
Because shims can only be selected in 0.05
mm increments, round off hundredths digit
and select appropriate shim(s).

6-59
 SHAFT DRIVE CHAS

Hundredths Round value

0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
In the example above, the calculated shim
thickness is 0.46 mm. The chart instructs
you, however, to round off the 6 to 5.
Thus you should use a 0.45 mm shims.

2. Install:

Shims (proper size as calculated)

Final drive shaft assembly

Bearing retainer (final drive shaft)
Use a Final Drive Shaft Bearing Retainer
Wrench (90890-04050).
NOTE:
The bearing retainer has left-hand threads; turn
retainer counterclockwise to tighten it.

Bearing Retainer:
110 Nm (11.0 m
kg, 80 ft
lb)

3. Install:

Coupling gear

Self-locking nut (coupling gear)
Use a Final Drive Shaft Holder
(90890-01229).

Self-locking Nut (Coupling Gear)

110 Nm (11.0 m
kg, 80 ft
lb)
LOCTITE

4. Install:

Ring gear assembly (without thrust washer)
5. Adjust:

Gear lash
Refer to “Gear Lash Measurement and Ad-
justment” section.
6. Measure/Select:

Ring gear thrust clearance

6-60
 SHAFT DRIVE CHAS

Thrust clearance measurement steps:

Remove the ring gear assembly.

Place four pieces of Plastigage between
originally fitted thrust washer and ring gear.

Install the ring gear assembly and tighten
the bolts and nuts to specification.

Bolts (Bearing Housing):

40 Nm (4.0 m
kg, 29 ft
lb)
Nuts (Bearing Housing):
23 Nm (2.3 m
kg, 17 ft
lb)
NOTE:
Do not turn the shaft drive and ring gear when
measuring clearance with Plastigage.

Remove the ring gear assembly.

Measure the thrust clearance. Calculate
width of flattened Plastigage 1 .

Ring Gear Thrust Clearance:

0.1
0.2 mm (0.004
0.008 in)

If the clearance is correct, install the ring

gear assembly.

If the out of specification, select the correct
washer.
Thrust washer selection steps:

Select the suitable thrust washer by the fol-
lowing chart.
Thrust Washer
1.4 1.5 1.6
Thickness (mm) 1.7 1.8 1.9
2.0 2.1 2.2
2.3

Repeat measurement steps until the ring
gear thrust clearance is within the specified
limits.

Ring Gear Thrust Clearance:

0.1
0.2 mm (0.004
0.008 in)

6-61
 SHAFT DRIVE CHAS
DRIVE SHAFT
Removal
1. Remove:

Rear wheel

Final gear assembly

Drive shaft 1

Inspection
1. Inspect:

Drive shaft splines
Wear/Damage
Replace.

Installation
When installing the drive shaft, reverse the re-
moval procedure. Note the following points.
1. Lubricate:

Shaft splines

Molybdenum Disulfide Grease

2. Install:

Drive shaft
NOTE:
Before installing, first set the universal joint in
place on the middle case side.

3. Apply:

Yamaha Bond No.1215
(90890-85505)
To the mating surfaces of both case halves.
4. Tighten:

Nuts (final gear case)

Nuts (Final Gear Case):

42 Nm (4.2 m
kg, 30 ft
lb)

6-62
 ELEC

CHAPTER 7.
ELECTRICAL
VMX12 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
STARTING CIRCUIT CUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . 7-9
STARTER MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
STARTER RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
STARTING CIRCUIT CUT-OFF RELAY TEST . . . . . . . . . . . . . . . . . . 7-14
DIODE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
NEUTRAL SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
CHARGING VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
STATOR COIL RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
RECTIFIER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
IGNITION SPARK GAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
IGNITION COIL RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
PICKUP COIL RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
LIGHTING TESTS AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
SIGNAL SYSTEM TESTS AND CHECKS . . . . . . . . . . . . . . . . . . . . . . 7-39
OIL LEVEL GAUGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
REED SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
SELF-CANCELLING FLASHER SYSTEM TEST . . . . . . . . . . . . . . . . 7-41
SWITCHES TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
 ELEC
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
ELECTRIC FAN AND THERMOSTATIC SWITCH . . . . . . . . . . . . . . . 7-48
THERMO-UNIT AND THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . 7-49

FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
“FUEL” (RESERVE) SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
FUEL PUMP RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
FUEL SENDER UNIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
 CIRCUIT DIAGRAM ELEC

ELECTRICAL
VMX12 CIRCUIT DIAGRAM

7-1
 CIRCUIT DIAGRAM ELEC
1 Ignition coil #1 32 Relay unit COLOR CODE
2 Spark plug #1 33 Starting circuit cut-off relay B ......... Black
3 Ignition coil #2 34 Flasher relay L ......... Blue
4 Spark plug #2 35 Cancelling unit O ........ Orange
5 Ignition coil #3 36 Starter switch G ........ Green
6 Spark plug #3 37 “TURN” switch R......... Red
7 Ignition coil #4 38 “TURN” indicator light P ......... Pink
8 Spark plug #4 39 Flasher light (Left) Y ......... Yellow
9 Temperature meter 40 Flasher light (Right) W ........ White
10 Thermo-unit 41 Reed switch Br . . . . . . . . Brown
11 Tachometer 42 Thermo switch Dg . . . . . . . Dark green
12 Horn 43 Electric fan Ch . . . . . . . Chocolate
13 “HORN” switch 44 Fuse Sb . . . . . . . . Sky blue
14 “FUEL” indicator light 45 AC Magneto Gy . . . . . . . Gray
15 Fuel sender unit 46 Rectifier with regulator G/R . . . . . . Green / Red
16 “OIL LEVEL” warning indicator 47 Main fuse G/Y . . . . . . Green / Yellow
light 48 Battery B/ R . . . . . . . Black/ Red
17 Oil level gauge 49 Starter motor B/ W . . . . . . Black/ White
18 “NEUTRAL” indicator light 50 Starter relay B/ Y . . . . . . . Black/ Yellow
19 Neutral switch 51 Main switch L/Y . . . . . . . Blue/ Yellow
20 Front brake switch 52 Fuse (IGNITION) L/B . . . . . . . Blue/ Black
21 Rear brake switch 53 “ENGINE STOP” switch L/W . . . . . . Blue/ White
22 “LIGHTS” (Dimmer) switch 54 Clutch switch R/ W . . . . . . Red/ White
23 Headlight 55 Diode R/ G . . . . . . Red/ Green
24 “HIGH BEAM” indicator light 56 Pressure sensor R/ B . . . . . . . Red/ Black
25 Meter light 57 Ignitor unit R/ Y . . . . . . . Red/ Yellow
26 “PASS” switch 58 Pick-up coil (#1
#4) W/ R . . . . . . White/ Red
27 “LIGHTS” switch 59 “FUEL” (RESERVE) switch W/ G . . . . . . White/ Green
28 Tail/ brake light 60 Fuel pump relay W/ B . . . . . . White/ Black
29 Fuse (HEAD) 61 Fuel pump Y/ R . . . . . . . Yellow/ Red
30 Fuse (SIGNAL) Y/ L . . . . . . . Yellow/ Blue
31 Auxiliary light Br/ W . . . . . Brown/ White

7-2
 ELECTRICAL COMPONENTS ELEC

ELECTRICAL COMPONENTS (1)

1 TCI unit
SPECIFICATIONS RESISTANCE
2 Pressure sensor
3 Ignition coil (#1 & #3) IGNITION COIL:
4 Neutral switch PRIMARY 2.4
3.0 Ω
5 Oil level gauge SECONDARY 10.6
15.8 kΩ
6 Ignition coil (#2 & #4) PICK-UP COIL: 93.5
126.5 Ω
7 Thermostatic switch
8 Thermo-unit

7-3
 ELECTRICAL COMPONENTS ELEC

ELECTRICAL COMPONENTS (2)

1 Starter relay
2 Main fuse
3 Battery
4 Rectifier with regulator
5 Rear brake switch
6 Horn
7 Relay unit
8 Fuel pump relay
9 Diode
10 Main switch
11 Wire harness

A BATTERY:
B CAPACITY: 12 V, 16 AH
C SPECIFIC GRAVITY:
1.280

7-4
 ELECTRIC STARTING SYSTEM ELEC

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

7-5
 ELECTRIC STARTING SYSTEM ELEC
Aforementioned circuit diagram shows electrical starting circuit in wiring diagram.

NOTE:
For the encircled numbers and color cords, see page 7-2.

18 “NEUTRAL” indicator light

19 Neutral switch
30 Fuse (SIGNAL)
32 Relay unit
33 Starting circuit cut-off relay
36 Starter switch
47 Main fuse
48 Battery
49 Starter motor
50 Starter relay
51 Main switch
52 Fuse (IGNITION)
53 “ENGINE STOP” switch
54 Clutch switch
55 Diode

7-6
 ELECTRIC STARTING SYSTEM ELEC
TROUBLESHOOTING
Troubleshooting Chart (1)

THE STARTER MOTOR DOES NOT

OPERATE.

Remove the seat.

Disconnect the “L/W” lead from the starter

relay.

NO
Check the battery voltage (12 V) on the “L/W”
Correct the battery terminal connection.
lead from the starter relay.

12 V

Connect the “L/W” lead from the starter relay

to the battery negative (–) terminal; use a
jumper lead 1 .

The engine does not operate.

If the starter relay does not click; replace the

relay.

The engine does not rev smoothly.

Recharge or replace the battery.

7-7
 ELECTRIC STARTING SYSTEM ELEC
Troubleshooting Chart (2)

THE STARTER MOTOR DOES NOT OPER-

ATE.

Check the starter relay and starter motor;

refer to CHART (1).

Remove the cover (left) and disconnect the

relay unit connector.

Main and engine stop switches are turned to

“ON”.

Check the battery voltage (12 V) on the “R/B”

NO
lead.
Check for an open or poor connection be-
tween the main switch and relay unit.

12 V

Connect the relay unit connector.

Connect “B/Y” lead to “ground” on the frame;

use a jumper lead 1 .

If the relay unit does not click, replace the

relay unit.

If the relay unit clicks, check the starter, clutch

and neutral switches. Replace switch(es) if
necessary.

7-8
ELECTRIC STARTING SYSTEM ELEC
STARTING CIRCUIT CUT-OFF SYSTEM
A starting circuit cut-off system is employed,
and operates as follows:

Starting Circuit Operation

The starting circuit on this model consist of the
starter motor, starter relay, and the relay unit
(starting circuit cut-off relay). If the engine stop
switch and the main switch are both on, the
starter motor can operate only if:

The transmission is in neutral (the neutral

switch is on).
or if
The clutch lever is pulled to the handlebar
(the clutch switch is on).
The starting circuit cut-off relay prevents the
starter from operating when neither of these
conditions has been met. In this instance, the
starting circuit cut-off relay is off so current can-
not reach the starter motor.

When one of both of the above conditions have

been met, however, the starting circuit cut-off
relay is on, 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 Starter motor
3 Starter relay
4 Starting circuit cut-off relay
5 Starter switch
6 Neutral switch
7 Clutch switch
8 To main switch
9 To engine stop switch

7-9
 ELECTRIC STARTING SYSTEM ELEC
STARTER MOTOR TEST
1 O-ring
2 Brush holder assembly
3 Brush

MINIMUM BRUSH LENGTH:

A
5.5 mm (0.22 in)
COMMUTATOR WEAR LIMIT:
B
27 mm (1.06 in)
MICA UNDERCUT:
C
0.7 mm (0.028 in)

10 Nm (1.0 m.kg, 7.2 ft.lb)

7-10
ELECTRIC STARTING SYSTEM ELEC
Removal
1. Remove:

Starter motor
Refer to “CHAPTER 3. ENGINE DIS-
ASSEMBLY” section.

Inspection and Repair

1. Inspect:

Commutator
Dirty
Clean with #600 grit sandpaper.
2. Measure:

Commutator diameter a
Out of specification
Replace starter motor.

Commutator Wear Limit:

27 mm (1.06 in)

3. Measure:

Mica undercut b
(between commutator segments)
Out of specification
Scrape mica to proper
valve.
Use a hacksaw blade that is ground to fit.

Mica Undercut:
0.7 mm (0.028 in)

NOTE:
The mica insulation of the commutator must be
undercut to ensure proper operation of the com-
mutator.

4. Measure:

Armature coil insulation/continuity
Defect(s)
Replace starter motor.

Insulation Resistance:
1 MΩ or more at 20C (68F)

1 Continuity check
2 Insulation check
3 Armature coil

7-11
ELECTRIC STARTING SYSTEM ELEC
5. Inspect:

Bearings 1

Oil seal 2

O-ring 3
Wear/Damage
Replace

6. Inspect:

Commutator brushes
Damage
Replace.
7. Measure:

Brush length a
Out of specification
Replace.

Minimum Brush Length:

5.5 mm (0.22 in)

8. Inspect:

Brush springs
Compare with new spring.
Wear/Damage
Replace.

Installation
1. Install:

Starter motor
NOTE:
Align the match marks 1 on the brackets with
the match marks 2 on the housing.

7-12
ELECTRIC STARTING SYSTEM ELEC
BATTERY INSPECTION
1. Inspect:

Battery
Refer to “CHAPTER 2. BATTERY INSPEC-
TION” section.

STARTER RELAY TEST

1. Inspect:

Starter relay
Poor condition
Replace.

Starter relay inspection steps:

Remove the seat.

Turn ignition switch to “ON”, engine stop
switch to “RUN” and shift pedal to “NEU-
TRAL”.

Disconnect the starter motor lead 1 from
the starter motor.

Push the starter switch and check to see if
the starter relay clicks.
Starter relay clicking
Starter relay OK.
Starter relay not clicking
Measure coil re-
sistance.

2. Measure:

Starter relay resistance
Out of specification
Replace.

Starter relay resistance measurement

steps:

Disconnect the “L/W” lead and the battery
positive lead.

Connect the Pocket Tester (90890-03112)
leads to the starter relay.
1 Blue/ White
2 Red

Measure the coil resistance.
Starter Relay Resistance:
3.9
4.7 Ω at 20C (68F)

If the resistance is not within specification,
replace the starter relay.

7-13
ELECTRIC STARTING SYSTEM ELEC
STARTING CIRCUIT CUT-OFF RELAY TEST
1. Remove:

Top cover

Cover (left)

Relay unit 1
2. Disconnect:

Relay unit connector

3. Measure:

Starting circuit out-off relay resistance
Use the Pocket Tester 1 (90890-03112).
Out of specification
Replace.

Starting Circuit Cut-off Relay

Resistance:
203
248 Ω at 20C (68F)

2 Red/ White
3 Black/ Yellow
4. Check:

Starting circuit cut-off relay contacts
Use 12 V battery 1 and the Pocket Tester 2
(90890-03112).
Out of specification
Replace.

Battery Connected 3 : 0 Ω
Battery Disconnected 4 : ∞

5 Blue/ White
6 Red/ White
7 Black/ Yellow

DIODE TEST
1. Remove:

Top cover

Meter panel

Diode 1

7-14
ELECTRIC STARTING SYSTEM ELEC
2. Check:
S Diode continuity/discontinuity
Defective element(s)
Replace diode.

Pocket tester
Checking
g connecting point
Good
element (+) (–)
(Red) (Black)
G L/W f
D1
L/W G
Y Sb f
D2
Sb Y
W/G W f
D3
W W/G
R G B
/
R 8.2 Ω
f: Continuity (0 Ω) (Scale Ω 1K)
: Discontinuity (∞) (Scale Ω 1)
NOTE:
The results “f” or “ ” should be reversed ac-
cording to the Pocket Tester polarity.

NEUTRAL SWITCH TEST

1. Disconnect:
S One lead (Blue)
2. Check:
S Neutral switch contact
Out of specification
Replace switch

In Neutral 1 : 0 Ω
In Gear 2 : ∞

3 Blue
4 Ground

7-15
ELECTRIC STARTING SYSTEM ELEC

— MEMO —

7-16
 CHARGING SYSTEM ELEC

CHARGING SYSTEM
CIRCUIT DIAGRAM

7-17
 CHARGING SYSTEM ELEC
Aforementioned circuit diagram shows charging circuit in wiring diagram.

NOTE:
For the encircled numbers and color codes, see page 7-2.

45 AC Magneto
46 Rectifier with regulator
47 Main fuse
48 Battery
51 Main switch

7-18
 CHARGING SYSTEM ELEC
TROUBLESHOOTING

THE BATTERY IS NOT CHARGED.

Remove the seat.

Measure the battery for voltage and specific No.

gravity.
Recharge the battery.
Battery voltage: More than 12 V
Specific gravity: 1,280

Yes

Connect the Pocket Tester to the battery to

measure the generator voltage.

Start the engine and accelerate to about Generator Voltage:

2,000 r/min or more. More than 15 V

Generator Voltage: Replace rectifier with regulator.

Less than 13 V

Check the stator coil resistance.

Stator coil resistance (White – White):
0.36
0.48 Ω at 20
C (68
F)

Replace the stator coil.

7-19
CHARGING SYSTEM ELEC
CHARGING VOLTAGE TEST
1. Remove:

Seat
2. Connect:

Pocket Tester (90890-03112)
To battery terminals.
3. Start the engine and accelerate to about
2,000 r/min or more.
4. Measure:

Generator voltage
Out of specification
Check battery, stator
coil, and rectifier/regulator.

Generator Voltage: 14
15 V

CAUTION:
Never disconnect the wires from the battery
while the generator is operating, otherwise
the voltage across the generator terminals
will increase and damage the semiconduc-
tors.

BATTERY INSPECTION
Refer to “CHAPTER 2. BATTERY INSPEC-
TION” section.

STATOR COIL RESISTANCE TEST

1. Remove:

Side cover (left)
2. Disconnect:

3-pin connector (White, White and White)
From rectifier/regulator.
3. Connect:

Pocket Tester (90890-03112)

7-20
CHARGING SYSTEM ELEC
4. Measure:

Stator coil resistance
Out of specification
Replace stator coils.

Stator Coil Resistance:

0.36  0.48 Ω at 20C (68F)
(White – White)

1 White

RECTIFIER TEST
1. Check:

Defective element
Replace rectifier.
1 White A IC Regulator
2 White B Brown
3 White C Rectifier
4 Red
5 Black
Pocket Tester
Connecting Point Replace Replace
Checking
g
Good (Element (Element
Element (+) (–) shorted) opened)
(Red) (Black)
d a  

D1
a d


d b  

D2
b d


d c  

D3
c d


a e  

D4
e a


b e  

D5
e b


c e  

D6
e c


: Continuity
: Discontinuity (∞)

NOTE:
The results “” or “
” should be reversed ac-
cording to the Pocket tester polarity.

CAUTION:
Do not overcharge rectifier or damage may
result.
Avoid:

A short circuit.

Inverting + and – battery leads.

Direct connection of rectifier to battery.

7-21
 CHARGING SYSTEM ELEC

— MEMO —

7-22
 IGNITION SYSTEM ELEC

IGNITION SYSTEM
CIRCUIT DIAGRAM

7-23
 IGNITION SYSTEM ELEC
Aforementioned circuit diagram shows ignition circuit in wiring diagram.

NOTE:
For the encircled numbers and color codes, see page 7-2.

1 Ignition coil #1 51 Main switch

2 Spark plug #1 52 Fuse (IGNITION)
3 Ignition coil #2 53 “ENGINE STOP” switch
4 Spark plug #2 56 Pressure sensor
5 Ignition coil #3 57 Ignitor unit
6 Spark plug #3 58 Pick-up coil (#1
#4)
7 Ignition coil #4
8 Spark plug #4

7-24
 IGNITION SYSTEM ELEC
TROUBLESHOOTING
The entire ignition system can be checked for
misfire and weak spark by using the Electro
Tester.
1. Warm up the engine so that all of the electri-
cal components are at operating tempera-
ture.

2. Connect:

Electro Tester (90890-03021) 1
3. Start the engine, and increase the spark gap
until misfire occurs. (Test at various r/min be-
tween idle and red line.)
2 Spark plug lead
3 Spark plug

CAUTION:
Do not run the engine in neutral above 6,000
r/min for more than 1 or 2 seconds.

Minimum Spark Gap:

6 mm (0.24 in)

Faulty ignition system operation (at the mini-

mum spark gap or smaller)
Follow the trou-
bleshooting chart until the source of the prob-
lem is located.

7-25
 IGNITION SYSTEM ELEC
Troubleshooting Chart
Check the entire ignition for connections. Correct.
Faulty

Measure the battery voltage and specific

gravity.
Recharge the battery.
Battery voltage: More than 12 V
Specific gravity: 1,280 No

Main and engine stop switches are turned to

Check the fuse “IGNITION” (15 A) and wiring
“ON”. Check for voltage (12 V) on the “R/W”
circuit.
lead at the TCI unit and ignition coils.
No

Measure the pickup coils resistance. Replace the pickup coil assembly.
Pickup coil: 93.5
126.5 Ω at 20
C (68
F)
No
(Black – Orange) (Black – Gray)
(Black – White/Green)
(Black – White/Red)

OK

Check the ignition coils for resistance (primary and secondary).

A Primary: 2.4
3.0 Ω at 20
C (68
F) B Secondary: 10.6
15.8 kΩ at 20
C (68
F)

OK No

TCI unit is faulty, replace the unit. Replace the ignition coil(s).
7-26
 IGNITION SYSTEM ELEC
DESCRIPTION
This model is equipped with a battery operated,
fully transistorized, breakerless ignition system.
By using magnetic pickup coils, the need for
contact breaker points is eliminated. This adds
to the dependability of the system by eliminating
frequent cleaning and adjustment of points and
ignition timing. The TCI (Transistor Control Igni-
tion) unit incorporates an automatic advance
circuit controlled by signals generated by the
pickup coil. This adds to the dependability of the
system by eliminating the mechanical ad-
vancer. This TCI system consists of two units; a
pickup unit and an ignitor unit.

A Pressure sensor
B Pickup coil
C Ignitor unit
D Advance control
E Electronic advance circuit
F Ignition coil 4
G Spark plug 4
H Battery

OPERATION
TCI Unit
The TCI functions on the same principle as a
conventional DC ignition system with the ex-
ception of using magnetic pickup coils and a
transistor control box (TCI) in place of contact
breaker points.
1 TCI unit

Pickup Unit
The pickup unit consists of two pickup coils 1
and a flywheel mounted onto the crankshaft.
When the projection on the flywheel passes a
pickup coil, a signal is generated and trans-
mitted to the ignitor unit. The width of the projec-
tion on the flywheel determines the ignition ad-
vance.
The pickup coils are located in the right crank-
case cover.

7-27
 IGNITION SYSTEM ELEC
IGNITION SPARK GAP TEST
1. Remove:

Top cover

Seat

Cover (left)

Electrical component board
2. Disconnect:

Ignition coil leads

Spark plug leads
3. Connect:

Electro Tester (90890-03021)
NOTE:
Be sure to use a fully charge 12 V battery 1 .

4. Turn the spark plug gap adjuster and in-

crease the gap to the maximum limit unless
A misfire occurs first.

Minimum Spark Gap:

6 mm (0.24 in)

IGNITION COIL RESISTANCE TEST

1. Connect:

Pocket Tester (90890-03112)
2. Measure:

Primary coil resistance A

Secondary coil resistance B
Out of specification
Replace.

Primary Coil Resistance:

2.4
3.0 Ω at 20C (68F)
Secondary Coil Resistance:
B
10.6
15.8 kΩ at 20C (68F)
Spark Plug Cap:
9
11 kΩ

7-28
 IGNITION SYSTEM ELEC
PICKUP COIL RESISTANCE TEST
1. Remove:

Seat
2. Disconnect:

5-pin connecter (Black, White/Red, Orange,
White/Green and Gray)
3. Measure

Pickup coil resistance
Use a Pocket Tester (90890-03112).
Out of specification
Replace.

Pickup Coil Resistance:

93.5
126.5 Ω at 20C (68F)
(B – O), (B – Gy),
(B – W/G), (B – W/R)

1 Black
2 White/ Red
3 Orange
4 Gray
5 White/ Green

SPARK PLUG INSPECTION

Refer to “CHAPTER 2. SPARK PLUG INSPEC-
TION” section.

PRESSURE SENSOR
Operation
This pressure sensor unit consists of a semi-
conductor strain gauge and an amplifying cir-
cuit.
Pressure to the carburetor joint (venturi portion)
is sensed by the strain gauge and amplified in
the circuit connected with this gauge. The am-
plified pressure signals are then transmitted to
the ignition system for the control of ignition tim-
ing advance.

1 Strain gauge
2 Amplifying circuit
3 Pressure intake tube
4 From carburetor joint

7-29
 IGNITION SYSTEM ELEC
Removal
1. Remove:

Top cover

Cover (left)

Electrical component board
2. Disconnect:

Sensor connector

Vacuum hose
3. Remove:

Pressure sensor 1

Inspection
1. Connect:

Pocket Tester (90890-03112)

Battery (12 V) 1
2. Measure:

Output voltage
Out of specification
Replace.

Output Voltage:
About 2.0 DC Volt

1 Output voltage
2 Atmospheric pressure
3 Pressure

Installation
1. Install:

Pressure sensor
Reverse the removal procedure.

7-30
 LIGHTING SYSTEM ELEC

LIGHTING SYSTEM
CIRCUIT DIAGRAM

7-31
 LIGHTING SYSTEM ELEC
Aforementioned circuit diagram shows lighting circuit in wiring diagram.

NOTE:
For the encircled numbers and color codes, see page 7-2.

22 “LIGHTS” (Dimmer) switch

23 Headlight
24 “HIGH BEAM” indicator light
25 Meter lights
26 “PASS” switch
27 “LIGHTS” switch
28 Tail/ brake light
29 Fuse (HEAD)
31 Auxiliary light
47 Main fuse
48 Battery
51 Main switch

7-32
 LIGHTING SYSTEM ELEC
LIGHTING TESTS AND CHECKS
The battery provides power for operation of the
headlight, taillight, and meter lights. If none of
the above fail to operate proceed further.
Low battery voltage indicates either a faulty bat-
tery, low battery fluid level, or a defective charg-
ing system.
Also check fuse condition. Replace any “open”
fuses. There are individual fuses for various cir-
cuits (see complete Circuit Diagram).
NOTE:
Check each bulb first before performing the fol-
lowing check.

7-33
 LIGHTING SYSTEM ELEC
Headlight Troubleshooting

HEADLIGHT DOES NOT COME ON HIGH BEAM DOES NOT OPERATION.

Faulty
Check headlight bulb. Replace.

OK
Faulty
Check fuse (HEAD). Replace.

OK
Faulty
Measure voltage on Brown lead from main
Check main switch, replace if necessary.
switch (“ON” position).

12 V
No voltage
Measure voltage on Blue/Black lead from
Check “LIGHTS” switch, if necessary.
“LIGHTS” switch (“ON” position).

12 V
No voltage
Measure voltage at “LIGHTS” (Dimmer) Check “LIGHTS” (Dimmer) switch, replace if
switch terminal. necessary.

12 V
No voltage
Measure voltage at headlight high beam or An open or poor connection between head-
low beam terminal. light and “LIGHTS” (Dimmer) switch terminal.

12 V

Poor ground or poor connection of headlight

wiring.

7-34
 LIGHTING SYSTEM ELEC
Taillight Troubleshooting

TAILLIGHT DOES NOT COME ON.

Faulty
Check taillight bulb. Replace.

OK
Faulty
Check main fuse. Replace.

OK
No voltage
Measure voltage on Blue lead from main
Check main switch, replace if necessary.
switch (“ON” position).

12 V
No voltage
Measure voltage at taillight terminal. An open or poor connection between taillight
and main switch terminal.
12 V

Poor ground or poor connection of taillight

wiring.

7-35
 LIGHTING SYSTEM ELEC

— MEMO —

7-36
 SIGNAL SYSTEM ELEC

SIGNAL SYSTEM
CIRCUIT DIAGRAM

7-37
 SIGNAL SYSTEM ELEC
Aforementioned circuit diagram shows signal circuit in wiring diagram.

NOTE:
For the encircled numbers and color codes, see page 7-2.

12 Horn 34 Flasher relay

13 “HORN” switch 35 Canelling unit
16 “OIL LEVEL” warning indicator light 37 “TURN” switch
17 Oil level gauge 38 “TURN” indicator light
18 “NEUTRAL” indicator light 39 Flasher light (Left)
19 Neutral switch 40 Flasher light (Right)
20 Front brake switch 41 Reed switch
21 Rear brake switch 47 Main fuse
28 Tail/ brake light 48 Battery
30 Fuse (SIGNAL) 51 Main switch
32 Relay assembly

7-38
 SIGNAL SYSTEM ELEC
SIGNAL SYSTEM TESTS AND CHECKS
The battery provides power for operation of the
horn, brakelight, indicator lights and flasher
lights. If none of the above operates, always
check battery voltage before proceeding fur-
ther.

Battery
1. Check:

Battery voltage
Defective components
Replace.

Faulty battery
Low battery fluid level
Check for:
Defective charging system
Faulty fuse(s)

Horn
1. Check:

Horn operation
Defective components
Replace.

12 V on Brown lead to horn

Good grounding of horn (Pink
Check for:
lead) when horn button is pressed
Faulty fuse

Brake Light
1. Check:

Brake light operation
Defective components
Replace.

Defective bulb
12 V on Yellow lead to brake light
Check for: 12 V on Brown lead to each
brake light switch (Front and rear
brake switch)

“NEUTRAL” Indicator Light

1. Check:

Indicator light operation
Defective components
Replace.

Defective bulb
12 V on Sky Blue lead to neutral
Check for: switch
12 V on Brown lead to indicator
light
7-39
 SIGNAL SYSTEM ELEC
“OIL LEVEL” Warning Indicator Light
1. Check:

Indicator light operation
Defective components
Replace.

Defective bulb
Defective oil level gauge
Check for:
12 V on Brown lead to indicator
light

Flasher Light
1. Check:

Flasher light operation
Refer to “SELF-CANCELLING FLASHER
SYSTEM” section.

OIL LEVEL GAUGE TEST

1. Drain:

Engine oil
2. Remove:

Oil level gauge
3. Measure:

Oil level gauge resistance
Use the Pocket Tester (90890-03112).
Out of specification
Replace.

Oil Level Gauge Resistance:

Float is down a
Infinity
Float is up b
Zero ohms

1 Black/ Red
2 Ground

4. Install:

Oil level gauge
5. Connect:

Leads
6. Fill:

Crankcase
Refer to “CHAPTER 2 ENGINE OIL RE-
PLACEMENT” section.

7-40
 SIGNAL SYSTEM ELEC
REED SWITCH TEST
1. Remove:

Headlight lens unit

Top cover

Cover (left)
2. Disconnect:

Relay assembly coupler 1
3. Measure:

Reed switch resistance
Use the Pocket Tester (90890-03112).
Out of specification
Replace.
Lift the front wheel and rotate the wheel by
hand.

Reed Switch Resistance:

About 7 Ω
Then return back 0 Ω” or ∞ Ω
when wheel is stopped

1 White/ Green
2 Black

SELF-CANCELLING FLASHER SYSTEM

TEST
Description
The self-cancelling flasher system turns off the
turn signal after a period of time or distance in-
volved in turning or changing lanes. Generally,
the signal will cancel after either 10 seconds, or
150 meters (490 feet), whichever is greater.
At very low speed, the function is determined by
distance; at high speed, especially when
changing speeds the cancelling determination
is a combination of both times and distance.
The self-cancelling determination is a comme-
chanism only operates when the motorcycle is
moving; thus the signal will not self-cancel while
you are stopped at an intersection.
1 Cancelling unit

7-41
 SIGNAL SYSTEM ELEC
Operation
The handlebar switch has three positions:
L (left), OFF, and R (right). The switch lever will
return to the “OFF” position after being pushed
to L or R, but the signal will function.
By pushing the lever in, the signal may be can-
celled manually. If the flasher self-cancelling
system should become inoperative, replace
relay unit.
Troubleshooting

Flasher light and indicator light inoperative.

Faulty
Check bulb. Replace.

OK

Left circuit:

Check for 12 V on Chocolate lead to light. No voltage

Check for ground on Black lead to light.
Correct.
Right circuit:

Check for 12 V on Dark green lead to light.

Check for ground on Black lead to light.

OK
12 V
Measure voltage at “TURN” switch as follows.

Brown/White lead Replace switch.

Yellow/Red lead

No voltage

No voltage on Brown/White lead:

Check flasher relay, fuses (SIGNAL and Poor condition
MAIN), main switch and battery.
Replace defective component(s).
No voltage on Yellow/Red lead:

Check cancelling unit, fuses (SIGNAL and
MAIN), main switch and battery.

OK
Poor condition
Check reed switch. Replace switch

OK

Replace cancelling unit.

7-42
 SIGNAL SYSTEM ELEC
SWITCHES TEST
Switches may be checked for continuity with a
Pocket Tester (90890-03112) on the “Ohm 1”
position.
1 “PASS” switch
2 “LIGHTS” (Dimmer) switch
3 “TURN” switch
4 “HORN” switch
5 “ENGINE STOP” switch
6 “LIGHTS” switch
7 “START” switch
Main Switch
Lead Color
Switch Position
R Br L L/R
P
OFF
ON

“PASS” Switch
Lead Color
Switch Position
R/Y Y
OFF
ON

“LIGHTS” (Dimmer) Switch

Lead Color
Switch Position
Y L/B G
HI
LO

“TURN” Switch
Lead Color
Switch Position
Ch Br/ W Dg Y/R B
L
L
N N
R
R

“HORN” Switch
Lead Color
Switch Position
P B
OFF
ON
7-43
 SIGNAL SYSTEM ELEC
“ENGINE STOP” Switch
Lead Color
Switch Position
R/W Br
OFF
ON

“LIGHTS” Switch
Lead Color
Switch Position
R/Y L L/B
OFF
PO
ON

“START” Switch
Lead Color
Switch Position
L/W B
OFF
ON

7-44
 COOLING SYSTEM ELEC

COOLING SYSTEM
CIRCUIT DIAGRAM

7-45
 COOLING SYSTEM ELEC
Aforementioned circuit diagram shows cooling circuit in wiring diagram.

NOTE:
For the encircled numbers and color codes, see page 7-2.

9 Temperature meter
10 Thermo-unit
30 Fuse (SIGNAL)
42 Thermostatic switch
43 Electric fan
44 Fuse
47 Main fuse
48 Battery
51 Main switch

7-46
 COOLING SYSTEM ELEC
TROUBLESHOOTING

The electric fan will not turn at coolant temperatures of 105 ± 3
C (221.0 ± 5.4
F) or more:

Defective
Check the connectors. Correct.

OK
Fan inoperative
Disconnect fan motor connector and connect Replace fan motor assembly.
battery as shown.

Fan operative No voltage

Check wiring circuit, and correct defective
Check battery voltage on Blue leads.
component(s).
12 V
Fan operative
Disconnect the lead of the thermostatic
Replace the thermostatic switch.
switch and ground it to the motor body.

Fan inoperative

Replace the fan motor assembly.

7-47
 COOLING SYSTEM ELEC
ELECTRIC FAN AND THERMOSTATIC
SWITCH
Operation
The electric fan will be switched ON or OFF ac-
cording to the coolant temperature in the radia-
tor.
1 Electric fan

NOTE:
The electric fan is controlled by the thermostatic
switch when the main switch is “ON”. Thus, un-
der certain operating conditions, this fan may
continue to run until the engine temperature has
cooled down to about 91C (195.8F).

A THERMOSTATIC SWITCH “ON”

B COOLANT TEMPERATURE

Electric Fan Inspection

The following
g problems mayy require
q repair or
replacement of components
Component Condition
Fan motor Unsmooth operation
Fan motor Excessive vibration
Fan motor bracket Cracks
Fan blades Cracks
Securing bolts Looseness
1 Fan
2 Electric fan motor

Thermostatic Switch Inspection

1. Remove:

Top cover

Cover (right)

Thermostatic switch 1

WARNING:
Handle the thermostatic valve very carefully.
Never subject it to strong shock or allow it to
be dropped. Should it be dropped, it must be
replaced.

7-48
 COOLING SYSTEM ELEC
2. Inspect:

Thermostatic switch operation

Thermostatic switch inspection steps:

Immerse thermostatic switch in water.

1 Thermometer
2 Thermostatic switch
3 Pocket Tester

Check continuity as indicated.

Note temperatures while heating the water.
Malfunction
Replace switch.

Test Pocket Tester

Water Temperature
Step (Ω 1)
0 X 98C
*1* Discontinuity
(32 X 208.4F)
More than 105 ± 3C
*2* Continuity
(221.0 ± 5.4F)
105 to 98C
*3* Continuity
(221.0 to 208.4F)
Less than 98C
*4* Discontinuity
(208.4F)
Test 1 & 2; Heat-up tests
Test 3* & 4*; Cool-down tests
3. Install:

Thermostatic switch

Thermostatic Switch:
15 Nm (1.5 m
kg, 11 ft
lb)
Three Bond Sealock #10

CAUTION:
After replacing the thermostatic switch,
check the coolant level in the radiator and
also check for any leakage.

THERMO-UNIT AND THERMOMETER

Operation
The thermo unit has less resistance at higher
temperatures and thus allows more current to
pass through. When more current flows to the
coil in the thermometer, the armature to which
the needle is attached by the increased mag-
netic field. In this way, the needle indicates the
temperature.
1 Temperature meter
2 Red zone

7-49
 COOLING SYSTEM ELEC
Thermo-unit Inspection
1. Remove:

Top cover

Cover (right)

Thermo-unit 1

WARNING:
Handle the thermo-unit with special care.
Never subject it to strong shock or allow it to
be dropped. Should it be dropped, it must be
replaced.

2. Inspect:

Thermo-unit operation

Thermo-unit inspection steps:

Immerse thermo-unit in water.

1 Temperature gauge
2 Thermo-unit
3 Pocket Tester
4 Water

Check continuity at indicated

Note temperatuers while heating the water.
Malfunction
Replace switch

Water 50C 80C 100C

Temperature (122F) (176F) (212F)
47.5
26.2

Resistance 153.9 Ω
56.8 Ω 29.3 Ω
3. Install:

Thermo-unit

Thermo-unit:
15 Nm (1.5 m
kg, 11 ft
lb)
Three Bond Sealock #10

CAUTION:
After replacing the thermo-unit, check the
coolant level in the radiator and also check
for any leakage.

7-50
 FUEL PUMP SYSTEM ELEC

FUEL PUMP SYSTEM

CIRCUIT DIAGRAM

7-51
 FUEL PUMP SYSTEM ELEC
Aforementioned circuit diagram shows fuel pump circuit in wiring diagram.

NOTE:
For the encircled numbers and color codes, see page 7-2.

14 “FUEL” indicator light

15 Fuel sender unit
47 Main fuse
48 Battery
51 Main switch
52 Fuse (IGNITION)
53 “ENGINE STOP” switch
59 “FUEL” (RESERVE) switch
60 Fuel pump relay
61 Fuel pump

7-52
 FUEL PUMP SYSTEM ELEC
FUEL PUMP CIRCUIT OPERATION 1 Fuel pump relay
The fuel pump circuit consists of the fuel pump 2 Fuel pump
relay, fuel pump, and fuel reserve switch. 3 Fuel reserve switch in “RES” position
The fuel pump starts and stops as indicated in 4 Fuel reserve switch in “ON” position
the chart below. 5 Ignitor unit
6 “FUEL” indicator light
7 Fuel sender in “FULL” position
8 Fuel sender in “EMPTY” position
9 Engine stop switch
10 Main switch
11 To main fuse and battery

FUEL PUMP
START STOP

Main/Engine stop
Engine turned on
Fuel warning
Engine turned off
switch turned to indicator light
“ON” comes on

Fuel reserve switch
turned to “RES”
For about 5 seconds After about After about After about
when carburetor fuel 0.1 second 30 seconds 5 seconds
level is low

7-53
 FUEL PUMP SYSTEM ELEC
TROUBLESHOOTING
Troubleshooting Chart (1)

Fuel pump fails to operate after engine is

started.

More than 11 V
Start the engine and the fuel pump input volt-
Check fuel pump, replace if necessary.
age (Blue/Black lead).

Less than 11 V
OK
Check ignitor unit output voltage condition Check fuel pump relay ground lead.
(Gray lead) by testing No.2 (Rear) cylinder
minimum spark gap. (Refer to Ignition System OK NO
Troubleshooting.)
Check fuel pump Correct.
relay, replace if nec-
NO essary.

12 V
Measure ignitor unit input voltage (Red/
Replace ignitor unit.
White lead).

No voltage

Check engine stop/main switch, main fuse

and battery.

Faulty and/or discharge

Replace faulty parts and/or charge battery.

7-54
 FUEL PUMP SYSTEM ELEC
Troubleshooting chart (2)

Fuel pump fails to operate for a 5 second interval when carburetor fuel level is low with the
main/engine stop switches turned to “ON” and fuel reserve switch turned to “RES”.

More than 11 V
Check fuel pump, replace if necessary.
Stop the engine and turn on the main/engine
stop switches and measure the fuel pump in- More than 11 V More than 11 V
put voltage (Blue/Black lead).
Turn the fuel reserve switch to “RES” and
measure the fuel pump input voltage
(Blue/Black lead).
Less than 11 V
Less than 11 V

Measure pump relay No voltage Check main/engine No voltage Measure fuel pump
input voltage (Red/ stop switches, main relay input voltage
White lead). fuse, and battery. (Red/Green lead).

No voltage
12 V 12 V
Check reserve switch,
replace if necessary.

Check fuel pump relay ground lead.

OK No

Replace fuel pump relay. Correct ground lead.

7-55
 FUEL PUMP SYSTEM ELEC
Troubleshooting Chart (3)

Fuel pump does not stop after 30 seconds when fuel indicater light comes on while engine is
running.

No voltage
Start the engine and measure the fuel pump
Check fuel pump connections correct if nec-
input voltage 30 seconds after fuel sender
essary.
Green lead is grounded (Blue/Black lead).

More than 11 V

Check fuel sender unit resistance. No

Fuel sender unit resistance: Replace.
0.7
1.1 kΩ at 20
C (68
F)

OK
No
Check fuel pump relay ground lead. Correct ground lead.

OK

Replace fuel pump relay.

7-56
FUEL PUMP SYSTEM ELEC
“FUEL” (RESERVE) SWITCH TEST
Switch 1 may be checked for continuity with a
Pocket Tester (90890-03112) on the “Ohm 1”
position.
Lead Color
Switch Position
R/W B/G
OFF
ON
FUEL PUMP RELAY TEST
1. Remove:

Top cover

Cover (left)
2. Check:

Fuel pump operation
Refer to “FUEL PUMP TEST” section.
3. Measure:

Battery voltage
Use the Pocket Tester (90890-03112).
Out of specification
Replace relay.
Main and engine stop switches are “ON”
position.

Fuel Pump Relay Input Voltage:

12 V

1 Red/ White
2 Black

FUEL PUMP TEST

Operation
The diaphragm is pulled left by the plunger al-
lowing fuel to be sucked into the fuel chamber.
Fuel is pushed out from the pump until carb float
chamber is filled with fuel, and then the cut-off
switch cuts off the circuit.
When the spring pushes the diaphragm further
to the end, the cut-off switch turns on and the
solenoid coil pulls the plunger with the dia-
phragm forcing fuel into the fuel chamber.

NOTE:
When the main and engine stop switches are
ON, the fuel pump relay is activated for five (5)
seconds at which time the fuel pump operates.

7-57
FUEL PUMP SYSTEM ELEC

1 Cut-out switch
2 Spring
3 Diaphragm
4 Plunger
5 Solenoid coil
6 Fuel chamber
7 Valve
8 Outlet
9 Inlet
Inspection
1. Connect:

Battery (12 V)
2. Check:

Fuel pump operation
Faulty operation
Replace.
3. Inspect:

Fuel pump
Cracks/Damage
Replace.
FUEL SENDER UNIT TEST
1. Remove:

Seat

Top cover
2. Measure:

Fuel sender unit resistance
Out of specification
Replace.

Fuel Sender Unit Resistance:

0.7
1.1 kΩ at 20C (68F)

1 Green 2 Black

7-58
 APPX

CHAPTER 8.
APPENDICES
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

DEFINITION OF UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

WIRING DIAGRAM
APPX
 SPECIFICATIONS APPX

APPENDICES
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model VMX12
Model Code Number 2EN
Engine Starting Number 2EN-000101
Frame Starting Number 2EN-000101
Dimensions:
Overall Length 2,300 mm (90.6 in)
Overall Width 2,795 mm (31.3 in)
Overall Height 1,160 mm (45.7 in)
Seat Height 2,765 mm (30.1 in)
Wheelbase 1,590 mm (62.6 in)
Minimum Ground Clearance 2,145 mm (25.7 in)
Basic Weight:
Weight Oil and Full Fuel Tank 281 kg (619 lb)
Minimum Turning Radius: 2,800 mm (110.2 in)
Engine:
Engine Type Liquid cooled 4-stroke gasoline, DOHC
Cylinder Arrangement V-4 cylinder
Displacement 1,198 cm3
Bore
Stroke 76
66 mm (2.992
2.598 in)
Compression Ratio 10.5 : 1
Compression Pressure 1,422 kPa (14.5 kg/cm2, 206 psi)
Starting System Electric starter
Lubrication System: Wep sump
Oil Type or Grade:
Engine Oil

SAE 20 W 40 type SE motor oil

(If temperature does not go below 5
C (40
F))
SAE 10 W 30 type SE motor oil
(If temperature does not go above 15
C (60
F))

Final Gear Oil SAE 80 API “GL-4” Hypoid gear oil

Oil Capacity:
Engine Oil:
Periodic Oil Change 3.5 L (3.1 Imp qt, 3.7 US qt)
With Oil Filter Replacement 3.8 L (3.3 Imp qt, 4.0 US qt)
Total Amount 4.7 L (4.1 Imp qt, 5.0 US qt)
Final Gear Case:
Total Amount 0.2 L (0.18 Imp qt, 0.21 US qt)
Radiator Capacity:
(Including All routes) 3.05 L (2.69 Imp qt, 3.22 qt)
Air Filter: Dry type element
Fuel:
Type Regular gasoline
Tank Capacity:
Total 15.0 L (3.3 Imp gal, 4.0 US gal)
Reserve 3.0 L (0.66 Imp gal, 0.80 US gal)

8-1
 SPECIFICATIONS APPX

Model VMX12
Carburetor:
Type/Manufacturer BDS35 4/MIKUNI
Spark Plug:
Type/Manufacturer DPR8EA-9/NGK, X24EPR-U9/NIPPONDENSO
Gap 0.8 X 0.9 mm (0.031 X 0.035 in)
Clutch Type: Wet, multiple-disc
Transmission:
Primary Reduction System Spar gear
Primary Reduction Ratio 87/49 (1.775)
Secondary Reduction System Shaft drive
Secondary Reduction Ratio 21/27 33/9 (2.851)
Transmission Type Constant mesh, 5-speed
Operation Left foot operation
Gear Ratio:
1st 43/17 (2.529)
2nd 39/22 (1.772)
3rd 31/23 (1.347)
4th 28/26 (1.076)
5th 26/28 (0.928)
Chassis:
Frame Type Double cradle
Caster Angle 29

Trail 119 mm (4.7 in)
Tire:
Type Tubeless
Size (F) 110/90 V 18
DUNLOP F20
Size (R) 150/90 V 15
DUNLOP K525
Wear Limit 1.0 mm (0.04 in)
Tire Pressure (Cold Tire):
Basic Weight:
With Oil and Full Fuel Tank 281 kg (619 lb)
Maximum Load* 218 kg (481 lb)
C
Cold Tire Pressure: FRONT REAR
Up to 90 kg (198 lb) Load* 235 kPa 255 kPa
(2.4 kg/cm2, 34 psi) (2.6 kg/cm2, 36 psi)
90 kg (198 lb)* X Maximum Load* 235 kPa 275 kPa
(2.4 kg/cm2, 34 psi) (2.8 kg/cm2, 40 psi)
High Speed Riding 235 kPa 255 kPa
(2.4 kg/cm2, 34 psi) (2.6 kg/cm2, 36 psi)
* Load is the total weight of cargo, rider,
passenger, and accessories.
Brake:
Front Dual disc brake
Operation Right hand operation
Rear Single disc brake
Operation Right foot operation
Suspension:
Front Suspension Telescopic fork
Rear Suspension Swing arm

8-2
 SPECIFICATIONS APPX

Model VMX12
Shock Absorber:
Front Shock Absorber Air/Coil spring, Oil damper
Rear Shock Absorber Coil spring, Oil damper
Wheel Travel:
Front Wheel Travel 140 mm (5.5 in)
Rear Wheel Travel 100 mm (3.9 in)
Electrical:
Ignition System T.C.I.
Generator System A.C. magneto generator
Battery Type or Model YB16AL-A2
Battery Capacity 12 V 16 AH
Headlight Type: Bulb type (Quartz bulb)
Bulb Wattage Quantity:
Headlight 12 V, 60 W/55 W 1
Tail/Brake Light 12 V, 5 W/21 W 2
Flasher Light 12 V, 21 W 4
Auxiliary Light 12 V, 4 W 1
Indicator Light:
“NEUTRAL” 12 V, 3 W 1
“HIGH BEAM” 12 V, 3 W 1
“OIL LEVEL” 12 V, 3 W 1
“TURN” 12 V, 3 W 1
“FUEL” 12 V, 3 W 1
Meter Light 12 V, 3 W 4
MAINTENANCE SPECIFICATIONS
Engine
Model VMX12
Cylinder Head:
Warp Limit* 0.03 mm (0.0012 in)
* Lines indicate straightedge measurement

Cylinder:
Bore Size/Measuring Point* 75.967 X 76.016 mm (2.991 X 2.993 in)/
40 mm (1.57 in)
Out of Roung Limit 0.05 mm (0.002 in)
Camshaft:
Drive Method Chain drive (Center)
Cam Cap Inside Dia. 25.000 X 25.021 mm (0.9843 X 0.9851 in)
Camshaft Outside Dia. 24.967 X 24.980 mm (0.9830 X 0.9835 in)
Shaft-to-Cap Clearance 0.020 X 0.054 mm (0.0008 X 0.0021 in)
Cam Dimensions
Intake “A” 35.75 X 35.85 mm (1.407 X 1.411 in)
<Limit> 35.65 mm (1.404 in)
Intake “B” 27.95 X 28.05 mm (1.100 X 1.104 in)
<Limit> 26.95 mm (1.061 in)
Exhaust “A” 35.75 X 35.85 mm (1.407 X 1.411 in)
<Limit> 35.65 mm (1.404 in)
Exhaust “B” 27.95 X 28.05 mm (1.100 X 1.104 in)
<Limit> 26.95 mm (1.061 in)

8-3
 SPECIFICATIONS APPX

Model VMX12
Camshaft Runout Limit 0.03 mm (0.0012 in)

Cam Chain:
Cam Chain Type/No. of Links DID219FTS/118
Cam Chain Adjustment Method Automatic
Valve, Valve Seat, Valve Guide:
Valve Clearance (Cold): IN. 0.11 X 0.15 mm (0.004 X 0.006 in)
EX. 0.26 X 0.30 mm (0.010 X 0.012 in)
Valve Dimensions:

“A” Head Dia. IN. 30.4 X 30.6 mm (1.197 X 1.205 in)

EX. 24.9 X 25.1 mm (0.980 X 0.988 in)
“B” Face Width IN. 1.6 X 3.1 mm (0.063 X 0.122 in)
EX. 1.3 X 2.4 mm (0.051 X 0.095 in)
“C” Seat Width IN. 0.9 X 1.1 mm (0.035 X 0.043 in)
EX. 0.9 X 1.1 mm (0.035 X 0.043 in)
<Limit> IN. 1.4 mm (0.055 in)
EX. 1.4 mm (0.055 in)
“D” Margin Thickness IN. 1.1 X 1.5 mm (0.043 X 0.059 in)
EX. 1.1 X 1.5 mm (0.043 X 0.059 in)
<Limit> IN 0.7 mm (0.028 in)
EX. 0.7 mm (0.028 in)
Stem Outside Dia. IN. 5.475 X 5.490 mm (0.2156 X 0.2161 in)
EX. 5.460 X 5.475 mm (0.2150 X 0.2156 in)
<Limit> IN. 5.445 mm (0.214 in)
EX. 5.420 mm (0.213 in)
Guide Inside Dia. IN. 5.500 X 5.512 mm (0.2165 X 0.2170 in)
EX. 5.500 X 5.512 mm (0.2165 X 0.2170 in)
<Limit> IN. 5.550 mm (0.219 in)
EX. 5.550 mm (0.219 in)
Stem-to-Guide Clearance IN. 0.010 X 0.037 mm (0.0004 X 0.0015 in)
EX. 0.025 X 0.052 mm (0.0010 X 0.0020 in)
<Limit> IN. 0.08 mm (0.0031 in)
EX. 0.10 mm (0.0039 in)
Stem Runout Limit 0.01 mm (0.0004 in)

8-4
 SPECIFICATIONS APPX

Model VMX12
Valve Spring:
Inner Spring:
Free Length IN. 39.65 mm (1.561 in)
EX. 39.65 mm (1.561 in)
<Limit> IN. 37.45 mm (1.474 in)
EX. 37.45 mm (1.474 in)
Set Length (Valve Closed) IN. 31.8 mm (1.25 in)
EX. 31.8 mm (1.25 in)
Compressed Pressure (Installed) IN. 6.29 X 7.39 kg (13.9 X 16.3 lb)
EX. 6.29 X 7.39 kg (13.9 X 16.3 lb)
Tilt Limit* IN. 2.5
/1.7 mm (0.067 in)
EX. 2.5
/1.7 mm (0.067 in)

Direction of Winding IN. Counterclockwise

EX. Counterclockwise
Outer Spring:
Free Length IN. 41.10 mm (1.618 in)
EX. 41.10 mm (1.618 in)
<Limit> IN. 38.90 mm (1.531 in)
EX. 38.90 mm (1.531 in)
Set Length (Valve Closed) IN. 33.8 mm (1.331 in)
EX. 33.8 mm (1.331 in)
Compressed Pressure (Installed) IN. 13.3 X 15.7 kg (29.3 X 34.6 lb)
EX. 13.3 X 15.7 kg (29.3 X 34.6 lb)
Tilt Limit* IN. 2.5
/1.8 mm (0.071 in)
EX. 2.5
/1.8 mm (0.071 in)

Direction of Winding IN. Clockwise

EX. Clockwise
Piston:
Piston Clearance 0.055 X 0.075 mm (0.0022 X 0.0030 in)
<Limit> 0.15 mm (0.0059 in)
Piston Size “D” 75.905 X 75.955 mm (2.9884 X 2.9903 in)
Measuring Point “H” 6.2 mm (0.244 in)

8-5
 SPECIFICATIONS APPX

Model VMX12
Oversize: 1st 76.25 mm (3.002 in)
2nd 76.50 mm (3.012 in)
Piston Ring:
Top ring:
Type Barrel
Dimensions (B T) 3.1 1.0 mm (0.122 0.040 in)
End Gap (Installed) 0.35 X 0.50 mm (0.0138 X 0.0197 in)
<Limit> 0.75 mm (0.0295 in)
Side Clearance (Installed) 0.03 X 0.07 mm (0.0012 X 0.0028 in)
<Limit> 0.12 mm (0.0047 in)
2nd Ring:
Type Taper
Dimensions (B T) 3.1 1.2 mm (0.122 0.047 in)
End Gap (Installed) 0.35 X 0.50 mm (0.0138 X 0.0197 in)
<Limit> 0.75 mm (0.0295 in)
Side Clearance 0.02 X 0.06 mm (0.0008 X 0.0024 in)
<Limit> 0.12 mm (0.0047 in)
Oil Ring:
Dimensions (B T) 3.1 2.5 mm (0.122 0.098 in)
End Gap (Installed) 0.2 X 0.8 mm (0.0080 X 0.032 in)
Connecting Rod:
Oil Clearance 0.021 X 0.039 mm (0.0008 X 0.0015 in)
Bearing Color Code 1. Blue 2. Black 3. Brown 4. Green
5. Yellow 6. Pink
Crankshaft:

Runout Limit “C” 0.03 mm (0.0012 in)

Big End Side Clearance “D” 0.320 X 0.924 mm (0.0126 X 0.0364 in)
Journal Oil Clearance 0.020 X 0.038 mm (0.0008 X 0.0015 in)
Bearing Color Code 1. Blue 2. Black 3. Brown 4. Green
5. Yellow 6. Pink 7. Red
Clutch:
Friction Plate: Thickness 2.9 X 3.1 mm (0.114 X 0.122 in)
Quantity 8 pcs.
Wear Limit 2.8 mm (0.11 in)
Clutch Plate: Thickness 2.2 X 2.4 mm (0.087 X 0.095 in)
Quantity 7 pcs.
Warp Limit 0.2 mm (0.008 in)
Clutch Spring: Free Height 7.0 mm (0.28 in)
Quantity 1 pc.
Minimum Height 6.5 mm (0.26 in)
Warp Limit 0.1 mm (0.004 in)
Push Rod Bending Limit 0.5 mm (0.02 in)
Transmission:
Main Axle Deflection Limit 0.08 mm (0.0031 in)
Drive Axle Deflection Limit 0.08 mm (0.0031 in)

8-6
 SPECIFICATIONS APPX

Model VMX12
Shifter:
Shifter Type Guide Bar
Guide Bar Bending Limit 0.025 mm (0.001 in)
Carburetor:
I.D. Mark 2EN00
Main Jet (M.J.) #1 & 3 : #152.5 #2 & 4 : #150
Main Air Jet (M.A.J.) ø2.0
Jet Needle (J.N.) 5EZ47-3
Needle Jet (N.J.) Y-0
Pilot Jet (P.J.) #37.5
Pilot Air Jet (P.A.J. 1) #90
(P.A.J. 2) #160
Pilot Screw (P.S.) 2
Pilot Outlet (P.O.) 0.9
Bypass (B.P. 1) 0.8
(B.P. 2) 0.8
(B.P. 3) 0.9
Valve Seat Size (V.S.) 1.5
Starter Jet (G.S. 1) #45
(G.S. 2) #0.8
Fuel Level 15.5 X 16.5 mm (0.61 X 0.65 in)
Engine Idling Speed 950 X 1,050 r/min
Vacuum Pressure at Idling Speed Above 170 mm Hg (6.69 in Hg)
Vacuum Synchronous Difference Below 20 mm Hg (0.79 in Hg)
Fuel Pump:
Type Electrical type
Consumption Amperage (Max.) 1.0 A
Out-put Pressure 16.2 X 20.1 kPa
(0.165 X 0.205 kg/cm2, 2.35 X 2.92 psi)
Lubrication System:
Oil Filter Type Paper type
Oil Pump Type: Trochoid type
Tip Clearance 0 X 0.12 mm (0 X 0.0047 in)
<Limit> 0.17 mm (0.0067 in)
Side Clearance 0.03 X 0.08 mm (0.0012 X 0.0031 in)
<Limit> 0.08 mm (0.0031 in)
Bypass Valve Setting Pressure 167 X 235 kPa (1.7 X 2.4 kg/cm2, 24 X 34 psi)
Relief Valve Operating Pressure 432 X 549 kPa (4.4 X 5.6 kg/cm2, 63 X 80 psi)

8-7
 SPECIFICATIONS APPX

Model VMX12
Lubrication Chart:

Camchain chamber
Intake camshaft Lifter Valve
Cylinder head
(Rear)
Exhaust camshaft Lifter Valve

Piston Piston
Balancer shaft
Connecting rod Connecting rod (Thrust)
#1, #3 #2, #4
Crankshaft Balancer shaft
(Thrust) (Right
Left)
Crankshaft
One-way
clutch Water pump
Main gallery
Crankcase
Main axle cover
Shift cam
(Gears) Oil
Drive axle Bypass valve
filter

Drain Middle gear

bolt Oil pump assembly
Trocoid
pump Relief valve Trocoid
pump
(Feed) (Scavenger)

Oip pan Oil strainer Drain bolt

Crankcase Tightening Sequence:

Upper Case
Lower Case

: With washer

8-8
 SPECIFICATIONS APPX

Model VMX12
Cooling System:
Radiator Core Size: Width 363.8 mm (14.3 in)
Height 240 mm (9.45 in)
Thickness 16 mm (0.63 in)
Radiator Cap Opening Pressure 73.6 X 103.0 kPa
(0.75 X 1.05 kg/cm2, 10.7 X 14.9 psi)
Reservoir Tank Capacity 0.3 L (0.26 Imp qt, 0.32 US qt)
<Front Low to Full Level> 0.2 L (0.18 Imp qt, 0.21 US qt)
Water Pump:
Type Single-suction centrifugal pump
Reduction Ratio 31/21 (1.476)
Shaft Drive:
Middle Gear Backlash 0.05 X 0.12 mm (0.002 X 0.005 in)
<Limit> 0.3 mm (0.012 in)
Final Gear Backlash 0.1 X 0.2 mm (0.004 X 0.008 in)
<Limit> 0.3 mm (0.012 in)
Ring Gear Stopper Clearance 0.30 X 0.60 mm (0.012 X 0.024 in)

8-9
 SPECIFICATIONS APPX
TIGHTENING TORQUE
Tightening torque
Part to be tightened Part name Thread size Q’ty
Q ty Remarks
Nm mSkg ftSlb
Camshaft Cap Bolt M6
1.0 32 10 1.0 7.2
Spark Plug – M12
1.25 4 17.5 1.75 12.5
Cylinder Head Nut M10
1.25 16 43 4.3 31
Cylinder Head Cover Bolt M6
1.0 16 10 1.0 7.2
Connecting Rod Bolt M8
0.75 8 36 3.6 25
AC Magneto Rotor Bolt M12
1.25 1 130 13.0 94
Cam Sprocket Flange bolt M7
1.0 8 24 2.4 17
Plate (Damper chain) Flange bolt M8
1.25 1 24 2.4 17
Tensioner Bolt M6
1.0 4 12 1.2 8.7
Tensioner Stopper Bolt Bolt M16
1.0 2 20 2.0 14
Water Pump Cover Bolt M6
1.0 6 10 1.0 7.2
Water Pump Housing Bolt M6
1.0 3 10 1.0 7.2
Coolant Drain Plug Bolt M14
1.5 1 43 4.3 31
Thermostatic Valve Housing Bolt M6
1.0 2 10 1.0 7.2
Thermostatic Valve Cover Screw M6
1.0 2 7 0.7 5.1
Electric Fan Motor Screw with M5
0.8 3 4 0.4 2.9
washer
Electric Fan Nut M5
0.8 1 4 0.4 2.9
Radiator Assembly Bolt with M6
1.0 4 7 0.7 5.1
washer
Breather Cover Bolt M6
1.0 10 10 1.0 7.2
Radiator Cover Screw M5
0.8 4 4 0.4 2.9
Cover (Left and right) Screw M5
0.8 4 4 0.4 2.9
Conduit Screw M6
1.0 6 7 0.7 5.1
Oil Pump Cover Screw M6
1.0 6 7 0.7 5.1
Oil Strainer Housing Screw M6
1.0 3 7 0.7 5.1
Oil Pump Bolt M6
1.0 3 10 1.0 7.2
Oil Filter Cover Union bolt M20
1.5 1 32 3.2 23
Engine Oil Drain Bolt Bolt M14
1.5 1 43 4.3 31
Oil Pan Bolt M6
1.0 12 10 1.0 7.2
Oil Baffle Plate Flange bolt M6
1.0 2 12 1.2 8.7
Oil Delivery Pipe (Lower) Union bolt M8
1.25 2 18 1.8 13
Oil Delivery Pipe (Upper) Union bolt M10
1.25 1 20 2.0 14
Oil Delivery Pipe (4) Flange bolt M6
1.0 2 12 1.2 8.7
Oil Pipe Union bolt M8
1.25 1 18 1.8 13
Stay 1 Flange bolt M6
1.0 1 12 1.2 8.7
Carburator Joint Bolt M6
1.0 8 10 1.0 7.2
Fuel Pump Flange bolt M6
1.0 2 12 1.2 8.7
Exhaust Pipe (#1, #3) & Joint Bolt M6
1.0 2 7 0.7 5.1
Exhaust Pipe Connection Bolt M8
1.25 1 20 2.0 14
Exhaust Pipe Flange Nut M8
1.25 8 20 2.0 14
Bolt M5
0.8 6 7 0.7 5.1
Exhaust Cover Screw M5
0.8 4 4 0.4 2.9
Muffler Stay Bolt M6
1.0 2 10 1.0 7.2
Muffler Bolt M10
1.25 3 25 2.5 18
Exhaust and Chamber Bolt M8
1.25 4 20 2.0 14

8-10
 SPECIFICATIONS APPX

Tightening torque
Part to be tightened Part name Thread size Q’ty Remarks
Nm mSkg ftSlb
Crankcase Bolt M6
1.0 10 12 1.2 8.7
Crankcase Bolt M8
1.25 19 24 2.4 17
Crankcase Bolt M10
1.25 8 40 4.0 29
Drive Axle Bearing Retainer Torx screw M8
1.25 4 25 2.5 18 Stake
Main Axle Bearing Retainer Screw M6
1.0 3 7 0.7 5.1
Crankcase Cover (Left) Bolt M6
1.0 11 10 1.0 7.2
Lead Clamp Screw M6
1.0 2 7 0.7 5.1
Crankcase Cover (Right) Bolt M6
1.0 6 10 1.0 7.2
Middle Gear Case Cover Bolt M6
1.0 9 10 1.0 7.2
Middle Gear Oil Drain Bolt Bolt M8
1.25 1 38 3.8 27
Starter One-way Clutch Bolt M8
1.25 3 24 2.4 17
Clutch Boss Nut M20
1.0 1 70 7.0 50 Use lock washer
Clutch Release Cylinder Special M6
1.0 2 12 1.2 8.7
Clutch Pressure Plate Bolt M6
1.0 6 8 0.8 5.8
Middle Drive Gear Nut M44
1.5 1 110 11 80 Stake
Middle Drive Shaft Self-lock nut M14
1.5 1 90 9.0 65
Middle Drive Shaft Bearing Bolt M8
1.25 3 30 3.0 22
Housing
Shift Cam Segment Screw M6
1.0 1 12 1.2 8.7
Shift Cam Plate (Neutral) Screw M5
0.8 1 4 0.4 2.9
Shift Calm Bearing Stopper Screw M6
1.0 3 7 0.7 5.1
Change Lever Adjuster Screw M8
1.25 1 22 2.2 16 Use lock washer
Shift Cam Stopper Lever Screw with M6
1.0 1 8 0.8 5.8
washer
Change Pedal Adjuster Lock Nut M6
1.0 4 10 1.0 7.2
Change Pedal / Linkage Bolt M6
1.0 3 10 1.0 7.2
Pinch Bolt
Thermostatic Switch – – 1 15 1.5 11 Apply Sealant
Thermo-unit – – 1 15 1.5 11 Apply Sealant
Neutral Switch Screw M5
0.8 3 4 0.4 2.9
Starter Motor Flange bolt M6
1.0 2 10 1.0 7.2
Oil Level Switch Bolt with M6
1.0 2 10 1.0 7.2
washer
ACM Stator Screw M6
1.0 3 7 0.7 5.1
Pick-up Coil Screw M6
1.0 4 7 0.7 5.1
Bearing Housing Nut M8
1.25 6 23 2.3 17
Flange-bolt M10
1.25 2 40 4.0 29
Bearing Retainer Retainer M65
1.5 1 110 11.0 80
Coupling Gear Nut M14
1.5 1 110 11.0 80
Final Gear Filler Bolt Bolt M14
1.5 1 23 2.3 17
Final Gear Drain Bolt Bolt M14
1.5 1 23 2.3 17

8-11
 SPECIFICATIONS APPX
Chassis
Model VMX12
Steering System:
Steering Bearing Type Taper roller bearing
Front Suspension:
Front Fork Travel 140 mm (5.51 in)
Fork Spring Free Length 492.5 mm (19.4 in)
<Limit> 487.5 mm (19.2 in)
Collar Length 136 mm (5.35 in)
Spring Rate: K1 3.92 N/mm (0.4 kg/mm, 22.4 lb/in)
K2 4.90 N/mm (0.5 kg/mm, 28.0 lb/in)
Stroke: K1 0 X 78 mm (0 X 3.07 in)
K2 78 X 140 mm (3.07 X 5.51 in)
Optional Spring No.
Oil Capacity 451 cm3 (15.9 Imp oz, 15.3 US oz)
Oil Level 139 mm (5.5 in)
Oil Grade Fork oil 10 wt or equivalent
Enclosed Air Pressure (Standard) 39.2 kPa (0.4 kg/cm2, 5.7 psi)
<Min. X Max.> 39.2 X 98.1 kPa
(0.4 X 1.0 kg/cm2, 5.7 X 14.2 psi)
Rear Suspension:
Shock Absorber Travel 85 mm (3.35 in)
Spring Free Length 245.5 mm (9.67 in)
<Limit> 240.5 mm (9.47 in)
Fitting Length 217.5 mm (8.56 in)
Spring Rate: K1 19.1 N/mm (1.95 kg/mm, 109 lb/in)
K2 26.5 N/mm (2.7 kg/mm, 151 lb/in)
Stroke: K1 0 X 50 mm (0 X 1.97 in)
K2 50 X 85 mm (1.97 X 3.35 in)
Optional Spring No.
Rear Arm:
Swingarm Free Play Limit: End Zero mm (Zero in)
Side Zero mm (Zero in)
Front Wheel:
Type Cast wheel
Rim Size MT2.15 18
Rim Material Aluminum
Rim Runout Limit: Vertical 2 mm (0.08 in)
Lateral 2 mm (0.08 in)
Rear Wheel:
Type Cast wheel
Rim Size MT3.50 15
Rim Material Aluminum
Rim Runout Limit: Vertical 2 mm (0.08 in)
Lateral 2 mm (0.08 in)
Front Disc Brake:
Type Dual
Disc Outside Diameter Thickness 282 7.5 mm (11.1 0.30 in)
Pad Thickness Inner 5.5 mm (0.22 in)
<Limit>* 0.5 mm (0.02 in)
Pad Thickness Outer 5.5 mm (0.22 in)
<Limit>* 0.5 mm (0.02 in)

8-12
 SPECIFICATIONS APPX

Model VMX12
Master Cylinder Inside Diameter 15.87 mm (0.63 in)
Caliper Cylinder Inside Diameter 45.4 mm (1.79 in)
Brake Fluid Type DOT #3
Rear Disc Brake:
Type Single
Disc Outside Diameter Thickness 282 7.5 mm (11.1 0.30 in)
Pad Thickness Inner 5.5 mm (0.22 in)
<Limit>* 0.5 mm (0.02 in)
Pad Thickness Outer 5.5 mm (0.22 in)
<Limit>* 0.5 mm (0.02 in)

Master Cylinder Inside Diameter 12.7 mm (0.50 in)

Caliper Cylinder Inside Diameter 42.85 mm (1.69 in)
Brake Fluid Type DOT #3
Clutch:
Master Cylinder Inside Diameter 15.87 mm (0.63 in)
Release Cylinder Inside Diameter 38.1 mm (1.50 in)
Brake Fluid Type DOT #3
Brake Lever and Brake Pedal:
Brake Lever Free Play 2 X 5 mm (0.08 X 0.20 in)
Brake Pedal Position 20 mm (0.8 in)
Brake Pedal Free Play Adjustment not permitted

Recommended combinations of the front fork and the rear shock absorber
Use this table as guidance to meet specific riding conditions and motorcycle load.
Front Fork Rear Shock Absorber Loading Condition
With accessory
Spring Damping Solo With With accessory
Air pressure equipments
seat adjuster rider passenger equipments
and passenger
39.2 X 58.8 kPa
(0.4 X 0.6 kg / cm2, 1 or 2 1 or 2 f
5.7 X 8.5 psi)
39.2 X 98.1 kPa
(0.4 X 1.0 kg / cm2, 3X5 2X4 f f
5.7 X 14.2 psi)
39.2 X 98.1 kPa
(0.4 X 1.0 kg / cm2, 5 4 f
5.7 X 14.2 psi)

8-13
 SPECIFICATIONS APPX
TIGHTENING TORQUE
Tightening torque
Part to be tightened Thread size Remarks
Nm mSkg ftSlb
Front Wheel Axle M14
1.5 60 6.0 43
Front Axle Pinch Bolt M8
1.25 20 2.0 14
Under Bracket & Inner Tube M8
1.25 23 2.3 17
Steering Crown & Inner Tube M8
1.25 20 2.0 14
Steering Crown & Steering Shaft M22
1.0 110 11.0 80
Steering Shaft Ring Nut (Lower) M25
1.0 50 5.0 36
Steering Shaft Ring Nut (Lower) M25
1.0 3 0.3 2.2 Refer to NOTE.
Steering Shaft Ring Nut (Upper) M25
1.0 – – –
Caliper & Front Fork M10
1.25 45 4.5 32 Front
Caliper & Bracket M10
1.25 45 4.5 32 Rear
Caliper & Bleed Screw M8
1.25 5 0.5 3.6
Brake Hose Union Bolt M10
1.25 25 2.5 18
Clutch Hose Union Bolt M10
1.25 25 2.5 18
Brake Hose & Brake Pipe M10
1.0 19 1.9 13
Clutch Hose & Clutch Pipe M10
1.0 19 1.9 13
Front Master Cylinder Cap M4
0.7 1 0.1 0.7 Brake & Clutch
Front Brake Master Cylinder Bracket M6
1.25 9 0.9 6.5
Clutch Master Cylinder Bracket M6
1.25 9 0.9 6.5
Rear Master Cylinder Union Bolt M10
1.25 25 2.5 18
Rear Master Cylinder & Frame M8
1.25 23 2.3 17
Pivot Shaft (Left) & Frame M22
1.5 100 10.0 72
Pivot Shaft (Right) & Frame M25
1.5 6 0.6 4.3
Pivot Shaft (Right) & Locknut M25
1.5 100 10.0 72
Front Fender & Fork Brace M6
1.0 9 0.9 6.5
Handlebar Upper Holder M8
1.25 20 2.0 14
Handlebar Lower Holder M10
1.25 40 4.0 29
Engine Bracket (Front upper) M10
1.25 40 4.0 29
Engine Bracket (Front lower) M10
1.25 40 4.0 29
Engine Bracket (Rear) M12
1.25 70 7.0 50
Engine Stay & Frame M8
1.25 15 1.5 11
Down Tube & Frame M10
1.25 45 4.5 32
Frame and Front Cross Frame M8
1.25 20 2.0 14
Muffler Bracket (Left) & Frame M8
1.25 25 2.5 18
Muffler Bracket (Left) & Back Stay M8
1.25 25 2.5 18
Back Stay & Frame M8
1.25 30 3.0 22
Rear Shock Absorber & Frame M8
1.25 20 2.0 14
Rear Shock Absorber & Swingarm M10
1.25 30 3.0 22
Rear Shock Absorber & Housing Gear M10
1.25 30 3.0 22
Swingarm & Housing Gear M10
1.25 42 4.2 30
Rear Wheel Axle & Nut M18
1.5 120 12.0 85
Footrest Bracket (Left) & Frame M10
1.25 37 3.7 27
Footrest Bracket (Right) & Frame M8
1.25 23 2.3 17

NOTE:
S Ring nut (lower):
1) First, tighten the ring nut approximately 50 Nm (5.0mSkg, 36 ftSlb) by using the torque wrench, then
loosen the ring nut completely.
2) Retighten the ring nut 3 Nm (0.3 mSkg, 2.2 ftSlb).
S Ring nut (upper):
1) Finger tighten the ring nut.
8-14
 SPECIFICATIONS APPX
Electrical
Model VMX12
Voltage: 12 V
Ignition System:
Ignition Timing (B.T.D.C.) 3
at 1,000 r/min
Advanced Timing (B.T.D.C.) 43
at 9,000 r/min
Advancer Type Vacuum and electrical
Ignition timing

10.6 kPa (80 mm Hg, 3.15 in Hg)

(B.T.D.C.)

5.3 kPa (40 mm Hg, 1.57 in Hg)

Engine speed ( 103 r / min)

T.C.I.:
Pickup Coil Resistance (Color) 93.5 X 126.5 Ω at 20
C (68
F)
(Black – Orange) (Black – Gray)
(Black – White/Green) (Black – White/Red)
T.C.I. Unit-Model/Manufacturer TID14-43 /HITACHI
Ignition Coil:
Model/Manufacturer CM11-61/HITACHI
Primary Winding Resistance 2.4 X 3.0 Ω at 20
C (68
F)
Secondary Winding Resistance 10.6 X 15.8 kΩ at 20
C (68
F)
Charging System/Type: A.C. magneto generator
A.C. Generator:
Model/Manufacturer FL130-04 /HITACHI
Nominal Output 14 V, 25 A at 5,000 r/min
Output current (A)

Engine speed ( 103 r / min)

Stator Coil Resistance 0.36 X 0.48 Ω at 20
C (68
F)

8-15
 SPECIFICATIONS APPX

Model VMX12
Voltage Regulator:
Type Short control
Model/Manufacture SH569/SHINDENGEN
No Load Regulated Voltage 14 X 15 V
Rectifier:
Model/Manufacturer SH569/SHINDENGEN
Capacity 25 A
Withstand Voltage 200 V
Battery:
Capacity 12 V, 16 AH
Specific Gravity 1.280
Electric Starter System:
Type Constant mesh type
Starter Motor:
Model/Manufacturer SM-229C/MITSUBA
Out put 0.6 kW
Bush:
Overall Length 12.5 mm (0.49 in)
<Limit> 5.5 mm (0.22 in)
Spring Pressure 560 X 680 g (19.7 X 23.9 oz)
Commutator:
Outside Diameter 28 mm (1.1 in)
<Wear Limit> 27 mm (1.06 in)
Mica Undercut 0.7 mm (0.028 in)
Starter Relay:
Model/Manufacturer A104-128/HITACHI
Amperage Rating 100 A
Coil Winding Resistance 3.9 X 4.7 Ω at 20
C (68
F)
Horn:
Type/Quantity Plain type 1
Model/Manufacturer YF-12/NIKKO
Maximum Amperage 2.5 A
Flasher Relay:
Type Semi transister type
Model/Manufacturer FX257N/NIPPONDENSO
Self Cancelling Device Yes.
Flasher Frequency 75 X 95 cycle/min
Wattage 21 W 2 + 3.4 W
Self Cancelling Unit:
Model/Manufacturer FX257N/NIPPONDENSO
Oil Level Switch:
Model/Manufacturer 1FK/NIPPONDENSO
Fuel Gauge:
Model/Manufacturer 1FK/NIPPONSEIKI
Sender Unit Resistance (Full) 0.7 X 1.1 kΩ at 20
C (68
F)

8-16
 SPECIFICATIONS APPX

Model VMX12
Starting Circuit Cut-off Relay:
Model/Manufacturer G4MW-1121T-100-Y10/TATEISHI
Coil Winding Resistance 203 X 248 Ω at 20
C (68
F)
Diode Yes.
Fuel Pump Relay:
Model/Manufacturer G8D-04Y/OMRON
Coil Winding Resistance 90 X 110 Ω at 20
C (68
F)
Electric Fan:
Model/Manufacturer 26H/NIPPONDENSO
Thermostatic Switch:
Model/Manufacturer 47X/NIPPON THERMOSTAT
Thermo-unit:
Model/Manufacturer 11H/NIPPONSEIKI
Circuit Breaker:
Type Fuse
Amperage for Individual Circuit Quantity:
Main 30 A 1
Headlight 15 A 1
Signal 10 A 1
Ignition 10 A 1
Reserve 30 A 1
15 A 1
10 A 1

8-17
 GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS APPX

GENERAL TORQUE SPECIFI- General torque

CATIONS A B specifications
This chart specifies torque for standard fasten- (Nut) (Bolt)
Nm mSkg ftSlb
ers with standard I.S.O. pitch threads. Torque
10 mm 6 mm 6 0.6 4.3
specifications for special components or as-
semblies are included in the applicable sections 12 mm 8 mm 15 1.5 11
of this book. To avoid warpage, tighten multifas- 14 mm 10 mm 30 3.0 22
tener assemblies in a crisscross fashion, in pro-
gressive stages, until full torque is reached. 17 mm 12 mm 55 5.5 40
Unless otherwise specified, torque specifica- 19 mm 14 mm 85 8.5 61
tions call for clean, dry threads. Components 22 mm 16 mm 130 13.0 94
should be at room temperature.

DEFINITION OF UNITS
Unit Read Definition Measure
mm millimeter 10-3 meter Length
cm centimeter 10-2 meter Length
kg kilogram 103 gram Weight
N Newton 1 kg
m/sec2 Force
Nm Newton meter N
m Torque
mSkg Meter kilogram m
kg Torque
Pa Paskal N/m2 Pressure
N/mm Newton per millimeter N/mm Spring rate
L Liter
– volume or Capacity
cm3 Cubic centimeter
r/min Rotation per minute – Engine speed

8-18
 LUBRICATION DIAGRAMS APPX

LUBRICATION DIAGRAMS
LUBRICATION DIAGRAM (1)

8-19
 LUBRICATION DIAGRAMS APPX
LUBRICATION DIAGRAM (2)

8-20
 LUBRICATION DIAGRAMS APPX
LUBRICATION DIAGRAM (3)

8-21
 LUBRICATION DIAGRAMS APPX
LUBRICATION DIAGRAM (4)

8-22
 CABLE ROUTING APPX

CABLE ROUTING
1 Headlight body 7 Brake joint
2 Hose guide 8 Wireharness
3 Front flasher light lead (Left) 9 Speedometer light lead
4 Clutch hose 10 Front flasher light lead (Right)
5 Speedometer cable 11 Front brake hose
6 Front brake hose

8-23
 CABLE ROUTING APPX
1 Fuel pump control unit 12 Horn lead A Pass the handlebar switch lead
2 Relay unit 13 Clamp inside the clutch hose
3 Clamp 14 Guide (For speedometer cable) B Pass the meter lead outside the
4 Clutch hose clamp 15 Clamp (For brake hose) clutch hose.
5 Throttle cable joint 16 Guide (For throttle cable) C Pass the clutch hose outside the
6 Fuse box 17 Guide (For clutch hose) throttle cable.
7 Band 18 Handlebar switch lead (Left) D Pass the brake hose outside the
8 Ignitor unit speedometer cable.
9 Ignition coil E Pass the clutch hose under the
10 Clamp throttle cable guide.
11 Radiator fan lead

8-24
 CABLE ROUTING APPX
1 Main fuse 10Guide (For clutch hose)
2 Ignition coil 11Clamp
3 Oil level switch lead 12Clamp (For clutch hose)
4 Neutral switch lead 13Starter relay
5 Regulater lead A Pass the band through the guide on frame
6 Rectifier/ Regulater lead on frame.
7 A.C. generator lead
8 Band
9 Clamp

8-25
 CABLE ROUTING APPX
1 Handlebar switch lead 13 Boot cover 25 Fuel pump
2 Diode 14 Taillight lead 26 Fuse box
3 Ignitor unit 15 Rear flasher light lead (Left) 27 Meter lead
4 Ignition coil lead 16 Ignition coil lead A Clamp the taillight lead and rear
5 Conduit lead 17 Pick up coil lead flasher light lead (Right).
6 Band 18 Starter relay lead B Clamp the rear flasher light lead
7 Starter relay 19 Starter motor lead (Left).
8 Battery negative (–) lead 20 Regulater lead
9 Ignition coil 21 Oil level switch lead
10 Ignition coil lead 22 Neutral switch lead
11 Starter relay lead 23 Battery positive (+) lead
12 Fuel filter 24 Main fuse

8-26
 CABLE ROUTING APPX
1 Earth lead 13 Battery negative (–) lead A Pass the wireharness outside
2 Conduit 14 Coolant reservoir tank the main switch stay.
3 Handlebar switch lead (Left) 15 Band B Earth lead:
4 Ignition coil lead 16 Main switch lead Pass the earth lead outside the
5 To conduit 17 Main switch reservoir tank breather hose.
6 Earth lead 18 Rear brake reservoir tank C Guide (For battery breather
7 Rear brake switch lead 19 Battery box hose, reservoir tank breather
8 Battery breather hose 20 Clamp (For battery breather hose and rear brake switch
9 Coolant reservoir tank breather hose) lead).
hose 21 Guide (For reservoir tank
10 Fuel sender lead breather hose and Battery
11 Rear brake switch lead breather hose)
12 Band 22 Rear brake switch

8-27
 CABLE ROUTING APPX
1 Fuel filter bracket 6 Battery band
2 Fuel filter 7 Fuel pump
3 Fuel pipe 8 Clamp
4 Filler cover 9 Fuel pipe
5 Filler cap

8-28
 CABLE ROUTING APPX
1 Reservoir tank 10 Over flow hose
2 Clip 11 Over flow valve
3 Spring 12 Clamp
4 Clip 13 Holder
5 Filler cover 14 Clamp
6 Pipe joint 15 Fuel sender
7 Clip 16 Clamp
8 Drain hose 17 Battery breather hose
9 Band

8-29
APPX
WIRING DIAGRAM
1. Handlebar switch (Left)
2. “PASS” switch
3. Clutch switch
4. “LIGHTS” (Dimmer) switch
5. “HORN” switch
6. “TURN” switch
7. Meter assembly
8. Temperature meter
9. Tachometer
10.Meter light
11. “HIGH BEAM” indicator light
12.“TURN” indicator light
13.“FUEL” warning light
14.“OIL LEVEL” indicator light
15.“NEUTRAL” indicator light
16.Front flasher light (Left)
17.Headlight
18. Auxiliary light
19. Front flasher light (Right)
20.Speedometer
21.Meter light
22.Reed switch
23.Handlebar switch (Right)
24. “LIGHTS” switch
25. “START” switch
26.“ENGINE STOP” switch
27. “FUEL” (Reserve) switch
28.Front brake switch
29.Main switch
30.Ignitor unit
31.Thermo switch
32. Thermo unit
33. Fan
34. Ignition coil
35.Spark plug
36. Fuel sender
37.Rear brake switch
38. Starter motor
39.Starter relay
40. Battery
41.Fuse
42.Main fuse
43.Rear flasher light (Right)
44.Tail/Brake light
45.Rear flasher light (Left)
46.Neutral switch
COLOR CODE 47.Oil level switch
48.Rectifier/Regulator
B Black L Blue Ch Chocolate L/Y Blue/Yellow B/R Black/Red L/R Blue/Red G/Y Green/Yellow 49.A.C. Magneto
50.Pick up coil
P Pink R Red Br Brown B/Y Black/Yellow G/R Green/Red W/G White/Green R/G Red/Green 51.Fuel pump
Y Yellow O Orange Dg Dark green R/Y Red/Yellow Y/R Yellow/Red L/W Blue/White W/R White/Red 52.Fuel pump control unit
53. Pressure sensor
G Green Gy Gray Sb Sky blue Br/W Brown/White L/B Blue/Black R/W Red/White W White 54.Relay unit
55.Diode assembly
56.Horn