AL115C

SERVICE MANUAL

14D-F8197-E0
EAS00000

AL115C
SERVICE
MANUAL
©2007 by Yamaha Motor Co., Ltd.
First edition, July
2007 All rights
reserved.
Any reproduction or unauthorized
use without the written permission of
Yamaha Motor Co., Ltd.
EAS00002

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual.
Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have
a basic understanding of mechanics and the techniques to repair these types of vehicle. Repair and
maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and
unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal- ers and
will appear in future editions of this manual where applicable.

NOTE:
Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

w Failure to follow WARNING instructions could result in severe injury or death to the
vehicle operator, a bystander or a person checking or repairing the vehicle.

cC A CAUTION indicates special precautions that must be taken to avoid damage to the
vehicle.

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

EASF0001

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title
1: This is a chapter with its symbol on the upper right of each page.
2nd title 2: This title appears on the upper of each page on the left of the chapter symbol. (For the
chapter “Periodic checks and adjustments” the 3rd title appears.)
3rd title 3: This is a final title.

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The infor- mation has
been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive
explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of triangle “▲” with each pro- cedure
preceded by alphabetical letters.

IMPORTANT FEATURES
9 Data and a special too are framed in a box preceded by a relevant symbol 5.
9 An encircled numeral 6 indicates a part name, and an encircled alphabetical letter or an align- ment mark
7, the others being indicated by an alphabetical letter in a box 8.
9 A condition of a faulty component will precede an arrow symbol and the course of action required the
symbol 9.

EXPLODED DIAGRAMS
Each chapter provide exploded diagrams before each disassembly section for ease in identifying correct
disassembly and assembly procedures.
EASF0002
1 2
SYMBOLS
GEN
INFO SPEC The following symbols are not relevant to every
vehicle.
Symbols 1 to 8 indicate the subject of each
3 4
chapter.
1 General information

CH ENG 2 Specifications
3 Periodic checks and adjustments
K 4
5
Engine
Carburetor
ADJ 6 Chassis
5 6 7 Electrical system
8 Troubleshooting

CARB CHAS
7 8 Symbols 9 to y indicate the following.
9 Serviceable with engine mounted
– + TRBL 0 Filling fluid
ELEC SHTG q Lubricant
w Special tool
e Tightening torque
9 0
r Wear limit, clearance
t Engine speed
y Electrical data

q w

e r

Symbols u to f in the exploded diagrams

indicate the types of lubricants and lubrication
points.
t y u Engine oil
i Gear oil
o Molybdenum-disulfide oil
p Brake fluid
a Wheel-bearing grease
u i o p s Lithium-soap-based grease d
Molybdenum-disulfide grease f
Silicone grease

E G M BF Symbols g to h in the exploded diagrams

indicate the following.
a s d f ®
g Apply locking agent (LOCTITE )
h Replace the part
B LS M S

g h

LT
New
 TABLE OF
EASF00

GENERAL INFORMATION GEN

INFO 1
SPECIFICATIONS
SPEC 2
PERIODIC CHECKS
AND ADJUSTMENTS CHK
ADJ 3
ENGINE
ENG 4
CARBURETOR
CARB 5
CHASSIS
CHAS 6
ELECTRICAL SYSTEM
– +

ELEC 7
TROUBLESHOOTING TRBL
SHTG 8
GEN INFO

CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION.............................................................................1-1
VEHICLE IDENTIFICATION NUMBER...............................................................1-1
ENGINE SERIAL NUMBER...................................................................................1-1

IMPORTANT INFORMATION...........................................................................1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY....................................1-2
REPLACEMENT PARTS........................................................................................1-2
GASKETS, OIL SEALS AND O-RINGS................................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS................................................1-3
BEARINGS AND OIL SEALS................................................................................1-3
CIRCLIPS................................................................................................................1-3

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

SPECIAL TOOLS..............................................................................................1-5
 GE
INFO
 GEN INFO
VEHICLE IDENTIFICATION
EAS00014

GENERAL INFORMATION
VEHICLE IDENTIFICATION
1 EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is
stamped into the frame.

1 ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the
crankcase.
NOTE:
Designs and specifications are subject to change
without notice.

1-
 GE
IMPORTANT
INFORMATION INFO
EAS00020

IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated parts together. This includes gears, cylin- ders, pistons and other
parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will
speed up assembly and allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.

EAS00021

REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom- mended
by Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.

1-
 GEN INFO
IMPORTANT INFORMATION
EAS00023

LOCK WASHERS/PLATES AND

COTTER PINS
After removal, replace all lock washers/plates 1
and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
1
300-000

EAS00024

BEARINGS AND OIL1SEALS

Install bearings and oil seals so that the man-
ufacturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips with a
light coat of lithium-soap-based grease. Oil
bearings liberally when installing, if appropriate.

300-003
1 Oil seal
cC
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1
1 Bearing

300-002

EAS00025

CIRCLIPS 1
3 Before reassembly, check all circlips carefully and
2 replace damaged or distorted circlips. Always
replace piston pin clips after one use. When
installing a circlip 1, make sure the sharp-edged
4
corner 2 is positioned opposite the thrust 3 that
the circlip receives.
300-001
4 Shaft

1-
 GEN INFO
CHECKING THE CONNECTIONS
EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc.
1. Disconnect:
9 lead
9 coupler
9 connector
2. Check:
9 lead
9 coupler
9 connector
Moisture  Dry with an air blower.
Rust/stains  Connect and disconnect
several times.

3. Check:
9 all connections
1 Loose connection  Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.

4. Connect:
9 lead
9 coupler
9 connector
NOTE:
Make sure all connections are tight.

5. Check:
9 continuity
(with the pocket tester)
Pocket tester
90890-03112

NOTE:
9 If there is no continuity, clean the terminals.
9 When checking the wire harness, perform steps
(1) to (3).
9 As a quick remedy, use a contact revitalizer
available at most part stores.

1-
 GE
SPECIAL N
EAS00027

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the
appropriate special tools as this will help prevent damage caused by the use of inappro- priate tools or
improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/Usage Illustration

Weight
Weight Slide hammer bolt
90890-01084
Slide hammer bolt
90890-01085 These tools are used when removing or
installing the rocker arm shafts.
Fork seal driver weight

90890-01184

This tool is used to installing the oil seal.

Fork seal driver attachment

90890-01186

This tool is used to installing the oil seal.

Flywheel puller

90890-01189
This tool is used for removing the A.C.
magneto rotor.
Rotor holding tool

90890-01235
This tool is used to hold the A.C. mag-
neto rotor when removing or installing
the A.C. magneto rotor nut.
Valve spring compressor
Compressor Valve spring compressor attachment
90890-01253
Attachment
90890-01243 These tools are used when removing or
installing the valve and the valve spring.
Ring nut wrench

90890-01268
This tool is used to loosen and tighten the
steering ring nut.

1-
 GE
SPECIAL N
Tool No. Tool name/Usage Illustration
Tappet adjusting tool

90890-01311
This tool is necessary for adjusting
valve clearance.
Fuel level gauge

90890-01312
This gauge is used to measure the fuel
level in the float chamber.
T-handle

90890-01326
This tool is used for holding the damper rod
holder when removing or installing the
damper rod holder.
Clutch spring holder

90890-01337
This tool is used to disassembly and
assembly the secondary sheave.
Oil seal guide

90890-01384

This tool is used to install oil seals.

Steering nut wrench

90890-01403
This tool is used to loosen and tighten the
steering ring nut.
Socket wrench

90890-01493
This tool is used to loosen and tighten the
clutch carrier locknut of the second- ary
sheave.
Sheave holder

90890-01701
This tool is used for holding the primary
sheave and secondary sheave.

1-
 GE
SPECIAL N
Tool No. Tool name/Usage Illustration
Compression gauge

90890-03081
These tools are used to measure the engine
compression.
Pocket tester

90890-03112
These instruments are invaluable for
checking the electrical system.
Engine tachometer

90890-03113
This tool is needed for detecting engine
rpm.
Flywheel puller

90890-01362
This tool is needed to remove the oil
pump cover.
Valve guide remover (ø5)

90890-04097
This tool is needed to remove and install
the valve guide.
Valve guide installer (ø5)

90890-04098
This tool is needed to install the valve
guide.
Valve guide reamer (ø5)

90890-04099
This tool is needed to rebore the new
valve guide.
Valve lapper

90890-04101

This tool is used for lapping the valve.

1-
 GE
SPECIAL N
Tool No. Tool name/Usage Illustration
Ignition checker

90890-06754
This instrument is necessary for check- ing
the ignition system components.
Yamaha bond No. 1215

90890-85505
This sealant (bond) is used for crank- case
mating surface, etc.

1-
SPEC

CHAPTER 2
SPECIFICATIONS

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

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

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

ELECTRICAL SPECIFICATIONS.................................................................2-13

CONVERSION TABLE.................................................................................2-16

GENERAL TIGHTENING TORQUE SPECIFICATIONS................................2-16

TIGHTENING TORQUES..............................................................................2-17
ENGINE TIGHTENING TORQUES..................................................................2-17
CHASSIS TIGHTENING TORQUES.................................................................2-19

LUBRICATION POINTS AND LUBRICANT TYPES.....................................2-21

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES......................2-21
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES....................2-22

CABLE ROUTING.........................................................................................2-23
SPEC
 SPEC
GENERAL SPECIFICATIONS

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model AL115C
Model code 14D1
Dimensions
Overall length 1,820 mm (71.7 in)
Overall width 675 mm (26.6 in)
Overall height 1,050 mm (41.3 in)
Seat height 745 mm (29.3 in)
Wheelbase 1,240 mm (48.8 in)
Minimum ground clearance Minimum 125 mm (4.92 in)
turning radius 1,800 mm (70.9 in)
Weight
Wet (with oil and full fuel tank) 94 kg (207 lb)
Maximum load* 163 kg (359 lb)
* Total weight of rider, passenger, cargo and
accessories

2-
 ENGINE SPE
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Forced-air-cooled 4-stroke, SOHC ----
Displacement 113.0 cm3 ----
Cylinder arrangement Forward-inclined single cylinder ----
Bore  stroke 50.0  57.9 mm (1.97  2.28 in) ----
Compression ratio 8.8:1 ----
Standard compression pressure 1,100 kPa (11 kgf/cm2 , 156.5 psi) ----
(at sea level) at 510 r/min
Starting system Electric starter and kickstarter ----
Engine idling speed 1,300 ~ 1,500 r/min ----
(New engine at set up)
1,450 ~ 1,650r/min
(After engine brake-in)
Fuel
Recommended fuel Regular gasoline ----
Fuel tank capacity 4.1 L (1.08 Imp gal, 0.90 US gal) ----
Engine oil
Recommended oil SAE 10W30, 10W40, 20W40 or 20W50 ----
API service SG type or higher,
JASO standard MA
Lubrication system Wet sump ----
Engine oil quantity
Periodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt) ----
Total amount 0.9 L (0.79 Imp qt, 0.95 US qt) ----
Final transmission oil
Recommended oil SAE 10W40 ----
API service SG type or higher,
JASO standard MA
Periodic oil change 0.10 L (0.09 Imp qt, 0.11 US qt) ----
Quantity 0.12 L (0.11 Imp qt, 0.13 US qt) ----
Oil pump
Oil filter type Wire mesh ----
Oil pump type Trochoid ----
Inner-rotor-to-outer-rotor-tip- 0.13 ~ 0.18 mm (0.0051 ~ 0.0071 in) 0.23 mm
clearance (0.0091 in)
Outer-rotor-to-oil-pump-housing 0.13 ~ 0.18 mm (0.0051 ~ 0.0071 in) 0.25 mm
clearance (0.0098 in)
Oil pump-housing-to-inner-rotor-and- 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) 0.17 mm
outer-rotor clearance (0.0067 in)
Rotor thickness 7.96 ~ 7.98 mm (0.313 ~ 0.314 in) ----
Spark plug
Type/manufacturer C7HSA/NGK ----
Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) ----

2-
 ENGINE SPE
Item Standard Limit
Cylinder head
Max. warpage “ ” ---- 0.05 mm
(0.0020 in)

Camshaft
Drive system Chain drive (left) ----
Intake camshaft lobe dimensions

B
Measurement A 25.881 ~ 25.981 mm (1.0189 ~ 1.0229 in) 25.780 mm
(1.0150 in)
Measurement B 21.195 ~ 21.295 mm (0.8344 ~ 0.8384 in) 21.095 mm
(0.8305 in)
Exhaust camshaft lobe dimensions

B
Measurement A 25.841 ~ 25.941 mm (1.0174 ~ 1.0213 in) 25.740 mm
(1.0134 in)
Measurement B 21.050 ~ 21.150 mm (0.8287 ~ 0.8327 in) 20.950 mm
(0.8248 in)
Max. camshaft runout ---- 0.03 mm
(0.0012 in)

Timing chain
Timing chain type/No. of links DID SCR-0404 SDH/90 ----

2-
 ENGINE SPE
Item Standard Limit
Rocker arm/rocker arm shaft
Rocker arm inside diameter Rocker 10.000 ~ 10.015 mm (0.3937 ~ 0.3943 in) 10.030 mm
(0.3949 in)
arm shaft outside diameter 9.981 ~ 9.991 mm (0.3930 ~ 0.3933 in) 9.950 mm
(0.3917 in)
Rocker-arm-to-rocker-arm shaft 0.009 ~ 0.034 mm (0.0004 ~ 0.0013 in) 0.08 mm
clearance (0.0031 in)
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) ----
EX 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) ----
Valve dimensions

B C
D
A
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 22.9 ~ 23.1 mm (0.9016 ~ 0.9094 in) ----
EX 19.9 ~ 20.1 mm (0.7835 ~ 0.7913 in) ----
“B” face width IN 1.20 ~ 2.50 mm (0.0472 ~ 0.0984 in) ----
EX 1.30 ~ 2.40 mm (0.0512 ~ 0.0945 in) ----
“C” seat width IN 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.0630 in)
“D” margin thickness IN 0.7 mm (0.0276 in) ----
EX 1.0 mm (0.0394 in) ----
Stem outside diameter IN 4.970 ~ 4.985 mm (0.1957 ~ 0.1963 in) 4.930 mm
(0.1941 in)
EX 4.955 ~ 4.970 mm (0.1951 ~ 0.1957 in) 4.920 mm
(0.1937 in)
Guide inside diameter IN 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in) 5.050 mm
(0.1988 in)
EX 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in) 5.050 mm
(0.1988 in)
Valve stem-to-guide clearance IN 0.015 ~ 0.042 mm (0.0006 ~ 0.0017 in) 0.080 mm
(0.0031 in)
EX 0.030 ~ 0.057 mm (0.0012 ~ 0.0022 in) 0.110 mm
(0.0043 in)
Valve stem runout limit ---- 0.010 mm
(0.0004 in)

2-
 ENGINE SPE
Item Standard Limit
Valve springs
Free length
Intake 35.44 mm (1.40 in) 34.0 mm
(1.34 in)
Exhaust 35.44 mm (1.40 in) 34.0 mm
(1.34 in)
Installed length (valve closed)
Intake 24.1 mm (0.95 in) ----
Exhaust 24.1 mm (0.95 in) ----
Compressed spring force (installed)
Intake 146 ~ 168 N ----
(14.9 ~ 17.1 kgf, 32.8 ~ 37.7 lb)
Exhaust 146 ~ 168 N ----
(14.9 ~ 17.1 kgf, 32.8 ~ 37.7 lb)
Spring tilt

Intake ---- 2.5/1.5 mm

(2.5/0.06 in)
---- 2.5/1.5 mm
Exhaust
(2.5/0.06 in)
Winding direction (top view)
Clockwise ----
Intake
Clockwise ----
Exhaust
Cylinder Measuring
point H Bore 10.0 mm (0.39 in) ----
Max. taper 50.000 ~ 50.010 mm (1.9685 ~ 1.9689 in) ----
---- 0.05 mm
Max. out-of-round H (0.0020 in)
---- 0.05 mm
Warp limit (0.0020 in)
---- 0.03 mm
(0.0012 in)

2-
 ENGINE SPE
Item Standard Limit
Piston
Piston-to-cylinder clearance 0.020 ~ 0.035 mm (0.0008 ~ 0.0014 in) 0.150 mm
(0.0059 in)
Diameter D 49.970 ~ 49.985 mm (1.9673 ~ 1.9679 in) ----

H
D

Height H 5 mm (0.20 in) ----

Piston pin bore (in the piston)
Diameter 15.002 ~ 15.013 mm (0.5906 ~ 0.5911 in) 15.043 mm
(0.5922 in)
Offset 0.5 mm (0.020 in) ----
Offset direction Intake side ----
Piston pin
Outside diameter 14.995 ~ 15.000 mm (0.5904 ~ 0.5906 in) 14.975 mm
(0.5896 in)
Piston-pin-to-piston-pin-bore 0.002 ~ 0.018 mm (0.0001 ~ 0.0007 in) 0.068 mm
clearance (0.0027 in)
Piston rings
Top ring
B
T
Ring type Barrel ----
Dimensions (B  T) 1.00  1.85 mm (0.039  0.073 in) ----
End gap (installed) 0.10 ~ 0.25 mm (0.004 ~ 0.010 in) 0.50 mm
(0.020 in)
Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.12 mm
(0.0047 in)
2nd ring
B
T
Taper ----
Ring type
1.0  2.0 mm (0.039  0.079 in) ----
Dimensions (B  T)
0.10 ~ 0.25 mm (0.004 ~ 0.010 in) 0.60 mm
End gap (installed) (0.024 in)
0.020 ~ 0.060 mm (0.0008 ~ 0.0024 in) 0.11 mm
Ring side clearance (0.0043 in)

2-
 ENGINE SPE
Item Standard Limit
Oil ring
B
T
Dimensions (B  T) 2.00  2.20 mm (0.079  0.087 in) ----
End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ----
Crankshaft

C C

E
D

A
Crank width “A” 45.45 ~ 45.50 mm (1.789 ~ 1.791 in) ----
Max. runout “C” ---- 0.03 mm
(0.0012 in)
Big end side clearance “D” 0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in) ----
Big end radial clearance “E” 0.004 ~ 0.014 mm (0.0002 ~ 0.0006 in) ----
Clutch type V-belt automatic ----
Automatic centrifugal clutch
Clutch shoe thickness 3.0 mm (0.12 in) 1.0 mm
(0.04 in)
Clutch shoe spring free length 30.6 mm (1.20 in) ----
Clutch housing inside diameter 112 mm (4.41 in) 112.5 mm
(4.43 in)
Compression spring free length 74.3 mm (2.93 in) 70.6 mm
(2.78 in)
Weight outside diameter 15.0 mm (0.59 in) 14.5 mm
(0.57 in)
Clutch - in revolution 2,650 ~ 3,050 r/min ----
Clutch - stall revolution 4,800 ~ 5,400 r/min ----
V-belt
V-belt width 18.2 mm (0.72 in) 17.2 mm
(0.68 in)
Transmission
Transmission type Primary V-belt automatic ----
reduction system Primary Helical gear ----
reduction ratio 47/15 (3.133) ----
Secondary reduction system Spur gear 42/13 ----
Secondary reduction ratio (3.231) ----
Operation Centrifugal automatic type ----
Single speed automatic 2.399 ~ 0.829:1 ----

2-
 ENGINE SPE
Item Standard Limit
Kickstarter
Kickstarter type Ratchet type ----
Kickstarter pinion gear clip friction 1.0 ~ 3.5 N (0.10 ~ 0.36 kgf, 0.22 ~ 0.79 lb) ----
force
Air filter
Air filter element Wet element ----
Carburetor
Type (manufacturer)/quantity NCV24 (KEIHIN)/1 ----
I.D. mark 14D1 00 ----
Main jet (M.J) #108 ----
Main air jet (M.A.J) #80 ----
Jet needle (J.N) N425-ESJ00 ----
Needle jet (N.J) N426-62A45 ----
Pilot air jet 1 (P.A.J.1) #130 ----
Pilot air jet 2 (P.A.J.2) #85 ----
Pilot outlet (P.O) ø1.0 ----
Pilot jet (P.J) #38/60 ----
Bypass 1 (B.P.1) ø0.7 ----
Bypass 2 (B.P.2) ø0.7 ----
Bypass 3 (B.P.3) ø0.7 ----
Bypass 4 (B.P.4) ø0.7 ----
Pilot screw turns out 2 3/8 ----
Valve seat size (V.S) ø1.6 ----
Starter jet 1 (G.S.1) #38 ----
Throttle cable free play 3 ~ 7 mm (0.12 ~ 0.28 in) ----
Throttle bulb size #120 ----

Model AL115C
Lubrication chart
OIL RING PISTON CYLINDER HEAD CAMSHAFT

CONNECTING
ROD BIG END

CRANKSHAFT

OIL PUMP

OIL STRAINER

OIL PAN

2-
 CHASSIS SPE
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Steel tube underbone ----
Caster angle 26.5 ----
Trail 100 mm (3.94 in) ----
Front wheel
Wheel type Cast wheel ----
Rim
Size 14  1.40 ----
Material Aluminum ----
Wheel travel 90 mm (3.54 in) ----
Wheel runout
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 1.0 mm
(0.04 in)
Rear wheel
Wheel type Cast wheel ----
Rim
Size 14  1.60 ----
Material Aluminum ----
Wheel travel 80 mm (3.15 in) ----
Wheel runout
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 1.0 mm
(0.04 in)
Front tire
Tire type With tube ----
Size 70/90-14M/C 34P ----
Manufacturer/model IRC/NF59 ----
Tire pressure (cold tire) 200 kPa (2.00 kgf/cm2, 29 psi) ----
Min. tire tread depth ---- 0.8 mm
(0.031 in)

2-9
 CHASSIS SPE
Item Standard Limit
Rear tire
Tire type With tube ----
Size 80/90-14M/C 40P ----
Manufacturer/model IRC/NR76 ----
Tire pressure (cold tire) 225 kPa (2.25 kgf/cm2, 33 psi) ----
Min. tire tread depth ---- 0.8 mm
(0.031 in)
Front brake
Brake type Single-disc brake ----
Operation Right-hand operation ----
Brake lever free play (at lever end) 0 mm (0 in) ----
Brake discs
Diameter  thickness 200  3.5 mm (7.87  0.14 in) ----
Min. thickness ---- 3.0 mm
(0.12 in)
---- 0.15 mm
Max. deflection
(0.006 in)
5.3 mm (0.21 in) 0.8 mm
Brake pad lining thickness-inner (0.031 in)
5.3 mm (0.21 in) 0.8 mm
Brake pad lining thickness-outer (0.031 in)
11 mm (0.43 in) ----
Master cylinder inside diameter 33.34 mm (1.31 in) ----
Caliper cylinder inside diameter DOT 4 ----
Recommended fluid

2-
 CHASSIS SPE
Item Standard Limit
Rear brake
Brake type Drum brake ----
Operation Left-hand operation ----
Drum brake type Leading, trailing ----
Brake lever free play (at lever end) 10 ~ 20 mm (0.39 ~ 0.79 in) ----
Drum inside diameter 130 mm (5.12 in) 131 mm
(5.16 in)
Lining thickness 4.0 mm (0.16 in) 2.0 mm
(0.079 in)
Shoe spring free length 52 mm (2.05 in) ----
Steering
Steering bearing type Angular bearing ----
Lock to lock angle (left) 47.5 ----
Lock to lock angle (right) 47.5 ----
Front suspension
Suspension type Telescopic fork ----
Front fork type Coil spring/oil damper ----
Front fork travel 90 mm (3.54 in) ----
Spring
Free length 266.7 mm (10.50 in) 261.4 mm
(10.29 in)
Installed length 256.7 mm (10.11 in) ----
3.9 N/mm (0.40 kgf/mm, 22.27 lb/in) ----
Spring rate (K1)
7.1 N/mm (0.72 kgf/mm, 40.54 lb/in) ----
Spring rate (K2)
0 ~ 50 mm (0 ~ 1.97 in) ----
Spring stroke (K1)
50 ~ 90 mm (1.97 ~ 3.54 in) ----
Spring stroke (K2)
No ----
Optional spring available
Fork oil Fork oil 10 W or equivalent ----
Recommended oil 57 cm3 (2.01 Imp oz, 1.93 US oz) ----
Quantity (each front fork leg) 88 mm (3.46 in) ----
Level (from the top of the inner
tube, with the inner tube fully
compressed, and without the fork
spring) 26 mm (1.02 in) ----
Inner tube outer diameter ---- 0.2 mm
Inner tube bend limit (0.008 in)

2-
 CHASSIS SPE
Item Standard Limit
Rear suspension
Suspension type Unit swing ----
Spring/shock absorber type Coil spring/oil damper ----
Rear shock absorber assembly travel 78 mm (3.07 in) ----
Spring
Free length 249.6 mm (9.83 in) 244.6 mm
(9.63 in)
Installed length 245.6 mm (9.67 in) ----
Spring rate (K1) 28.5 N/mm (2.91 kgf/mm, 162.74 lb/in) ----
Spring rate (K2) 40.0 N/mm (4.08 kgf/mm, 228.40 lb/in) ----
Spring stroke (K1) 0 ~ 50 mm (0 ~1.97 in) ----
Spring stroke (K2) 50 ~ 78 mm (1.97 ~ 3.07 in) ----
Optional spring available No ----

2-
 ELECTRICAL SPE
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V ----
Ignition system
Ignition system type DC. C.D.I. ----
Ignition timing (B.T.D.C.) 5at 1,500 r/min ----
Advanced type Digital ----
DC.C.D.I.
Magneto model/manufacturer F5TL/MORIC ----
Pickup coil resistance/color 248 ~ 372  at 20 C (68 F)/W/L–W/R ----
C.D.I. unit model/manufacturer 5TL/MORIC ----
Ignition coil
Model/manufacturer 4ST/MORIC ----
Minimum ignition spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.32 ~ 0.48  at 20 C (68 F) ----
Secondary coil resistance 5.68 ~ 8.52 k at 20 C (68 F) ----
Spark plug cap
Material Resin ----
Resistance 5 k at 20 C (68 F) ----
Charging system
Type A.C. magneto ----
Model/manufacturer F5TL/MORIC ----
Standard output 14 V 100 W at 5,000 r/min ----
Lighting coil resistance/color 0.24 ~ 0.36  at 20 C (68 F)/Y/R–B
Charging coil resistance/color 0.32 ~ 0.48  at 20 C (68 F)/W–B ----
Rectifier/regulator
Regulator type Semi conductor-short circuit ----
Model/manufacturer SH656A-12/SHINDENGEN ----
No load regulated voltage (DC) 14.0 ~ 15.0 V ----
(AC) 12.3 ~ 13.3 V ----
Rectifier capacity (DC) 8A ----
(AC) 12 A ----
Battery
Model/manufacturer YTZ5S-MF/GS ----
Battery voltage/capacity 12 V/3.5 A ----
Specific gravity 1.320 ----
Headlight type Krypton bulb ----

2-
 ELECTRICAL SPE
Item Standard Limit
Bulbs (voltage/wattage  quantity)
Headlight 12 V 32 W/32 W  1 ----
Tail/brake light 12 V 5 W/21 W  1 ----
Front turn signal light 12 V 10 W  2 ----
Rear turn signal light 12 V 10 W  2 ----
Meter light 12 V 1.7 W  2 ----
Indicator light
(voltage/wattage  quantity)
Turn signal indicator light 12 V 1.7 W  1 ----
High beam indicator light 12 V 1.7 W  1 ----
Electric starting system
System type Constant mesh ----
Starter motor
Model/manufacturer 5TL/MORIC ----
Power output 0.25 kW ----
Armature coil resistance 0.0315 ~ 0.0385  at 20 C (68 F) ----
Brushes
Overall length 9.5 mm (0.37 in) 3.5 mm
(0.14 in)
Spring force 5.52 ~ 8.28 N ----
(563 ~ 844 gf, 19.87 ~ 29.80 oz)
Commutator diameter 22 mm (0.87 in) 21 mm
(0.83 in)
Mica undercut 1.5 mm (0.06 in) ----
Starter relay
Model/manufacturer 5TN/OMRON ----
Amperage 50 A ----
Coil resistance 54 ~ 66  at 20 C (68 F) ----
Horn
Horn type Plane ----
Model/manufacturer  quantity UBH-F21/MITSUBA  1 ----
Max. amperage 1.5 A ----
Performance 97 ~ 107 dB/2 m ----
Coil resistance 4.30 ~ 4.80  ----
Turn signal relay
Relay type Condenser ----
Model/manufacturer FR22-091/MITSUBA ----
Self-cancelling device built-in No ----
Turn signal blinking frequency 75 ~ 95 cycles/min. ----
Wattage 10 W  2  3.4 W ----
Fuel gauge
Model/manufacturer 14D1/NIPPON SEIKI ----
Sender unit resistance- full 4 ~ 10  at 20 C (68 F) ----
Sender unit resistance- empty 90 ~ 100  at 20 C (68 F) ----

2-
 ELECTRICAL SPE
Item Standard Limit
Fuses (amperage  quantity)
Fuse 10 A  1 ----
Reserve fuse 10 A  1 ----

2-
 CONVERSION TABLE/ SPEC
GENERAL TIGHTENING TORQUE SPECIFICATIONS
EAS00028 EAS00030

CONVERSION TABLE GENERAL TIGHTENING TORQUE

All specification data in this manual are listed in SPECIFICATIONS
SI and METRIC UNITS. This chart specifies tightening torques for standard
Use this table to convert METRIC unit data to fasteners with a standard ISO thread pitch.
IMPERIAL unit data. Tightening torque specifications for spe- cial
components or assemblies are provided for each
Ex. chapter of this manual. To avoid warpage, tighten
METRIC MULTIPLIER IMPERIAL multi-fastener assemblies in a crisscross pattern
** mm  0.03937 = ** in and progressive stages until the specified
2 mm  0.03937 = 0.08 in tightening torque is reached. Unless otherwise
specified, tighten- ing torque specifications require
CONVERSION TABLE clean, dry threads. Components should be at room
METRIC TO IMPERIAL tem- perature.
Metric unit Multiplier Imperial unit
m·kg 7.233 ft·lb
Tighten-
ing torque m·kg 86.794 in·lb
cm·kg 0.0723 ft·lb
cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
g 0.03527 oz
Speed km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
Distance m 1.094 yd
cm 0.3937 in A: Distance between flats B:
mm 0.03937 in Outside thread diameter
cc (cm3) 0.03527 oz (IMP lip.)
Volume/ cc (cm3) 0.06102 cu.in General tightening
Capacity lt (liter) 0.8799 qt (IMP liq.) A B torques
lt (liter) 0.2199 gal (IMP liq.) (nut) (bolt)
Nm m0kg ft0lb
kg/mm 55.997 lb/in
Misc.
kg/cm2 14.2234 psi (lb/in2) 10 mm 6 mm 6 0.6 4.3
Centigrade 9/532 Fahrenheit (F)
(C) 12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94

2-
 TIGHTENING SPE
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES

Thread Tightening torque

Part to be tightened Part name Q’ty Remarks
size Nm m · kg ft · lb
Spark plug — M10 1 15 1.5 11
Cylinder head Nut M8 4 22 2.2 16 E

Cylinder head (timing chain side) Bolt M6 2 10 1.0 7.2

Cylinder head stud bolt Bolt M8 2 13 1.3 9.4
Oil gallery bolt Bolt M6 1 7 0.7 5.1
Tappet cover (intake and exhaust side) — M45 2 18 1.8 13
Camshaft sprocket cover Bolt M6 2 12 1.2 8.7
Camshaft retainer Bolt M6 1 12 1.2 8.7
Camshaft sprocket cover breather plate Bolt M6 1 10 1.0 7.2
Camshaft sprocket Bolt M8 1 30 3.0 22
Valve adjusting locknut Nut M5 2 7 0.7 5.1
Timing chain guide (intake side) Bolt M6 1 7 0.7 5.1
Timing chain tensioner Bolt M6 2 9 0.9 6.5
Engine cooling fan cover Screw M6 2 7 0.7 5.1
Engine cooling fan Bolt M6 3 8 0.8 5.8
A.C. magneto rotor Nut M12 1 70 7.0 50
Oil pump cover Bolt M6 3 10 1.0 7.2
Oil pump assembly Screw M5 2 4 0.4 2.9
Engine oil drain plug Plug M30 1 20 2.0 14
Engine oil drain bolt Bolt M12 1 20 2.0 14
Transmission oil drain bolt Bolt M8 1 22 2.2 16
Muffler and cylinder head Nut M8 2 20 2.0 14
Muffler and muffler stay (lower bolt) Bolt M8 1 35 3.5 25
Muffler and muffler stay (upper bolt) Bolt M10 1 50 5.0 36
Muffler stay and right crankcase Bolt M8 2 37 3.7 27
Muffler protector 1 Screw M6 2 8 0.8 5.8 LT

Air induction system assembly Screw M6 1 7 0.7 5.1

Muffler protector 2 Bolt M6 2 10 1.0 7.2
Intake manifold Bolt M6 2 10 1.0 7.2
Air filter case Bolt M6 3 7 0.7 5.1
Kickstarter crank Bolt M6 1 12 1.2 8.7
V-belt case air filter assembly Bolt M6 2 10 1.0 7.2
V-belt case air filter cap Bolt M5 4 2 0.2 1.4
V-belt case cover protector Screw M6 2 7 0.7 5.1
V-belt case air duct clamp Bolt M4 2 2 0.2 1.4
V-belt case air duct Screw M6 2 7 0.7 5.1
V-belt case cover Bolt M6 13 10 1.0 7.2
Kickstarter shaft plate Screw M6 6 9 0.9 6.5
Secondary sheave nut Nut M10 1 40 4.0 29
Clutch carrier nut Nut M27 1 55 5.5 40
Transmission case cover Bolt M6 6 13 1.3 9.4
Bearing retainer (primary drive gear) Bolt M6 1 10 1.0 7.2 LT

2-
 TIGHTENING SPE
Thread Tightening torque
Part to be tightened Part name Q’ty Remarks
size Nm m · kg ft · lb
Primary sheave nut Nut M12 1 48 4.8 35
Idle gear plate Bolt M6 2 10 1.0 7.2
Starter wheel gear holder Bolt M6 1 10 1.0 7.2
Crankcase (left and right) Bolt M6 9 10 1.0 7.2
Crankcase stud bolt Bolt M8 4 13 1.3 9.4
Stator coil assembly Bolt M6 3 11 1.1 8.0
Pickup coil bracket Screw M6 2 7 0.7 5.1
Starter motor Bolt M6 2 7 0.7 5.1
Ignition coil Screw M6 2 7 0.7 5.1
Air shroud 1 and 2 (cylinder) Screw M6 2 1.5 0.2 1.1
Air shroud 2 and 3 (cylinder) Screw M6 2 1.5 0.2 1.1
Air shroud 1, 2 and plate (cylinder) Screw M6 1 1.5 0.2 1.1
Air shroud 1, 2 and plate (cylinder) Bolt M6 1 2.5 0.3 1.8
Plate Screw M6 1 7 0.7 5.1

2-
 TIGHTENING SPE
CHASSIS TIGHTENING TORQUES
Tightening torque
Part to be tightened Thread size Remarks
Nm m · kg ft · lb
Brake master cylinder M6 11 1.1 8.0
Rear brake lever assembly M6 7 0.7 5.1
Front brake lever M6 7 0.7 5.1
Starter lever M6 7 0.7 5.1
Handlebar nut M10 53 5.3 39
Steering ring nut (upper) M25 75 7.5 54 See NOTE
Steering ring nut (lower) M25 30 3.0 22 See NOTE
Engine mounting nut M12 59 5.9 43
Engine mounting rubber damper and engine
M8 16 1.6 11
bracket
Engine bracket and engine assembly M10 35 3.5 26
Rear shock absorber assembly nut M10 32 3.2 23
Rear shock absorber assembly bolt M8 16 1.6 11
Front wheel axle nut M10 40 4.0 29
Rear wheel axle nut M14 135 13.5 100
Disc brake and hub M8 23 2.3 17 LT

Front brake hose holder and front fork outer tube M6 7 0.7 5.1
Front brake hose holder, bracket, and lower
M6 7 0.7 5.1
bracket
Lower front brake hose holder and bracket M6 7 0.7 5.1
Speedometer cable guide and lower bracket M6 7 0.7 5.1
Brake caliper bracket bolt M10 35 3.5 26
Bleed screw M7 6 0.6 4.3
Brake hose union bolt M10 26 2.6 19
Brake camshaft lever bolt M6 7 0.7 5.1
Front fender M6 7 0.7 5.1
Lower bracket pinch bolt (upper and lower) M10 38 3.8 27
Front fork cap bolt M20 20 2.0 14
Damper rod bolt M10 23 2.3 17 LT

Rearview mirror M10 32 3.2 23

Sidestand bolt M8 26 2.6 19 LS
Sidestand nut M8 16 1.6 11
Rear brake cable holder M6 7 0.7 5.1
Fuel tank and frame M6 7 0.7 5.1
Grab bar and frame M6 10 1.0 7.2
Fuel cock and fuel tank M6 7 0.7 5.1
Storage box and frame M6 9 0.9 6.6

2-
 TIGHTENING SPE
Tightening torque
Part to be tightened Thread size Remarks
Nm m · kg ft · lb
Sender and fuel tank M5 4 0.4 2.9
Seat M6 7 0.7 5.1
Seat lock assembly and frame M6 7 0.7 5.1
Rear fender M6 8 0.8 5.8
Rectifier/regulator M6 7 0.7 5.1
Footboard and frame M6 4 0.4 2.9
Footboard and frame M6 9 0.9 6.6
Footboard and frame M5 2 0.2 1.4
Leg shield and frame M6 7 0.7 5.1
Front cowling and frame M6 7 0.7 5.1
Horn bracket and stay M6 7 0.7 5.1
Main switch and frame M6 7 0.7 5.1
Spoke — 3 0.3 2.2
Throttle cable housing screw M5 4 0.4 2.9
Left handlebar switch bracket screw M5 4 0.4 2.9
Side cover and frame M6 7 0.7 5.1

NOTE:
1. First tighten the ring nut (lower) 30 Nm (3.0 m • kg, 22 ft • lb) by using the torque wrench, then loosen
the ring nut quarter turn.
2. Then, hold the ring nuts (lower) and tighten the ring nut (upper) 75 Nm (7.5 m • kg, 54 ft • lb) by
using the torque wrench.

2-
 SPEC
LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant
Oil seal lips LS

O-rings LS

Bearings E

Piston outside and ring groove E

Piston ring E

Piston pin E

Cylinder inner surface E

Timing chain E

Rocker arm shaft M

Rocker arm inner surfaces M

Camshaft lobes and camshaft journals M

Valve stem M

Valve stem seal M

Oil pump assembly E

Kickstarter pinion gear shaft LS

Shell Dolium
Primary sliding sheave inner surface
Grease R®
Shell Dolium
Secondary sheave guide pin
Grease R®
Shell Dolium
Secondary fixed sheave inner surface
Grease R®
Shell Dolium
Secondary sliding surface
Grease R®
Idle gear shaft LS

Centerstand pivot LS

Sidestand pivot LS

Crankcase mating surfaces Yamaha bond No.1215

2-
 SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point Lubricant

Front wheel oil seal lips LS

Front wheel axle LS

Speedometer gear unit inner surface and oil seal lip LS

Lower brake caliper retaining bolt LS

Caliper bracket shat and boot LS

Rear brake cam pivot shaft and camshaft surface LS

Brake lever pivot shaft LS

Tube guide (throttle grip) inner surface LS

Throttle cable (throttle grip) LS

Starter cable (starter lever) LS

Steering head bearing (upper/lower) LS

Steering head bearing inner and outer race LS

Cover ball race (Lip) LS

2-
 CABLE SPE
EAS00035

CABLE ROUTING
1 Front brake switch lead 0 Speedometer cable q
2 Right handlebar switch lead Front brake hose w
3 Speedometer lead Throttle cable
4 Speedometer assembly
5 Rear brake cable å Connect the speedometer lead coupler on the left side
6 Left handlebar switch lead of the speedometer assembly.
7 Starter cable ∫ Route the left handlebar switch lead behind the
8 Rear brake switch lead handlebar, and then connect it on the left side of the
9 Wireharness meter assembly.

12 3 A 4 å 56

8 7
ƒ ´ 9
w ∫
0ç
∂ q
A

q˙
w
9

5
7
C B-B
B
0
B
q
©
5
7 ˆ
A-A
C

2-
 CABLE SPE
ç Pass the wireharness and speedometer cable through
the guide, and then install the grommet on the front ˙ Route the wiring as follow procedure,throttle cable,
brake hose in the holder. wireharness, front brake hose and speedometer
∂ Set the grommet to the holder completely. cable.
´ Route the front brake switch lead behind the front ˆ Route the handlebar top.
brake hose, and then connect it on the right side of
the speedometer assembly.
ƒ Route the right handlebar switch lead behind the
handlebar, and then connect it on the right side of
the speedometer assembly.
© Route the bracket completely.

12 3 A 4 å 56

8 7
ƒ ´ 9
w ∫
0ç
∂ q
A

q˙
w
9

5
7
C B-B
B
0
B
q
©
5
7 ˆ
A-A
C

2-
 CABLE SPE
1 Speedometer cable 2
Front brake hose 3 w Main switch lead
Wireharness e Turn signal light relay
4 Clamp r Stay
5 Starter cable t Headlight assembly lead
6 Rear brake cable
7 Throttle cable å Insert the headlight assembly coupler into the
8 Cable guide holder.
9 Starter motor lead ∫ Fasten the starter cable, rear brake cable, and throttle
0 Engine bracket cable with the holder.
q Horn ç Fasten the starter motor lead with the holder.

6
w BB
w 7
5 © 3 1
6
4˙ w
q e
3 r 5
2 6
t 3 17
´ 2
B-B
C
8ƒ

2 3

1
A
w
A
C

4∫
å

5
6 9
8ç
7

4∫

∂ 0

2-
 CABLE SPE
∂ Pass the rear brake cable through the cable guide.
´ To the headlight assembly.
ƒ Pass the speedometer cable through the cable guide
as shown.
© Pass the main switch lead coupler into the hold- er.
˙ Fasten the wireharness with the holder.

6
w BB
w 7
5 © 3 1
6
4˙ w
q e
3 r 5
2 6
t 3 17
´ 2
B-B
C
8ƒ

2 3

1
A
w
A
C

4∫
å

5
6 9
8ç
7

4∫

∂ 0

2-
 CABLE SPE
1 Clamp
2 Fuel cock assembly å Clamp the wireharness and A.C. magneto lead.
3 Fuel hose 1 ∫ Route the fuel overflow hose as shown.
4 Fuel hose 2
5 Vacuum hose
6 Starter motor
7 Engine assembly
8 Holder
9 Rear brake cable

8 9

A-A

1å 2

3
4
5

∫6 A

2-
 CABLE SPE
1 Positive battery lead
2 Guide w Starter relay
3 Wireharness e Starter motor positive lead
4 Clamp r Footboard
5 Main switch lead 6
Front brake hose 7 å Fasten the positive battery lead, starter relay lead,
A.C. magneto lead and fuse lead with the holder.
8 Negative battery lead ∫ Fasten the wireharness with the holder.
9 Fuse lead ç Fasten the grommet on the wireharness with the
0 Starter relay lead holder as shown.
q Fuse ∂ Clamp the upper side of the grommet on the
wireharness.

8
ˆ∆˚ 9
0
1
2 ˜
q3
7

8
r
C-C

µ 5 2
w
2 4´
4¬ e 4
B
4
ƒ

1 ©
∂
A ç
3
˙
A C 2å
C
B 3
7
4
A-A
2
6
∫4

2-
 CABLE SPE
´ Fasten the wireharness with the holder.
ƒ To the headlight assembly. ˜ Pass the wireharness, A.C. magneto lead and negative
© Pass the wireharness through the clamp from battery lead through the footboard.
upper side.
˙ Clearance of the clamp : Maximum 6 mm
ˆ To the ignition coil.
∆ To the A.C. magneto.
˚ To the starter motor.
¬ Fasten the starter motor lead with the holder.
µ To the starter motor.

8
ˆ∆˚ 9
0
1
2 ˜
q3
7

8
r
C-C

µ 5 2
w
2 4´
4¬ e 4
B
4
ƒ

1 ©
∂
A ç
3
˙
A C 2å
C
B 3
7
4
A-A
2
6
∫4

2-
 CABLE SPE
1 CDI unit assembly
2 Tail / brake light assembly å Pass the fuel sender lead through the hole in the fuel
3 Clamp tank rubber damper.
4 Fuel sender lead 5 ∫ Clamp the upper side of the grommet on the
Rectifier / regulator 6 wireharness.
Fuel tank ç Fasten the grommet on the wireharness with the
7 Tail / brake light lead holder as shown.
8 Left turn signal light lead ∂ To the fuel sender.
9 Right turn signal light lead
0 Tail / brake light assembly lead

2 8

A A

90 ∂

2
78

A-A 3 å4 56 3 ∫ç

2-
 CABLE SPE
1 Wireharness
2 Clamp e Starter motor positive lead
3 Ignition coil r Guide
4 Ignition coil lead t Throttle cable
5 A.C. magneto lead y Starter cable
6 Negative lead u Rear brake cable
7 Air filter assembly i Air shroud
8 Starter motor o Seal
9 Fuel hose 1
0 Fuel cock å Pass the air induction system pipe as shown.
q Fuel hose 2 ∫ Pass the A.C. magneto lead, ignition coil lead, and
w Vacuum hose negative battery lead through the guide on the air
filter case.

o
ƒ
u
i
y

t
´
A-A

A 2
∂ å

r 3

4
ç
e2

∫
w
2
q

0
5

9 6

8 7

2-
 CABLE SPE
ç Pass the vacuum hose as shown and connect the
intake manifold.
∂ Fasten the throttle cable at the white mark and the
starter cable grommet with the holder.
´ Route the cylinder head breather hose as shown.
ƒ Install the spark plug cap securely so that there is
no space between the rubber seal on the spark plug
cap and the air shroud.

o
ƒ
u
i
y

t
´
A-A

A 2
∂ å

r 3

4
ç
e2

∫
w
2
q

0
5

9 6

8 7

2-
 CABLE SPE
1 Air induction system pipe
2 Air induction system hose (air cut-off valve å Install the clip toward outside.
assembly to cylinder head) ∫ Install the white tape paint portion of the crankcase
3 Air cut-off valve breather hose toward left side.
4 Vacuum hose (3-way joint to air cut-off valve)
5 Crankcase breather hose
6 Vacuum hose (intake manifold to 3-way joint)
7 Vacuum hose (3-way joint to fuel cock)
8 Fuel hose 2

1 å2

2
6 54 3

3 ∫ 3 4
8
6
6
C
C-C
7 C
1

2-
SPEC
 CHK ADJ

CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION..........................................................................................3-1

PERIODIC MAINTENANCE AND LUBRICATION CHART.........................3-1

COVERS......................................................................................................3-3
REMOVING THE SEAT AND SIDE COVERS................................................3-3
INSTALLING THE SEAT AND SIDE COVERS..............................................3-4
REMOVING THE FRONT COWLING AND LEG SHIELD............................3-4
INSTALLING THE FRONT COWLING AND LEG SHIELD..........................3-6

ENGINE........................................................................................................3-8
ADJUSTING THE VALVE CLEARANCE........................................................3-8
ADJUSTING THE ENGINE IDLING SPEED.................................................3-10
ADJUSTING THE THROTTLE CABLE FREE PLAY...................................3-12
CHECKING THE SPARK PLUG.....................................................................3-13
MEASURING THE COMPRESSION PRESSURE..........................................3-14
CHECKING THE ENGINE OIL LEVEL.........................................................3-16
CHANGING THE ENGINE OIL......................................................................3-17
CHANGING THE TRANSMISSION OIL........................................................3-18
CHECKING THE AIR FILTER ELEMENT....................................................3-19
CHECKING THE V-BELT...............................................................................3-20
CLEANING THE V-BELT CASE AIR FILTER ELEMENT...........................3-21
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD........3-22
CHECKING THE FUEL AND VACUUM HOSES..........................................3-23
CHECKING THE BREATHER HOSES...........................................................3-23
CHECKING THE EXHAUST SYSTEM..........................................................3-24

CHASSIS....................................................................................................3-25
ADJUSTING THE REAR BRAKE...................................................................3-25
CHECKING THE BRAKE FLUID LEVEL.....................................................3-25
CHECKING THE FRONT BRAKE PADS.......................................................3-26
CHECKING THE REAR BRAKE SHOES.......................................................3-26
CHECKING THE FRONT BRAKE HOSE......................................................3-27
BLEEDING THE HYDRAULIC BRAKE SYSTEM........................................3-27
CHECKING AND ADJUSTING THE STEERING HEAD..............................3-29
CHECKING THE FRONT FORK....................................................................3-30
CHECKING THE TIRES..................................................................................3-31
CHECKING THE WHEELS.............................................................................3-34
CHECKING AND LUBRICATING THE CABLES.........................................3-34
LUBRICATING THE LEVERS........................................................................3-35
LUBRICATING THE SIDESTAND.................................................................3-35
LUBRICATING THE CENTERSTAND..........................................................3-35
 ADJ
CH
ELECTRICAL SYSTEM.............................................................................3-36
CHECKING AND CHARGING THE BATTERY...........................................3-36
CHECKING THE FUSE...................................................................................3-40
REPLACING THE HEADLIGHT BULB.........................................................3-41
ADJUSTING THE HEADLIGHT BEAM........................................................3-42
 INTRODUCTION/PERIODIC MAINTENANCE AND CHK ADJ
LUBRICATION CHART
EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer
service life and reduce the need for costly overhaul work. This information applies to vehicles already in
service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar
with this entire chapter.
EAS00037

PERIODIC MAINTENANCE AND LUBRICATION CHART

ODOMETER READING (x 1000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 4 7 10 13 CHECK

1 * Fuel line Check fuel and vacuum hoses for cracks or damage.
Check condition.
2 Spark plug Clean and regap.
Replace if necessary.
Check valve clearance.
3 * Valves
Adjust.

4 Air filter element (wet type) Replace if necessary. Every 15000 km

5 V-belt case air air filter Clean. Replace if neccesary.

element

6 * MF Battery Check voltage.

Check operation, fluid level and vehicle for fluid leakage.

7 * Front brake
Replace brake pads if necessary.
Check operation and adjust brake lever free play. Replace
8 * Rear brake
brake shoes if necessary.
Check for cracks or damage.
9 * Brake hose
Replace if necessary. Every 4 years
Check tread depth and for damage.
Replace if necessary.
10 * Tires
Check air pressure.
Correct if necessary.
11 * Wheel bearings Check bearing for looseness or damage.
Check operation and for excessive play.
12 * Swingarm
Lubricate with lithium-soap-based grease. Every 12000 km
Check bearing play and steering for roughness.
13 * Steering bearings
Lubricate with lithium-soap-based grease. Every 12000 km
Make sure that all nuts, bolts and screws are properly tightened.
14 * Chassis fasteners

Check operation.
15 Sidestand, centerstand
Lubricate.
16 * Front fork Check operation and for oil leakage.
Shock absorber assem-
17 * Check operation and shock absorber for oil leakage.
bly

18 * Carburetor Check starter (choke) operation. Adjust

engine idling speed.
Change.
19 Engine oil
Check oil level and vehicle for oil leakage.

3-
 ADJ
CH
PERIODIC MAINTENANCE AND LUBRICATION CHART
ODOMETER READING (x 1000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 4 7 10 13 CHECK

Front and rear

20 * Check operation.
brake switches
Moving parts and
21 Lubricate.
ca- bles
Check operation and free play.
Throttle grip
22 * Adjust the throttle cable free play if necessary.
housing and cable
Lubricate the throttle grip housing and cable.
Check the air cut-off valve, reed valve, and hose for dam- age.
23 * Air induction system Replace any damaged parts if necessary.

Lights, signals Check operation. Adjust

24 *
and switches headlight beam.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
7 From 16,000 km (10,000 mi), repeat the maintenance intervals starting from 4,000 km (2,500 mi).
7 Depending on riding conditions, the V-belt replacement interval may vary.
7 This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned
with compressed air to avoid damaging it.
7 The air filter element needs to be replaced more frequently riding in unusually wet or dusty areas.
7 Hydraulic brake system
9 After disassembling the brake master cylinder, and caliper cylinder, always change the fluid. Regularly
check the brake fluid level and fill reservoir as required.
9 Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every two
years.
9 Replace the brake hose every four years or if cracked or damaged.

3-
 CH
COVER K
EASF0004

COVERS
REMOVING THE SEAT AND SIDE COVERS
1. Remove:
1 9 seat 1

2. Remove:
9 center cover 1

3. Remove:
9 grab bar 1
1

4. Remove:
9 side cover (left and right) 1
1 NOTE:
Remove the side cover by sliding it backward
slightly.

3-
 ADJ
CH
COVERS
INSTALLING THE SEAT AND SIDE COVERS
2 For installation, reverse the removal procedure.
a 1. Install:
1 9 side cover (left and right) 1
b 9 screw 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
NOTE:
9 Before tightening the side cover screws, make
sure that all projections are securely fit- ted.
9 Push the side cover as shown and fit the pro-
jection a on the tail/brake light assembly into
the hole b of the side cover.
1
2. Install:
9 grab bar 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

3. Install:
9 center cover 1
NOTE:
9 Install the projection into the groove of the side
1 cover.
9 Make sure install the front of side cover to outside
of the center cover.

4. Install:
9 seat 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

REMOVING THE FRONT COWLING AND

LEG SHIELD
1. Remove:
9 seat
9 center cover
9 grab bar
9 side cover (left and right)
Refer to “REMOVING THE SEAT AND
SIDE COVERS”.

3-
 CH
COVER K
2. Remove:
9 front cowling 1
NOTE:
Disconnect the headlight assembly coupler 2.

3. Remove:
9 leg shield 1

4. Remove:
9 bottom cowling 1

1
1

3-
 ADJ
CH
COVERS
9 front bottom cowling 2

5. Remove:
9 footboard 1

INSTALLING THE FRONT COWLING AND

5 3
6 LEG SHIELD
1. Install:
7 9 footboard 1
4 9 bolt 2 4 Nm (0.4 m·kg, 2.9 ft·lb)

3 9 bolt 3 9 Nm (0.9 m·kg, 6.6 ft·lb)

2 1 9 screw 4 2 Nm (0.2 m·kg, 1.4 ft·lb)

2 NOTE:
Pass the wireharness 5, A.C. magneto lead 6 and
negative battery lead 7 through the foot- board 1.
Refer to “CABLE ROUTING” in chap- ter 2.

1
2. Install:
9 leg shield 1
9 screw 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
2

3. Install:
9 front bottom cowling 1

3-
 CH
COVER K
4. Install:
9 front cowling 2
1 9 screw 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
NOTE:
Connect the headlight assembly coupler 1. Refer
to “CABLE ROUTING” in chapter 2.

3
2

3 3

3 3

5. Install:
9 bottom cowling 1

3-
 ADJ
CH
COVERS/ADJUSTING THE VALVE CLEARANCE
6. Install:
9 side cover (left and right)
9 grab bar
9 center cover
9 seat
Refer to “INSTALLING THE SEAT AND
SIDE COVERS”.

EAS00049

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

1. Remove:
9 seat
9 center cover
Refer to “REMOVING THE SEAT AND
SIDE COVERS”.

2. Remove:
1 9 intake tappet cover 1
9 exhaust tappet cover 2
9 camshaft sprocket cover 3
(with O-ring)
3

3. Open the rubber damper 1.

3-
 ADJ
CH
ADJUSTING THE VALVE CLEARANCE
4. Measure:
9 valve clearance
Out of specification  Adjust.
b Valve clearance (cold)
a Intake valve
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
Exhaust valve
0.08 ~ 0.12 mm
d (0.0031 ~ 0.0047 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c a. Turn the crankshaft clockwise.
b. When the piston is at the Top Dead Center
(TDC) on the compression stroke, align the
“I” mark a in the camshaft sprocket with
the stationary b on the cylinder head.
c. Align the “I” mark c on the A.C. magneto
rotor with the stationary pointer d on the
crankcase.
d. Measure the valve clearance with a thick-
ness gauge 1.
1 Out of specification  Adjust.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Adjust:
9 valve clearance
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Loosen the locknut 1.
b. Insert a thickness gauge 2 between the end
of the adjusting screw and the valve tip.
c. Turn the adjusting screw 3 in direction a
or b until the specified valve clearance is
obtained.

Valve clearance is
Direction a
increased.
Valve clearance is
b Direction b
decreased.

a Tappet adjusting
3 tool 90890-01311

3-
 ADJUSTING THE VALVE CLEARANCE/ CHK ADJ
ADJUSTING THE ENGINE IDLING SPEED
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifi-
cation.

Locknut
7 Nm (0.7 m·kg, 5.1 ft·lb)
e. Measure the valve clearance again.
f. If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear- ance
is obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
9 rubber damper
NOTE:
Install the flap of the rubber damper securely in the
hole in the engine cooling fan cover.

7. Install:
9 O-ring
9 camshaft sprocket cover
12 Nm (1.2 m·kg, 8.7 ft·lb)
9 O-ring
2 9 exhaust tappet cover
1 New 18 Nm (1.8 m·kg, 13 ft·lb)
9 O-ring 1
9 intake tappet cover 2
18 Nm (1.8 m·kg, 13 ft·lb)
8. Install:
9 center cover
9 seat
Refer to “INSTALLING THE SEAT AND
SIDE COVERS”.

EAS00054

ADJUSTING THE ENGINE IDLING SPEED

NOTE:
Prior to adjusting the engine idling speed, the air
filter element should be clean, and the engine
should have adequate compression.

1. Start the engine and let it warm up for sev-

eral minutes.

3-
 ADJ
CH
ADJUSTING THE ENGINE IDLING SPEED
2. Remove:
9 seat
9 center cover
Refer to “REMOVING THE SEAT AND
SIDE COVERS”.
3. Attach:
9 engine tachometer
(onto the spark plug lead)

Engine tachometer
90890-03113
4. Check:
9 engine idling speed
Out of specification  Adjust.
Engine idling speed
1,300 ~ 1,500 r/min
(New engine at set up)
1,450 ~ 1,650 r/min
(After engine brake-in)
5. Adjust:
9 engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the pilot screw 1 in or out until it is
lightly seated.
b. Turn the pilot screw out the specified num-
ber of turns.
Pilot screw setting
1
2 turns out

c. Remove the rubber cap 2.

d. Turn the throttle stop screw 3 in direction a
2 or b until the specified engine idling
speed is obtained.

Engine idling speed is

Direction a
increased.
Engine idling speed is
Direction b
decreased.

e. Install the rubber cap.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Adjust:
9 throttle cable free play
b Refer to “ADJUSTING THE THROTTLE
3
CABLE FREE PLAY”.

Throttle cable free play (at the

a
flange of the throttle grip)
3 ~ 7 mm (0.12 ~ 0.28 in)

3-
 ADJUSTING THE ENGINE IDLING SPEED/ CHK ADJ
ADJUSTING THE THROTTLE CABLE FREE PLAY
7. Install:
9 center cover
9 seat
Refer to “INSTALLING THE SEAT AND
SIDE COVERS”.

EAS00058

ADJUSTING THE THROTTLE CABLE FREE

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

1. Check:
9 throttle cable free play a
Out of specification  Adjust.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 7 mm (0.12 ~ 0.28 in)
a
2. Adjust:
9 throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 in direction a or b
until the specified throttle cable free play is
obtained.

Throttle cable free play is

Direction a
1 3 b increased.
Throttle cable free play is
Direction b
decreased.
a
2
d. Tighten the locknut.
e. Slide the rubber cover to its original posi- tion.

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3-
 ADJ
CH
CHECKING THE SPARK PLUG
EAS00060

CHECKING THE SPARK PLUG

1. Remove:
9 seat
9 center cover
Refer to “REMOVING THE SEAT AND
SIDE COVERS”.
2. Disconnect:
9 spark plug cap
3. Remove:
9 spark plug

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

4. Check:
9 spark plug type Incorrect  Change.
Spark plug type (manufacturer)
C7HSA (NGK)
5. Check:
9 electrode 1
Damage/wear  Replace the spark plug.
9 insulator 2
Abnormal color  Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
9 spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
9 spark plug gap a
(with a wire thickness gauge) Out
of specification  Regap.
Spark plug gap
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
8. Install:
9 spark plug 15 Nm (1.5 m·kg, 11 ft·lb)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.

9. Connect:
9 spark plug cap

3-
 CHECKING THE SPARK PLUG/ CHK ADJ
MEASURING THE COMPRESSION PRESSURE
10. Install: 9
center cover 9
seat
Refer to “INSTALLING THE SEAT AND
SIDE COVERS”.

EAS00067

MEASURING THE COMPRESSION

PRESSURE
NOTE:
Insufficient compression pressure will result in a
loss of performance.

1. Remove:
9 seat
9 center cover
2. Measure:
9 valve clearance
Out of specification  Adjust
Refer to “ADJUSTING THE
VALVE CLEARANCE”.
3. Start the engine, warm it up for several
minutes, and then turn it off.
4. Disconnect:
9 spark plug cap
5. Remove:
9 spark plug

cC
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug well to prevent it
from falling into the cylinder.

6. Install:
1 9 compression gauge 1

Compression gauge
90890-03081

3-
 ADJ
CH
MEASURING THE COMPRESSION PRESSURE
7. Measure:
9 compression pressure
Out of specification  Refer to steps (c) and
(d).
Compression pressure (at sea
level)
Minimum
960 kPa (9.6 kg/cm2, 136.5 psi)
Standard
1,100 kPa
(11 kg/cm2, 156.5 psi)
Maximum
1,230 kPa
(12.3 kg/cm2, 174.9 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to "ON".
b. With the throttle wide open, crank the engine
until the reading on the compres- sion gauge
stabilizes.

w
To prevent sparking, ground the spark plug
lead before cranking the engine.

c. If the compression pressure is above the

maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits  Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
engine of oil into the spark plug bore and
measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Piston ring(s) wear
Higher than with-
or damage 
out oil
Repair.
Piston, valves, cyl-
Same as without inder head gasket
oil or piston possibly
defective  Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
9 spark plug 15 Nm (1.5 m·kg, 11 ft·lb)

3-
 MEASURING THE COMPRESSION PRESSURE/ CHK ADJ
CHECKING THE ENGINE OIL LEVEL
9. Connect:
9 spark plug cap
10. Install: 9
center cover 9
seat
Refer to “INSTALLING THE SEAT AND
SIDE COVERS”.

EAS00070

CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle on a level surface.
NOTE:
9 Place the vehicle on a suitable stand.
9 Make sure the vehicle is upright.

2. Start the engine, warm it up for several

minutes, and then turn it off.
3. Remove:
9 dipstick 1
4. Check:
9 engine oil level
b The engine oil level should be between the
a minimum level a and maximum level b.
Below the minimum level  Add the rec-
1 ommended engine oil to the proper level.

Recommended oil
Refer to the chart for the engine
oil grade which is best suited for
-20 -10 0 10 20 30 40 50 C certain atmospheric tempera-
tures.
SAE 10W-30 SAE API service SG type or higher,
JASO standard MA
10W-40

SAE 20W-40 cC
SAE 20W-50
Do not allow foreign materials to enter the
crankcase.

NOTE:
9 Before checking the engine oil level, wait a
few minutes until the oil has settled.
9 Do not screw the dipstick in when checking the
oil level.

5. Install:
9 dipstick

3-
 CHECKING THE ENGINE OIL LEVEL/ CHK ADJ
CHANGING THE ENGINE OIL
6. Start the engine, warm it up for several
minutes, and then turn it off.
7. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.

EAS00075

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several
1 minutes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
9 dipstick 1
9 engine oil drain bolt 2
(along with the gasket) 9
engine oil drain plug 3
9 O-ring 4
3 2
9 spring 5
9 engine oil strainer 6
NOTE:
When only changing the engine oil, remove
engine oil drain bolt only.

4. Drain:
9 engine oil
(completely from the crankcase)
6 5. Check:
9 engine oil strainer
5 Dirt  Clean.
6. Check:
4 9 engine oil drain bolt gasket
Damage  Replace.
3 7. Install:
9 engine oil drain bolt
(along with the gasket)
20 Nm (2.0 m·kg, 14 ft·lb)
9 spring
9 engine oil strainer
9 O-ring
9 engine oil drain plug
20 Nm (2.0 m·kg, 14 ft·lb)

3-
 CHANGING THE ENGINE OIL/ CHK ADJ
CHANGING THE TRANSMISSION OIL
8. Fill:
9 crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
0.9 L (0.79 Imp qt, 0.95 US qt)
Periodic replacement
0.8 L (0.70 Imp qt, 0.85 US qt)
9. Install:
9 dipstick
10. Start the engine, warm it up for several
minutes, and then turn it off.
11. Check:
9 engine
(for engine oil leaks)
12. Check:
9 engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.

CHANGING THE TRANSMISSION OIL

1. Start the engine, warm it up for several
minutes, and then turn it off.
2. Place a container under the transmission oil
drain bolt.
1 3. Remove:
9 transmission oil filler plug 1
9 transmission oil drain bolt 2
(along with the gasket)
4. Drain:
9 transmission oil
(completely from the transmission case)
5. Check:
9 transmission oil drain bolt gasket Damage
2
 Replace.
6. Install:
9 transmission oil drain bolt
(along with the gasket)
22 Nm (2.2 m·kg, 16 ft·lb)

3-
 CHANGING THE TRANSMISSION OIL/ CHK ADJ
CLEANING THE AIR FILTER ELEMENT
7. Fill:
9 transmission case
(with the specified amount of the recom-
mended transmission oil)
Recommended oil
Engine oil
Quantity
Total amount
0.12 L (0.11 Imp qt, 0.13 US qt)
Periodic replacement
0.10 L (0.09 Imp qt, 0.11 US qt)
8. Install:
9 transmission oil filler plug

EAS00086

REPLACING THE AIR FILTER ELEMENT

1. Check:
1 9 check cap 1
NOTE:
Check the air filter check cap locating at the bottom of
air filter case. If a foreign material such as dust and
water is found, replace the air filter element. Also,
clean the air filter case and air filter check cap.

2. Remove:
9 air filter case cover 1
NOTE:
1
Unhook the mud flap 2 from the check cap, and
then remove the air filter case cover and the air
filter element together.

3. Remove:
1 9 air filter element 1

3-
 CLEANING THE AIR FILTER ELEMENT/ CHK ADJ
CHECKING THE V-BELT
4. Check:
9 air filter element Damage/obstruction
 Replace.
cC
Do not clean using a compressed air.

NOTE:
9 Peplace the air filter element every 15000 km
(9321 mi) of operation.
9 The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.
5. Install:
9 air filter element
9 air filter case cover
cC
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible
overheat- ing.

NOTE:
When installing the air filter element into the air
filter case cover, make sure their sealing sur- faces
are aligned to prevent any air leaks.

EAS00320

CHECKING THE V-BELT

1. Remove:
1 9 V-belt case cover
Refer to “KICKSTARTER” in chapter 4.
2. Check:
a 9 V-belt 1
Cranks/damage/wear  Replace. Grease/oil
 Clean the primary and sec- ondary
sheaves.
Refer to “BELT DRIVE” in chapter 4.
3. Measure:
9 V-belt width a
Out of specification  Replace. Refer
to “BELT DRIVE” in chapter 4.

V-belt width
18.2 mm (0.72 in)
<Limit>: 17.2 mm (0.68 in)
4. Install:
9 V-belt case cover
Refer to “KICKSTARTER” in chapter 4.

3-
 CHK ADJ
CLEANING THE V-BELT CASE AIR FILTER ELEMENT
EAS00091

CLEANING THE V-BELT CASE AIR FILTER

ELEMENT
1 NOTE:
On the bottom of the V-belt case cover is a check
hose 1. If dust or water or both collects in this
hose, clean the V-belt air filter elements.

1. Loosen:
9 V-belt case air duct clamp bolt 1
2. Remove:
1
9 V-belt case air filter assembly 2
9 V-belt case air filter cap 3
9 V-belt case air filter element 4

3. Clean:
9 V-belt case air filter dust seal
Wipe the V-belt case air filter dust seal clean
with a dry cloth.
4. Clean:
9 V-belt case air filter element
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the element gently, but thoroughly in
solvent.

w
Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.

b. Squeeze the excess solvent out of the ele-

ment and let it dry.

3-
 CLEANING THE V-BELT CASE AIR FILTER ELEMENT/ CHK ADJ
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD

cC
Do not twist or wring out the element. This
could damage the foam material.

c. Apply oil of the recommended type to the

entire surface of the element, and then squeeze
the excess oil out.
NOTE:
The element should be wet but not dripping.

Recommended oil
Engine oil

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
9 V-belt case air filter element
9 V-belt case air filter cap
9 V-belt case air filter cap bolt
2 Nm (0.2 m·kg, 1.4 ft·lb)
9 V-belt case air filter assembly
9 V-belt case air filter assembly bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
6. Install:
9 V-belt case air duct clamp bolt
2 Nm (0.2 m·kg, 1.4 ft·lb)

EAS00094

CHECKING THE CARBURETOR JOINT

AND INTAKE MANIFOLD
1. Remove:
9 seat
9 center cover
Refer to “REMOVING THE SEAT AND
SIDE COVERS”.

2. Check:
9 intake manifold 1
2 9 carburetor joint 2
Cracks/damage  Replace.
Refer to “CARBURETOR” in chapter 5.

3-
 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/ CHK ADJ
CHECKING THE FUEL AND VACUUM HOSES/CHECKING THE BREATHER HOSES
3. Install:
9 center cover
9 seat
Refer to “INSTALLING THE SEAT AND
SIDE COVERS”.

EAS00096

CHECKING THE FUEL AND VACUUM

HOSES
1. Remove:
9 seat
9 center cover
9 grab bar
9 left side cover
Refer to “REMOVING THE SEAT AND
SIDE COVERS”.

1
2. Remove:
9 V-belt case air duct 1

3. Check:
9 fuel hose 1 1
9 vacuum hose 2 2
9 fuel hose 2 3
Cracks/damage  Replace.
Loose connection  Connect properly.
4. Install:
9 V-belt case air duct
3 1
2 9 V-belt case air duct screw
7 Nm (0.7 m·kg, 5.1 ft·lb)
9 left side cover
9 grab bar
9 center cover
9 seat
Refer to “INSTALLING THE SEAT AND
SIDE COVERS”.
EAS00098

CHECKING THE BREATHER HOSES

1. Remove:
9 seat
9 center cover
Refer to “REMOVING THE SEAT AND
SIDE COVERS”.

3-
 CHECKING THE BREATHER HOSES/ CHK ADJ
CHECKING THE EXHAUST SYSTEM
2. Check:
9 cylinder head breather hose 1
9 crankcase breather hose 2
Cracks/damage  Replace.
Loose connection  Connect properly.

cC
1 Make sure the cylinder head breather hose
is routed correctly.

2 3. Install:
9 center cover
9 seat
Refer to “INSTALLING THE SEAT AND
SIDE COVERS”.

CHECKING THE EXHAUST SYSTEM

1. Remove:
9 seat
9 center cover
Refer to “REMOVING THE SEAT AND
SIDE COVERS”.
2. Check:
1
9 exhaust pipe nuts 1
Loose/damage  Tighten/replace.
20 Nm (2.0 m·kg, 14 ft·lb)
3. Check:
9 muffler 1
Cracks/damage  Replace.
9 exhaust pipe gasket 2
Exhaust gas leaks  Tighten/replace.

3-
 ADJUSTING THE REAR BRAKE/ CHK ADJ
CHECKING THE BRAKE FLUID LEVEL
EAS00108

CHASSIS
a EAS00114

ADJUSTING THE REAR BRAKE

1. Check:
9 brake lever free play a
Out of specification  Adjust.
Brake lever free play (lever end)
10 ~ 20 mm (0.39 ~ 0.79 in)

2. Adjust:
9 brake lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting nut 1 in direction a or b
until the specified brake lever free play is
obtained.

Brake lever free play is

Direction a
increased.
Brake lever free play is
Direction b
decreased.

cC
After adjusting the brake lever free play,
make sure there is no brake drag.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00115

CHECKING THE BRAKE FLUID LEVEL

1. Stand the vehicle on a level surface.
NOTE:
9 Place the vehicle on a suitable stand.
9 Make sure the vehicle is upright.

2. Check:
9 brake fluid level
a Below the minimum level mark a 
Remove the reservoir cap and add the rec-
ommended brake fluid to the proper level.
Recommended brake fluid
DOT 4

3-
 CHECKING THE BRAKE FLUID LEVEL/ CHK ADJ
CHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKE SHOES
w
9 Use only the designated brake fluid. Other
brake fluids may cause the rubber seals
to
deteriorate, causing leakage and poor
brake performance.
9 Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
perfor- mance.
9 When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.

cC
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

NOTE:
9 If DOT 4 brake fluid is not available, DOT 3
brake fluid can be used.
9 In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.

EAS00120

CHECKING THE FRONT BRAKE PADS

1. Operate the brake.
2. Check:
9 front brake pads
Wear indicator groove 1 almost disap-
1 peared  Replace the brake pads as a set.
1 Refer to “REPLACING THE FRONT
BRAKE PADS” in chapter 6.

EAS00126

CHECKING THE REAR BRAKE SHOES

1. Operate the brake.
2. Check:
9 wear indicator 1
Reaches the wear limit line 2  Replace
the brake shoes as a set.
Refer to “REAR WHEEL AND BRAKE” in
1 2 chapter 6.

3-
 CHECKING THE FRONT BRAKE HOSE/ CHK ADJ
BLEEDING THE HYDRAULIC BRAKE SYSTEM
EAS00129

CHECKING THE FRONT BRAKE HOSE

1. Check:
9 brake hose
Cracks/damage/wear  Replace.
2. Check:
9 brake hose holder
Loose connection  Tighten the clamp bolt.
3. Hold the vehicle upright and apply the front
brake several times.
4. Check:
9 brake hose
Brake fluid leakage  Replace the dam- aged
hose.
Refer to “FRONT BRAKE” in chapter 6.

EAS00133

BLEEDING THE HYDRAULIC BRAKE

SYSTEM

w
Bleed the hydraulic brake system whenev-
er:
9 the system is disassembled.
9 a brake hose is loosened, disconnected or
replaced.
9 the brake fluid level is very low.
9 brake operation is faulty.

NOTE:
9 Be careful not to spill any brake fluid or allow the
brake master cylinder reservoir to over- flow.
9 When bleeding the hydraulic brake system, make
sure there is always enough brake fluid before
applying the brake. Ignoring this pre- caution
could allow air to enter the hydraulic brake
system, considerably lengthening the bleeding
procedure.
9 If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat the
bleeding procedure when the tiny bubbles in the
hose have disappeared.

3-
 CHK ADJ
BLEEDING THE HYDRAULIC BRAKE SYSTEM
1. Bleed:
9 hydraulic brake system
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the brake master cylinder reservoir
diaphragm.
1
c. Connect a clear plastic hose 1 tightly to
the bleed screw 2.
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Fully pull the brake lever without releasing it.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the pressure
and cause the brake lever to contact the throttle
grip.

h. Tighten the bleed screw and then release the

brake lever.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake fluid
in the plastic hose.
j. Tighten the bleed screw to specification.

Bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid. Refer
to “CHECKING THE BRAKE FLUID
LEVEL”.

w
After bleeding the hydraulic brake system,
check the brake operation.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3-
 ADJ
CH
CHECKING AND ADJUSTING THE STEERING HEAD
EAS00148

CHECKING AND ADJUSTING THE

STEERING HEAD
1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there
is no danger of it falling over.

NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.

2. Check:
9 steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness  Adjust the steering
head.
3. Remove:
9 front cowling
9 leg shield
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD”.

4. Adjust:
9 steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Loosen the upper ring nut 1.
b. Loosen the lower ring nut 2 and then
tighten it to specification with the steering
nut wrench 3.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
3
Steering nut wrench
90890-01403
2
Lower ring nut
30 Nm (3.0 m·kg, 22 ft·lb)

3-
 CHECKING AND ADJUSTING THE STEERING HEAD/ CHK ADJ
CHECKING THE FRONT FORK
c. Loosen the lower ring nut counterclock-
1 wise 1/4 of a turn.
d. Hold the lower ring nut with a ring nut
wrench 4 and tighten the upper ring nut 1
4 with a steering nut wrench.

w
Do not overtighten the lower ring nut.

Ring nut wrench

90890-01268

Upper ring nut

75 Nm (7.5 m·kg, 54 ft·lb)
e. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chapter 6.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
9 leg shield
9 front cowling
Refer to “INSTALLING THE FRONT
COWLING AND LEG SHIELD”.

EAS00149

CHECKING THE FRONT FORK

1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there
is no danger of it falling over.

3-
 ADJ
CH
CHECKING THE FRONT FORK/CHECKING THE TIRES
2. Check:
9 inner tube
Damage/scratches  Replace.
9 oil seal
Oil leakage  Replace.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
9 front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement  Repair.
Refer to “FRONT FORK” in chapter 6.

EASF0015

CHECKING THE TIRES

The following procedure applies to both of the tires.
1. Check:
9 tire pressure
Out of specification  Regulate.

w
9 The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
9 The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated rid-
ing speed.
9 Operation of an overloaded vehicle could
cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE VEHICLE.

3-
 CHK ADJ
CHECKING THE TIRES

Basic weight
(with oil and
94 kg (207 lb)
a full fuel
tank)
Maximum
163 kg (359 lb)
load*
Front Rear
Cold tire 200 kPa 225 kPa
pressure (2.00 kgf/cm , (2.25 kgf/cm2,
2

29 psi) 33 psi)
* Total weight of rider, passenger, cargo and
accessories

w
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.

2. Check:
9 tire surfaces
Damage/wear  Replace the tire.
Minimum tire tread depth
0.8 mm (0.031 in)
1 Tire tread depth
2 Sidewall
3 Wear indicator

3-
 ADJ
CH
CHECKING THE TIRES

w
9 Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
9 When using tube tires, be sure to install
the correct tube.
9 Always replace a new tube tire and a new
tube as a set.
9 To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
9 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.
Tube wheel Tube tire only
Tube or tubeless
Tubeless wheel
tire.

9 After extensive tests, the tires listed

below have been approved by Yamaha
Motor Co., Ltd. for this model. The front
and rear tires should always be by the
same manufac- turer and of the same
design. No guaran- tee concerning
handling characteristics can be given if a
tire combination other than one approved
by Yamaha is used on this vehicle.

w
9 New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
(60 mi) should be traveled at normal
speed before any high-speed riding is
done.
9 After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 properly.

NOTE:
For tires with a direction of rotation mark 2:
9 Install the tire with the mark pointing in the
direction of wheel rotation.
9 Align the mark 3 with the valve installation
point.

3-
 CHECKING THE WHEELS/ CHK ADJ
CHECKING AND LUBRICATING THE CABLES
EAS00168

CHECKING THE WHEELS

The following procedure applies to both of the
wheels.
1. Check:
9 wheel
Damage/out-of-round  Replace.

w
Never attempt to make any repairs to the
wheel.

NOTE:
After a tire or wheel has been changed or replaced,
always balance the wheel.

EAS00170

CHECKING AND LUBRICATING THE

CABLES
The following procedure applies to all of the inner
and outer cables.

w
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.

1. Check:
9 outer cable
Damage  Replace.
2. Check:
9 cable operation
Rough movement  Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant

NOTE:
Hold the cable end upright and pour a few drops of
lubricant into the cable sheath or use a suitable
lubricating device.

3-
LUBRICATING THE LEVERS/LUBRICATING THE SIDESTAND/ CHK ADJ
LUBRICATING THE CENTERSTAND
EAS00171

LUBRICATING THE LEVERS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers.

Recommended lubricant
Lithium-soap-based grease

EAS00172

LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.

Recommended lubricant
Lithium-soap-based grease

EAS00173

LUBRICATING THE CENTERSTAND

Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.

Recommended lubricant
Lithium-soap-based grease

3-
 CH
CHECKING AND CHARGING THE K
EAS00178

ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY

w
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
9 Wear protective eye gear when handling
or working near batteries.
9 Charge batteries in a well-ventilated area.
9 Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
9 DO NOT SMOKE when charging or han-
dling batteries.
9 KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
9 Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
9 Skin — Wash with water.
9 Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
9 Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.

1. Open the seat.

2. Unhook the battery band 1 and open the lid

1 2.

3-
 CH
CHECKING AND CHARGING THE K
3. Disconnect:
3 9 battery leads
(from the battery terminals)
1 cC
First, disconnect the negative battery lead
1, and then positive battery lead 2.
2
4. Remove:
9 battery 3
5. Check:
9 battery terminals
Dirt  Clean with a wire brush.

6. Check:
9 battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery ter-
minals.

Positive tester probe 

positive battery terminal
Negative tester probe 
negative battery terminal

NOTE:
9 The charge state of an MF battery can be checked
by measuring its open-circuit voltage (i.e., the
voltage when the positive battery ter- minal is
disconnected).
9 No charging is necessary when the open-cir- cuit
voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown in

the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3-
 CH
CHECKING AND CHARGING THE K
7. Charge:
9 battery
(refer to the appropriate charging method
illustration)

w
Do not quick charge a battery.

cC
9 Never remove the MF battery sealing
caps.
9 Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
bat- tery overheating and battery plate
dam- age.
9 If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
9 When charging a battery, be sure to
remove it from the vehicle. (If charging
has to be done with the battery mounted
on the vehicle, disconnect the negative
battery lead from the battery terminal.)
9 To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
9 Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
9 Make sure the battery charger lead clips
are in full contact with the battery
terminal and that they are not shorted. A
corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
9 If the battery becomes hot to the touch at
any time during the charging process,
dis- connect the battery charger and let
the battery cool before reconnecting it.
Hot batteries can explode!

3-
 CH
CHECKING AND CHARGING THE K
9 As shown in the following illustration, the
open-circuit voltage of an MF battery sta-
bilizes about 30 minutes after charging
has been completed. Therefore, wait 30
minutes after charging is completed
before measuring the open-circuit volt-
age.

8. Install:
9 battery 3
3
9. Lubricate:
9 battery terminals
2
Recommended lubricant
Dielectric grease
10. Connect:
1
9 battery leads
(to the battery terminals)

cC
First, connect the positive battery lead 1,
and then the negative battery lead 2.

11. Close the lid 1 and hook the battery band

2 2.
12. Close the seat.
1

3-
 ADJ
CH
CHECKING THE FUSE
EASF0017

CHECKING THE FUSE

cC
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.

1. Open the seat.

2. Unhook the battery band 1 and open the lid

1 2.
3. Check:
2 9 fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “  1”.

Pocket tester
90890-03112
b. If the pocket tester indicates “”, replace the
fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Replace:
9 blown fuse

w
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
2
5. Close the lid 1 and the hook battery band
2.
1

3-
 ADJ
CH
REPLACING THE HEADLIGHT BULB
EAS00182

REPLACING THE HEADLIGHT BULB

1. Remove:
9 front cowling
Refer to “REMOVING THE FRONT
COWLING AND LEG SHIELD”.
2. Remove:
9 cap 1
1 9 headlight bulb holder 2

3. Remove:
9 headlight bulb 3

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

4. Install:
9 headlight bulb
Secure the new headlight bulb with the
headlight bulb holder.

cC
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of
the bulb and the luminous flux will be
adverse- ly affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.

5. Install:
9 headlight bulb holder
9 cap
6. Install:
9 front cowling
Refer to “INSTALLING THE FRONT
COWLING AND LEG SHIELD”.

3-
 ADJ
CH
ADJUSTING THE HEADLIGHT BEAM
EAS00186

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
a b 9 headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the headlight adjusting bolt 1 in a or
1
out b.

Headlight beam is
Turn in a
lowered.
Headlight beam is
Turn out b
raised.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3-
 EN
CHAPTER 4
ENGINE

REMOVING THE ENGINE...........................................................................4-1

ENGINE OIL......................................................................................................4-1
COVERS.............................................................................................................4-1
LEADS AND STORAGE BOX..........................................................................4-1
CARBURETOR..................................................................................................4-2
MUFFLER..........................................................................................................4-2
CABLE AND HOSE...........................................................................................4-2
REAR SHOCK ABSORBER ASSEMBLY BOLT.............................................4-3
ENGINE ASSEMBLY........................................................................................4-3

INSTALLING THE ENGINE.........................................................................4-3

ENGINE ASSEMBLY........................................................................................4-3
REAR SHOCK ABSORBER ASSEMBLY BOLT.............................................4-4
CABLE AND HOSE...........................................................................................4-4
MUFFLER..........................................................................................................4-4
CARBURETOR..................................................................................................4-5
LEADS AND STORAGE BOX..........................................................................4-5
COVERS.............................................................................................................4-6
ENGINE OIL......................................................................................................4-6

CYLINDER HEAD........................................................................................4-7
REMOVING THE CYLINDER HEAD..............................................................4-8
CHECKING THE CYLINDER HEAD.............................................................4-11
CHECKING THE TIMING CHAIN GUIDE...................................................4-12
CHECKING THE TIMING CHAIN TENSIONER..........................................4-12
INSTALLING THE CYLINDER HEAD..........................................................4-13

CAMSHAFT...............................................................................................4-18
REMOVING THE ROCKER ARMS AND CAMSHAFT................................4-19
CHECKING THE CAMSHAFTS.....................................................................4-20
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS............4-21
CHECKING THE CAMSHAFT SPROCKET..................................................4-22
CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER
..........................................................................................................................4-22
INSTALLING THE CAMSHAFTS AND ROCKER ARMS...........................4-22

VALVES AND VALVE SPRINGS...............................................................4-24

REMOVING THE VALVES............................................................................4-25
CHECKING THE VALVES AND VALVE GUIDES......................................4-26
CHECKING THE VALVE SEATS...................................................................4-28
CHECKING THE VALVE SPRINGS..............................................................4-30
INSTALLING THE VALVES...........................................................................4-31
 CH
CYLINDER AND PISTON..........................................................................4-33
REMOVING THE CYLINDER AND PISTON................................................4-34
ENG
CHECKING THE CYLINDER AND PISTON.................................................4-35
CHECKING THE PISTON RINGS..................................................................4-36
CHECKING THE PISTON PIN........................................................................4-37
INSTALLING THE PISTON AND CYLINDER..............................................4-38

KICKSTARTER..........................................................................................4-40
REMOVING THE KICKSTARTER.................................................................4-41
DISASSEMBLING THE KICKSTARTER SHAFT.........................................4-41
CHECKING THE KICKSTARTER..................................................................4-42
ASSEMBLING THE KICKSTARTER.............................................................4-43
INSTALLING THE KICKSTARTER...............................................................4-43

BELT DRIVE..............................................................................................4-45
V-BELT, PRIMARY AND SECONDARY SHEAVE......................................4-45
REMOVING THE SECONDARY SHEAVE AND V-BELT...........................4-47
REMOVING THE PRIMARY SHEAVE..........................................................4-48
DISASSEMBLING THE SECONDARY SHEAVE.........................................4-49
CHECKING THE CLUTCH HOUSING..........................................................4-50
CHECKING THE CLUTCH SHOES................................................................4-50
CHECKING THE V-BELT...............................................................................4-51
CHECKING THE PRIMARY SHEAVE WEIGHTS........................................4-51
CHECKING THE SECONDARY SHEAVE....................................................4-51
ASSEMBLING THE PRIMARY SHEAVE......................................................4-52
ASSEMBLING THE SECONDARY SHEAVE................................................4-54
INSTALLING THE BELT DRIVE...................................................................4-56

STARTER CLUTCH...................................................................................4-58
REMOVING THE STARTER CLUTCH..........................................................4-59
CHECKING THE STARTER CLUTCH...........................................................4-59
INSTALLING THE STARTER CLUTCH........................................................4-60

A.C. MAGNETO.........................................................................................4-61
REMOVING THE A.C. MAGNETO................................................................4-62
INSTALLING THE A.C. MAGNETO..............................................................4-63

OIL PUMP..................................................................................................4-64
REMOVING THE OIL PUMP..........................................................................4-65
DISASSEMBLING THE OIL PUMP...............................................................4-65
CHECKING THE OIL PUMP...........................................................................4-66
CHECKING THE OIL STRAINER..................................................................4-67
ASSEMBLING THE OIL PUMP......................................................................4-67
INSTALLING THE OIL PUMP........................................................................4-67

TRANSMISSION........................................................................................4-69
REMOVING THE TRANSMISSION...............................................................4-70
CHECKING THE TRANSMISSION................................................................4-71
INSTALLING THE TRANSMISSION.............................................................4-71

3-
 EN
CRANKSHAFT...........................................................................................4-73
DISASSEMBLING THE CRANKCASE..........................................................4-74
REMOVING THE CRANKSHAFT ASSEMBLY............................................4-75
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE..............4-76
CHECKING THE CRANKSHAFT AND CONNECTING ROD.....................4-76
CHECKING THE CRANKCASE.....................................................................4-77
CHECKING THE BEARINGS AND OIL SEALS...........................................4-77
INSTALLING THE CRANKSHAFT................................................................4-78
ASSEMBLING THE CRANKCASE................................................................4-78
ENG
 ENG
REMOVING THE ENGINE
EASF0018

ENGINE
REMOVING THE ENGINE
NOTE:
It is not necessary to remove the engine in order
to remove the following components.
9 Cylinder head
9 Cylinder
9 Piston
9 Starter clutch
9 Starter motor
9 Kickstarter shaft
9 V-belt
9 Primary sheave
9 Secondary sheave
9 Transmission
9 Rear wheel assembly
9 Oil pump
9 A.C. magneto

ENGINE OIL
1. Drain:
9 engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.

COVERS
1. Remove:
9 footboard
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
1
LEADS AND STORAGE BOX
1. Remove:
9 storage box 1

2. Disconnect:
9 battery cable coupler 9
starter relay coupler 1 9
starter motor coupler

4-
 ENG
REMOVING THE ENGINE
CARBURETOR
1. Loosen:
9 air filter case bolt
Refer to “AIR FILTER CASE” in chapter 5.

MUFFLER
1. Remove:
9 muffler nuts 1

2. Remove:
9 muffler bolts 1
4 1
9 washer
9 nuts
9 washer
9 spacer
9 muffler 2
2
3 9 muffler stay bolts 3
1
9 washers
9 muffler stay 4

1
CABLE AND HOSE
1. Disconnect:
9 air induction system hose 1

2. Disconnect:
9 vacuum hose 1
9 cylinder head breather hose 2
9 battery coupler

4-
 ENG
REMOVING THE ENGINE/INSTALLING THE ENGINE
3. Remove:
9 rear brake cable 1
9 rear brake cable holder 2

REAR SHOCK ABSORBER ASSEMBLY

BOLT
1. Remove:
9 V-belt air filter case assembly

2. Remove:
1 9 rear shock absorber assembly bolt 1

ENGINE ASSEMBLY
1. Remove:
9 engine mounting nut 1
9 washer
9 engine mount bolt 2
9 engine assembly

2
1 w
Securely support the vehicle so there is no
danger of it falling over.

EASF0019

INSTALLING THE ENGINE

ENGINE ASSEMBLY
w
Securely support the vehicle so there is no
danger of it falling over when installing
engine.

1. Install:
9 engine assembly 9
engine mounting bolt 9
washer
9 engine mounting nut
59 Nm (5.9 m·kg, 43 ft·lb)

4-
 INSTALLING THE EN
REAR SHOCK ABSORBER ASSEMBLY
BOLT
1. Install:
9 rear shock absorber assembly bolt
16 Nm (1.6 m·kg, 11 ft·lb)
2. Install:
9 V-belt air filter case assembly
10 Nm (1.0 m·kg, 7.2 ft·lb)

CABLE AND HOSE

1. Connect:
9 vacuum hose
2. Install:
9 rear brake cable
9 rear brake cable holder
9 rear brake cable holder screws
7 Nm (0.7 m·kg, 5.1 ft·lb)
3. Connect:
9 cylinder head breather hose
9 vacuum hose
4. Adjust:
9 rear brake lever free play
Refer to “ADJUSTING THE REAR
BRAKE” in chapter 3.

MUFFLER
1. Install:
1 9 muffler stay 1
4 3
0 (to the muffler 2)
9 muffler upper bolt 3
q (install without tightening)
9 7 9 nut 4
9 spacer 5
2 8 5 6 9 washer 6
9 muffler lower bolt 7
(install without tightening)
9 washer 8
9 nut 9
NOTE:
Install the washer 8 and the nut 9 as shown.

4-
 ENG
INSTALLING THE ENGINE
2. Install:
9 muffler stay
(to the right crankcase)
9 washer
9 muffler stay upper bolt 0
(tighten temporarily)
9 washer
9 muffler stay lower bolt q
(tighten temporarily)

3. Tighten:
9 nuts 1 20 Nm (2.0 m·kg, 14 ft·lb)
4. Tighten:
9 muffler stay upper bolt
9 muffler stay lower bolt
37 Nm (3.7 m·kg, 27 ft·lb)
5. Tighten:
9 muffler upper bolt
50 Nm (5.0 m·kg, 36 ft·lb)
9 muffler lower bolt
35 Nm (3.5 m·kg, 25 ft·lb)

CARBURETOR
1. Install:
9 air filter case
Refer to “AIR FILTER CASE” in chapter 5.
2. Adjust:
9 throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.

LEADS AND STORAGE BOX

1. Connect:
9 starter motor coupler 9
starter relay coupler 9
battery cable coupler

2. Install: 9
storage box 9
storage box bolt
9 Nm (0.9 m·kg, 6.6 ft·lb)

4-
INSTALLING THE EN
COVERS
1. Install:
9 footboard
Refer to “INSTALLING THE FRONT
COWLING AND LEG SHIELD” in chapter
3.

ENGINE OIL
1. Fill:
9 crankcase
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.

4-
 CYLINDER EN
EASF0023

CYLINDER HEAD
1 Cylinder head 8 O-ring y Rubber cover
2 Spark plug 9 Camshaft sprocket cover u Timing chain tensioner
3 O-ring 0 Dowel pin i Gasket
4 Tappet cover o Ignition coil assembly bracket
q Gasket w
5 Camshaft sprocket
Gasket e p Ignition coil assembly
6 Camshaft sprocket plate a Engine cooling fan
O-ring
7 Timing chain guide r Intake manifold s Engine cooling fan cover
(exhaust side) t Air shroud

4-
 CYLINDER EN
EAS00225

REMOVING THE CYLINDER HEAD

1. Remove:
9 seat
9 center cover
9 grab bar
9 side cover (left and right)
9 footboard
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.

2. Remove:
9 battery
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.

3. Remove:
9 storage box
Refer to “REMOVING THE ENGINE”.

4. Remove:
9 air filter case
Refer to “AIR FILTER CASE” in chapter 5.
9 carburetor assembly
Refer to “CARBURETOR” in chapter 5.

5. Remove:
9 muffler
Refer to “REMOVING THE ENGINE”.
6. Remove:
9 spark plug cap 1
9 spark plug 2
9 ignition coil assembly 3

3
2
1

2 7. Remove:
9 vacuum hose 1
4 9 cylinder head breather hose holder 2
1
3 9 intake manifold 3
9 air induction system pipe 4
9 ignition coil assembly bracket 5

4-
 CYLINDER EN
HEAD
1 9 intake tappet cover 1
9 exhaust tappet cover 2
9 camshaft sprocket cover 3
(with the O-ring)
3

9. Remove:
1
9 rubber cover 1
9 air shroud (left) 2
9 engine cooling fan cover 3
9 air shroud (right) 4
2

10. Remove:
9 engine cooling fan 1

4-
 CYLINDER EN
11. Align:
9 “I” mark a on the A.C. magneto rotor (with
the stationary pointer b on the
b crankcase)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a a. Turn the crankshaft clockwise.
b. When the piston is at the Top Dead Center
(TDC) on the compression stroke, align the
“I” mark c on the camshaft sprocket with
the stationary pointer d on the cylinder
head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d

12. Loosen:
9 camshaft sprocket bolt 1
NOTE:
While holding the A.C. magneto rotor with the
rotor holding tool 2, loosen the camshaft sprocket
bolt.
1

2 Rotor holding tool

90890-01235
13. Remove:
9 timing chain tensioner 1
1 (along with the gasket)

14. Remove:
1 9 camshaft sprocket bolt 1
9 camshaft sprocket plate 2
2 9 camshaft sprocket 3
9 timing chain 4
3 NOTE:
4 To prevent the timing chain from falling into the
crankcase, fasten it with a wire.

4-
 CYLINDER EN
15. Remove:
9 cylinder head

6 2 NOTE:
4 9 Loosen the bolts and nuts in the proper sequence as
shown.
3 9 Loosen each nut 1/2 of a turn at a time. After all
5 1 of the nuts are fully loosened, remove them.

16. Remove: 9
1 dowel pins 1 9
gasket 2
9 timing chain guide (exhaust side) 3
2

EAS00227

CHECKING THE CYLINDER HEAD

1. Eliminate:
9 combustion chamber carbon deposits (with a
rounded scraper)
NOTE:
Do not use a sharp instrument to avoid dam- aging
or scratching:
9 spark plug bore threads
9 valve seats

2. Check:
9 cylinder head Damage/scratches 
Replace.

4-
 CYLINDER EN
3. Measure:
9 cylinder head warpage
Out of specification  Resurface the cylin-
der head.
Maximum cylinder head warpage
0.05 mm (0.0020 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on the
surface plate and resurface the cylin- der head
using a figure-eight sanding pat- tern.
NOTE:
To ensure an even surface, rotate the cylinder head
several times.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

CHECKING THE TIMING CHAIN GUIDE

1. Check:
9 timing chain guide (exhaust side) Damage/wear
 Replace.

EAS00210

CHECKING THE TIMING CHAIN TEN- SIONER

1. Check:
1
9 timing chain tensioner
Cracks/damage  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the plug cap.
b. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with
a thin screwdriver 1.
c. Remove the screwdriver and slowly release the timing chain tensioner rod.
d. Make sure that the timing chain tensioner rod
comes out of the timing chain tension- er
housing smoothly. If there is rough movement,
replace the timing chain ten- sioner.
e. Install the plug cap.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-
 CYLINDER EN
2. Check:
9 one-way cam
9 timing chain tensioner rod
Damage/wear  Replace the defective part(s).

EAS00231

2
INSTALLING THE CYLINDER HEAD
For installation, reverse the removal procedure.
1. Install:
9 timing chain guide (exhaust side) 1
New 3
9 dowel pins 2
9 gasket 3
1

2. Install:
4 9 cylinder head
3. Tighten:
1 5 9 cylinder head nuts
6 3
22 Nm (2.2 m·kg, 16 ft·lb)
7 9 cylinder head bolts
4
6 10 Nm (1.0 m·kg, 7.2 ft·lb)
2
5 NOTE:
9 Lubricate the cylinder head nuts with engine oil.
9 Tighten the cylinder head nuts and bolts in the
proper tightening sequence as shown and torque
them in two stages.
9 Install the copper washer onto the 4 and 5 stud
bolt then install the steel washer onto the 6 and
7 stud bolt.

4-
 CYLINDER EN
HEAD
9 camshaft sprocket 1
9 timing chain 2
b ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the “I” mark a on the A.C. mag-
a neto rotor is aligned with the stationary
pointer b on the crankcase.
b. Align the “I” mark c on the camshaft
sprocket with the stationary pointer d on the
cylinder head.
c. Install the timing chain onto the camshaft
1 sprocket, and then install the camshaft
sprocket onto the camshaft.
d
NOTE:
9 When installing the camshaft sprocket, be sure to
c keep the timing chain as tight as pos- sible on the
exhaust side.
2
9 Align the projection e on the camshaft
sprocket with the slot in the camshaft.

e cC
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.

d. While holding the camshaft, temporarily

tighten the camshaft sprocket bolt.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Install
9 timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Remove the plug cap.
b. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod fully
clockwise with a thin screwdriver 1.
NOTE:
Make sure that the tensioner rod has been fully set
clockwise.
1
c. Install the gasket and the timing chain ten-
sioner 2 onto the cylinder.
2
w
Always use a new gasket.

4-
 CYLINDER EN
Timing chain tensioner bolt
9 Nm (0.9 m·kg, 6.5 ft·lb)

d. Turn the timing chain tensioner rod coun-

terclockwise with a thin screwdriver 1, make
sure it releases, and then install the plug cap.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6. Tighten:
9 camshaft sprocket bolt
30 Nm (3.0 m·kg, 22 ft·lb)

cC
Be sure to tighten the camshaft sprocket
bolt to the specified torque to avoid the
possibility of the bolt coming loose and
damaging the engine.

7. Turn:
9 crankshaft
(several turns clockwise)

8. Check:
9 “I” mark a
Align the “I” mark on the A.C. magneto
b rotor with the stationary pointer b on the
crankcase.
a 9 “I” mark c
Align the “I” mark on the camshaft sprock- et
with the stationary pointer d on the
cylinder head.
Out of alignment  Correct.
Refer to the installation steps above.

4-
 CYLINDER EN
HEAD
9 engine cooling fan
9 engine cooling fan bolts
8 Nm (0.8 m·kg, 5.8 ft·lb)

10. Install:
9 air shroud (right)
9 engine cooling fan cover 1
9 engine cooling fan cover screws 2
7 Nm (0.7 m·kg, 5.1 ft·lb)
9 air shroud (left)
2 9 rubber cover
1 2

11. Install:
9 camshaft sprocket cover
9 camshaft sprocket cover bolts
12 Nm (1.2 m·kg, 8.7 ft·lb)
12. Install:
9 exhaust tappet cover
9 intake tappet cover
18 Nm (1.8 m·kg, 13 ft·lb)

13. Install:
9 intake manifold
9 cylinder head breather hose holder
9 intake manifold bolts
10 Nm (1.0 m·kg, 7.2 ft·lb)
14. Install:
9 ignition coil assembly
9 ignition coil assembly screws
7 Nm (0.7 m·kg, 5.1 ft·lb)

4-
 CYLINDER EN
15. Install:
9 spark plug 9 15 Nm (1.5 m·kg, 11 ft·lb)
spark plug cap 9
muffler
Refer to “REMOVING THE ENGINE”.
9 carburetor assembly
Refer to “CARBURETOR” in chapter 5.
9 air filter case
Refer to “AIR FILTER CASE” in chapter 5.
9 storage box
9 battery
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
9 footboard
9 side cover (left and right)
9 center cover
9 seat
Refer to “INSTALLING THE SEAT AND
SIDE COVERS” in chapter 3.

4-
 CAMSHAF EN
EASF0020

CAMSHAFT
1 Locknut 5 Rocker arm shaft (intake side) 6
2 Adjusting screw Rocker arm shaft (exhaust side) 7
3 Rocker arm (intake side)
Camshaft
4 Rocker arm (exhaust side) 8 Camshaft retainer

4-
 CAMSHAF EN
EASF0022

REMOVING THE ROCKER ARMS 2

AND CAMSHAFT
1 NOTE:
Prior to remove the rocker arms and camshaft,
remove the cylinder head.

1. Loosen:
9 locknuts 1
9 adjusting screws 2
2. Remove:
9 camshaft retainer
1 1

3. Remove:
9 intake rocker arm shaft 9 exhaust rocker arm shaft 9 intake rocker arm 9 exhaust
2 1
rocker arm
NOTE:
Remove the rocker arm shafts with the slide
hammer bolt 1 and weight 2.

Slide hammer bolt

1 90890-01085
Weight
90890-01084
2
4. Remove:
9 camshaft 1
NOTE:
Screw 8 mm bolt 2 into the threaded end of the
camshaft and then pull out the camshaft.

4-
 CAMSHAF EN
EAS00205

CHECKING THE CAMSHAFTS

1. Check:
9 camshaft lobes
Blue discoloration/pitting/scratches 
Replace the camshaft.

2. Measure:
9 camshaft lobe dimensions a and b
Out of specification  Replace the camshaft.

Camshaft lobe dimension limit

Intake
a 25.881 ~ 25.981 mm
(1.0189 ~ 1.0229 in)
<Limit>: 25.780 mm (1.0150 in)
b 21.195 ~ 21.295 mm
(0.8344 ~ 0.8384 in)
<Limit>: 21.095 mm (0.8305 in)
Exhaust
a 25.841 ~ 25.941 mm
(1.0174 ~ 1.0213 in)
<Limit>: 25.740 mm (1.0134 in)
b 21.050 ~ 21.150 mm
(0.8287 ~ 0.8327 in)
<Limit>: 20.950 mm (0.8248 in)
3. Check:
9 camshaft oil passage
Obstruction  Blow out with compressed air.

4-
 CAMSHAF EN
EAS00206

CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
The following procedure applies to all of the
rocker arms and rocker arm shafts.
1. Check:
9 rocker arm
Damage/wear  Replace.
2. Check:
9 rocker arm shaft
Blue discoloration/excessive wear/pitting/ scratches  Replace or check the lubrica- tion system.
3. Measure:
9 rocker arm inside diameter
Out of specification  Replace.
Rocker arm inside diameter
10.000 ~ 10.015 mm
(0.3937 ~ 0.3943 in)
<Limit>: 10.030 mm (0.3949 in)
4. Measure:
9 rocker arm shaft outside diameter Out of specification  Replace.
Rocker arm shaft outside diameter
9.981 ~ 9.991 mm
(0.3930 ~ 0.3933 in)
<Limit>: 9.950 mm (0.3917 in)
5. Calculate:
9 rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the rocker
arm shaft outside diameter from the rocker arm
inside diameter.

Above 0.08 mm (0.0031 in)  Replace the

defective part(s).

Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.034 mm
(0.0004 ~ 0.0013 in)
<Limit>: 0.08 mm (0.0031 in)

4-
 CAMSHAF EN
EAS00207

CHECKING THE CAMSHAFT SPROCK- ET

1. Check:
9 camshaft sprocket
More than 1/4 tooth wear a  Replace the
camshaft sprocket and the timing chain as a
set.
a Wear
b Correct
1 Timing chain roller
2 Camshaft sprocket

EAS00212

CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER

The following procedure applies to both of the
tappet covers and O-rings.
1. Check:
9 tappet cover
9 camshaft sprocket cover
9 O-ring
Damage/wear  Replace the defective part(s).

EAS00219

INSTALLING THE CAMSHAFTS AND ROCKER ARMS

1 1. Lubricate:
9 camshaft journals
Recommended lubricant
Molybdenum disulfide grease

M
2. Install:
9 camshaft 1

4-
 CAMSHAF EN
3. Lubricate:
9 rocker arm shafts 1

M Recommended lubricant
Molybdenum disulfide oil
4. Install:
9 exhaust rocker arm 9
intake rocker arm 9
1 exhaust rocker arm shaft 9
intake rocker arm shaft

5. Install:
9 camshaft retainer
1 1
9 camshaft retainer bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
NOTE:
Install the camshaft retainer with the folded side
facing inward.

4-
 VALVES AND VALVE EN
EASF0024

VALVES AND VALVE SPRINGS

1 Valve cotter
2 Upper spring seat
3 Valve spring
4 Valve stem seal 5
Lower spring seat 6
Intake valve
7 Exhaust valve

4-
 VALVES AND VALVE EN
EASF0025

REMOVING THE VALVES

NOTE:
Prior to remove the valves, remove the cylinder
head, rocker arms, and camshaft.

The following procedure applies to all of the

valves and related components.
NOTE:
Before removing the internal parts of the cylin- der
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.

1. Check:
9 valve sealing
Leakage at the valve seat  Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent a into the intake and exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat
1.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
9 valve cotters 1
NOTE:
Remove the valve cotters by compressing the valve
spring with the valve spring compressor 2.

Valve spring compressor

90890-01253
Valve spring compressor attach-
ment
90890-01243

4-
 VALVES AND VALVE EN
3. Remove:
9 upper spring seat 1
9 valve spring 2
9 valve stem seal 3
9 lower spring seat 4
9 valve 5
NOTE:
Identify the position of each part very carefully so
that it can be reinstalled in its original place.

EAS00239

CHECKING THE VALVES AND VALVE GUIDES

The following procedure applies to all of the
valves and valve guides.
1. Measure:
9 valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b

Out of specification  Replace the valve guide.

Valve-stem-to-valve-guide clear-
ance
Intake
0.015 ~ 0.042 mm
(0.0006 ~ 0.0017 in)
<Limit>: 0.080 mm (0.0031 in)
Exhaust
0.030 ~ 0.057 mm
(0.0012 ~ 0.0022 in)
<Limit>: 0.110 mm (0.0043 in)

4-
 VALVES AND VALVE EN
2. Replace:
9 valve guide
NOTE:
To ease valve guide removal and installation, and
to maintain the correct fit, heat the cylinder head to
100 C (212 F) in an oven.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve guide remover 1.
b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3 to
obtain the proper valve-stem-to-valve guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.

Valve guide remover (ø5)

90890-04097
Valve guide installer (ø5)
90890-04098
Valve guide reamer (ø5)
90890-04099
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
9 carbon deposits
(from the valve face and valve seat)
4. Check:
9 valve face
Pitting/wear  Grind the valve face.
9 valve stem end
Mushroom shape or diameter larger than the
body of the valve stem  Replace the valve.

5. Measure:
9 valve margin thickness a
Out of specification  Replace the valve.

Valve margin
thickness Intake
0.7 mm (0.0276 in)
Exhaust
1.0 mm (0.0394 in)

4-
 VALVES AND VALVE EN
6. Measure:
9 valve stem runout
Out of specification  Replace the valve.
NOTE:
9 When installing a new valve, always replace the
valve guide.
9 If the valve is removed or replaced, always replace
the valve stem seal.

Valve stem runout

0.010 mm (0.0004 in)

EAS00240

CHECKING THE VALVE SEATS

The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
9 carbon deposits
(from the valve face and valve seat)
2. Check:
9 valve seat
Pitting/wear  Replace the cylinder head.
3. Measure:
9 valve seat width a
Out of specification  Replace the cylin-
der head.
Valve seat width
Intake and exhaust
1.6 mm
(0.0630 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.

4-
 VALVES AND VALVE EN
NOTE:
Where the valve seat and valve face contacted one
another, the blueing will have been removed.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound a to the valve face.

cC
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.

b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping
compound.

Valve lapper
90890-04101
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.

e. Apply a fine lapping compound to the valve

face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from the
valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b

onto the valve face.

4-
 VALVES AND VALVE EN
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width c again. If the
valve seat width is out of specification, reface
and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00241

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the valve
springs.
1. Measure:
9 valve spring free length a
Out of specification  Replace the valve
spring.

Valve spring free length

Intake and exhaust valve spring
35.44 mm (1.40 in)
<Limit>: 34.0 mm (1.34 in)

2. Measure:
9 compressed valve spring force a
Out of specification  Replace the valve
spring.
b Installed length

Compressed valve spring force

(installed)
Intake and exhaust valve spring
146 ~ 168 N
(14.9 ~ 17.1 kgf, 32.8 ~ 37.7 lb)
at 24.1 mm (0.95 in)

4-
 VALVES AND VALVE EN
3. Measure:
9 valve spring tilt a
Out of specification  Replace the valve
spring.

Valve spring tilt limit

Intake and exhaust valve spring
2.5/1.5 mm (2.5/0.06 in)

EAS00245

INSTALLING THE VALVES

The following procedure applies to all of the
valves and related components.
1. Deburr:
9 valve stem end
(with an oil stone)

2. Lubricate:
9 valve stem 1
9 valve stem seal 2
(with the recommended lubricant)

Recommended lubricant
Molybdenum disulfide oil

3. Install:
9 valve 1
9 lower spring seat 2
9 valve stem seal 3
9 valve spring 4
9 upper spring seat 5
(into the cylinder head)
NOTE:
Install the valve spring with the larger pitch a
facing up.

b Smaller pitch

4-
 VALVES AND VALVE EN
4. Install:
9 valve cotters 1
NOTE:
Install the valve cotters by compressing the valve
spring with the valve spring compressor 2.

Valve spring compressor

90890-01253
Valve spring compressor attach-
ment
90890-01243

5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.

cC
Hitting the valve tip with excessive force
could damage the valve.

4-
 CYLINDER AND EN
EASF0027

CYLINDER AND PISTON

1 Cylinder 8 Piston pin
2 Cylinder gasket
9 Piston pin circlip
3 Dowel pin
4 Top ring
5 2nd ring
6 Oil ring
7 Piston

4-
 CYLINDER AND EN
EASF0028

REMOVING THE CYLINDER AND PIS-

TON
NOTE:
1 Prior to remove the cylinder and piston, remove
the cylinder head.

1. Remove:
9 cylinder 1

2. Remove:
1 9 dowel pins 1
9 gasket 2

3. Remove:
9 piston pin clip 1
9 piston pin 2
9 piston 3

cC
2 3 Do not use a hammer to drive the piston
pin out.
1

NOTE:
9 Before removing the piston pin clip, cover the
crankcase opening with a clean rag to pre- vent
the piston pin clip from falling into the crankcase.
9 Before removing the piston pin, deburr the piston
pin clip’s groove and the piston’s pin bore area.
If both areas are deburred and the piston pin is
still difficult to remove, remove it with the piston
pin puller set.

4. Remove:
9 top ring
9 2nd ring
9 oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.

4-
 CYLINDER AND EN
EAS00255

CHECKING THE CYLINDER AND PIS-

TON
1. Check:
9 piston wall
9 cylinder wall
Vertical scratches  Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
9 piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-to side
and front-to-back measurements of the cylinder.
Then, find the average of the mea- surements.

50.000 ~ 50.010 mm
Cylinder bore “C”
(1.9685 ~ 1.9689 in)
Taper limit “T” 0.05 mm (0.0020 in)
Out-of-round “R” 0.05 mm (0.0020 in)

“C” = maximum of D1 ~ D2
“T” = maximum of D1 or D2 – maximum of
D5 or D6
“R” = maximum of D1, D3 or D5 – minimum
of D2, D4 or D6

b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.
c. Measure piston skirt diameter “P” with the micrometer.
a 5 mm (0.20 in) from the bottom edge of the
piston
Piston size “P”
49.970 ~ 49.985 mm
Standard
(1.9673 ~ 1.9679 in)
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance with
the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”

4-
 CYLINDER AND EN
Piston-to-cylinder clearance
0.020 ~ 0.035 mm
(0.0008 ~ 0.0014 in)
<Limit>: 0.15 mm (0.0059 in)

f. If out of specification, rebore or replace the

cylinder, and replace the piston and piston
rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00263

CHECKING THE PISTON RINGS

1. Measure:
9 piston ring side clearance
Out of specification  Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clear- ance,
eliminate any carbon deposits from the piston ring
grooves and piston rings.

Piston ring side clearance

Top ring
0.030 ~ 0.070 mm
(0.0012 ~ 0.0028 in)
<Limit>: 0.12 mm (0.0047 in)
2nd ring
0.020 ~ 0.060 mm
(0.0008 ~ 0.0024 in)
<Limit>: 0.11 mm (0.0043 in)
2. Install:
9 piston ring
a (into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.

a 5.0 mm (0.20 in)

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

4-
 CYLINDER AND EN
Piston ring end gap
Top ring
0.10 ~ 0.25 mm (0.004 ~ 0.010 in)
<Limit>: 0.5 mm (0.020 in)
2nd ring
0.10 ~ 0.25 mm (0.004 ~ 0.010 in)
<Limit>: 0.6 mm (0.024 in)
Oil ring
0.20 ~ 0.70 mm (0.008 ~ 0.028 in)
EAS00265

CHECKING THE PISTON PIN

1. Check:
9 piston pin
Blue discoloration/grooves  Replace the
piston pin and then check the lubrication
system.
2. Measure:
9 piston pin outside diameter a
Out of specification  Replace the piston pin.
Piston pin outside diameter
14.995 ~ 15.000 mm
(0.5904 ~ 0.5906 in)
<Limit>: 14.975 mm (0.5896 in)
3. Measure:
9 piston pin bore diameter (of the piston) b
Out of specification  Replace the piston.
Piston pin bore diameter (of the
piston)
15.002 ~ 15.013 mm
(0.5906 ~ 0.5911 in)
<Limit>: 15.043 mm (0.5922 in)
4. Calculate:
9 piston-pin-to-piston-pin-bore clearance Out of
specification  Replace the piston pin and
piston as a set.

Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter b –
Piston pin outside diameter a

Piston-pin-to-piston-pin-bore
clearance
0.002 ~ 0.018 mm
(0.0001 ~ 0.0007 in)
<Limit>: 0.068 mm (0.0027 in)

4-
 CYLINDER AND EN
EAS00267

INSTALLING THE PISTON AND CYLIN- DER

1. Install:
9 top ring 1
9 2nd ring 2
9 oil ring expander 3
9 lower oil ring rail 4
9 upper oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.

2. Install:
9 piston 1
9 piston pin 2
9 piston pin clip 3
NOTE:
a 9 Apply engine oil the piston pin.
2 1 9 Make sure the arrow mark a on the piston points
towards the exhaust side of the cylin- der.
3 New
9 Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre- vent
the clip from falling into the crankcase.

4-
 CYLINDER AND EN
3. Install:
2 9 gasket 1
9 dowel pins 2
4. Lubricate:
New 1 9 piston
9 piston rings
9 cylinder
(with the recommended lubricant)

Recommended lubricant
Engine oil

5. Offset:
e a 9 piston ring end gaps
a Top ring
b Upper oil ring rail
c Expander end
d Lower oil ring rail
f f
d b e 2nd ring
c f 20 mm (0.79 in)
å å exhaust side

6. Install:
9 cylinder 1
NOTE:
9 While compressing the piston rings with one
1
hand, install the cylinder with the other hand. 9
Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.

4-
 KICKSTARTE EN
EASF0033

KICKSTARTER
1 V-belt case air duct clamp 7 Dowel pin r Kickstarter pinion gear clip
2 V-belt case air filter assembly 8 V-belt case cover t Spacer
3 V-belt case air filter element 9 Kickstarter crank y Kickstarter spring
cap 0 Oil seal u Kickstarter shaft
4 V-belt case air filter dust seal 5 q Circlip i Kickstarter shaft plate
V-belt case air filter element 6 V- w Washer
belt case cover protector e Kickstarter pinion gear

10 Nm (1.0 m•kg, 7.2 ft•lb)

2 Nm (0.2 m•kg, 1.4 ft•lb) 7

2 Nm (0.2 m•kg, 1.4 ft•lb)
5

u
3
y

t
LS
8
r e 10 Nm (1.0 m•kg, 7.2 ft•lb)
i

10 Nm (1.0 m•kg, 7.2 ft•lb) q0

9
w
7 Nm (0.7 m•kg, 5.1 ft•lb)

4-
 KICKSTARTE EN
REMOVING THE KICKSTARTER
1
1. Loosen:
9 V-belt case air duct clamp bolt 1
2. Remove:
9 V-belt case air duct
9 V-belt case air filter assembly
Refer to “CLEANING THE V-BELT CASE
AIR FILTER ELEMENT” in chapter 3.

1 3. Disconnect:
9 crankcase breather hose 1
9 V-belt case cover protector

4. Remove:
9 fuel overflow hose holder 1
9 V-belt case cover 2
9 dowel pins

1 2

DISASSEMBLING THE KICKSTARTER

SHAFT
1. Remove:
9 kickstarter shaft plate 1

4-
 KICKSTARTE EN
2. Remove:
1gear 1
9 kickstarter pinion
2 9 kickstarter pinion gear clip 2
NOTE:
Turn the kickstarter crank attached to the kick-
starter shaft in the direction of the arrow a and
a
remove the kickstarter pinion gear and kick-
starter pinion gear clip together.

3. Remove:
1 9 kickstarter crank bolt
2 9 kickstarter crank
4. Remove:
3 9 oil seal 1
9 circlip 2
9 washer 3

5. Remove:
1
9 kickstarter spring 1
9 kickstarter shaft 2
9 spacer

EAS00339

CHECKING THE KICKSTARTER

1. Check:
9 kickstarter shaft
9 kickstarter pinion gear
Damage/wear  Replace.
2. Check:
9 kickstarter spring
Damage/wear  Replace.
3. Measure:
9 kickstarter pinion gear clip friction force (with the spring gauge)
Out of specification  Replace the kick-
starter pinion gear clip.

Kickstarter pinion gear clip

friction force
1.0 ~ 3.5 N
(0.10 ~ 0.36 kgf, 0.22 ~ 0.79 lb)

4-
 KICKSTARTE EN
EAS00340

ASSEMBLING THE KICKSTARTER

2 1 1. Install:
9 spacer
9 kickstarter spring
9 kickstarter shaft
9 washer
9 circlip
9 oil seal
NOTE:
9 Install the circlip securely into the groove on the
kickstarter shaft.
9 Hook the straight end of the kickstarter spring
onto the notch 1 in the kickstarter shaft and
hook the hooked end of the kickstarter spring
onto the projection 2 to pulling the kick-
starter spring with wire.

2. Install:
9 kickstarter pinion gear clip 9
kickstarter pinion gear 9
kickstarter shaft plate 9
kickstarter shaft plate screws
9 Nm (0.9 m·kg, 6.5 ft·lb)

INSTALLING THE KICKSTARTER

For installation, reverse the removal procedure.
1. Install:
9 dowel pins
9 V-belt case cover
9 fuel overflow hose holder
9 V-belt case cover bolts
10 Nm (1.0 m·kg, 7.2 ft·lb)

cC
Inject the grease (0.5-1.0cm3) into the inner
race of the ball bearing inside of the V-belt
case cover before install it.

2. Install:
9 kickstarter crank 1
9 kickstarter crank bolt
b 12 Nm (1.2 m·kg, 8.7 ft·lb)
NOTE:
1
a To install the kickstarter crank, align the notch a in
the kickstarter crank with the projection b on
the V-belt case cover.

4-
 KICKSTARTE EN
3. Install:
9 V-belt case cover protector
9 V-belt case cover protector screw
7 Nm (0.7 m·kg, 5.1 ft·lb)
4. Install:
9 V-belt case air filter assembly
Refer to “CLEANING THE V-BELT CASE
AIR FILTER ELEMENT” in chapter 3.
9 V-belt case air duct
9 V-belt case air duct clamp bolt
2 Nm (0.2 m·kg, 1.4 ft·lb)

4-
 BELT EN
EASF0030

BELT DRIVE
V-BELT, PRIMARY AND SECONDARY SHEAVE

1 O-ring 8 Secondary sliding sheave 9

2 Clutch housing Secondary fixed sheave 0
3 Clutch carrier
Guide pin
4 Spring q V-belt
5 Spring seat w Conical spring washer
6 Oil seal e Kickstarter one-way clutch
7 O-ring r Claw washer * Shell Dolium Grease R®

4-
 BELT EN
t Primary fixed sheave
y Washer
u Spacer
i Oil seal
o Primary sliding sheave p
Primary sheave weight a
Slider
s Plastic slider guide
d Gasket

* Shell Dolium Grease R®

4-
 BELT EN
EAS00318

REMOVING THE SECONDARY SHEAVE

AND V-BELT
1. Remove:
9 V-belt case cover
Refer to “KICKSTARTER”.

2. Remove:
3 9 O-ring 1
9 secondary sheave nut 2
4 9 clutch housing 3
2
1 NOTE:
While holding the clutch housing with the
sheave holder 4, loosen the secondary sheave
nut.

Sheave holder
90890-01701

3. Loosen:
9 clutch carrier nut

cC
Do not remove the clutch carrier nut at this
stage.

NOTE:
While holding the clutch carrier with the rotor
holding tool 1, loosen the clutch carrier nut one
full turn with the socket wrench 2.

Rotor holding tool

90890-01235
Socket wrench
90890-01493

4-
 BELT EN
4. Remove:
2 9 secondary sheave 1
9 V-belt 2
NOTE:
Pull the secondary sliding sheave out as shown,
remove the V-belt along with the sec- ondary
sheave 1, and then remove the V-belt 2 from the
1 primary sheave.

EASF0031

REMOVING THE PRIMARY SHEAVE

1. Remove:
9 primary sheave nut 1 9
conical spring washer 9
kickstarter one-way clutch 9
1 claw washer
2 9 primary fixed sheave 2
3 9 washer
9 primary sliding sheave
NOTE:
While holding the primary fixed sheave with the
sheave holder 3, loosen the primary sheave nut.

Sheave holder
90890-01701

2. Remove:
1 9 gasket 1

4-
 BELT EN
3. 3
Remove: 3 1
9 plastic slider guides 1 2
9 slider 2
9 primary sheave weights 3
9 spacer 4
9 oil seals
1 1
4
3

EAS00319

DISASSEMBLING THE SECONDARY

SHEAVE
1. Remove:
1
9 clutch carrier nut 1
9 spring
NOTE:
2
Install the clutch spring holder 2 onto the sec-
ondary sheave as shown. Then, compress the
spring, and remove the clutch carrier nut.

Clutch spring holder

90890-01337

2. Remove:
9 spring seat 1
3. Remove:
9 guide pins 19
secondary sliding sheave 9
secondary fixed sheave

4-
 BELT EN
EAS00290

CHECKING THE CLUTCH HOUSING

1. Check:
9 clutch housing Damage/wear
 Replace.
2. Measure:
a 9 clutch housing inside diameter a
Out of specification  Replace the clutch
housing.

Clutch housing inside diameter

112 mm (4.41 in)
<Limit>: 112.5 mm (4.43 in)

EAS00291

CHECKING THE CLUTCH SHOES

The following procedure applies to all of the
clutch shoes.
1. Check:
9 clutch shoe
Damage/wear  Replace the clutch shoes and
springs as a set.
Glazed areas  Sand with course sand-
paper.
NOTE:
a with a cloth.
After sanding the glazed areas, clean the clutch

2. Measure:
9 clutch shoe thickness a
Out of specification  Replace the clutch
shoes and springs as a set.

Clutch shoe thickness

3.0 mm (0.12 in)
<Limit>: 1.0 mm (0.04 in)

4-
 BELT EN
EAS00320

CHECKING THE V-BELT

1 1. Check:
9 V-belt 1
Cracks/damage/wear  Replace. Grease/oil
a  Clean the primary and sec- ondary sheave.
2. Measure:
9 V-belt width a
Out of specification  Replace.

V-belt width
18.2 mm (0.72 in)
<Limit>: 17.2 mm (0.68 in)

EAS00321

CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the
primary sheave weights.
1. Check:
9 primary sheave weight Cracks/damage/wear
 Replace.

2. Measure:
9 primary sheave weight outside diameter a
Out of specification  Replace.

Primary sheave weight outside

diameter
15 mm (0.59 in)
<Limit>: 14.5 mm (0.57 in)
a

EAS00322

CHECKING THE SECONDARY SHEAVE

1. Check:
9 secondary fixed sheave
9 secondary sliding sheave Cracks/damage/wear
 Replace the sec- ondary fixed and sliding
sheaves as a set.

4-
 BELT EN
2. Check:
9 torque cam groove 1
2 Damage/wear  Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
9 guide pin 2
Damage/wear  Replace the secondary
fixed and sliding sheaves as a set.
1

4. Check:
9 spring free length
Out of specification  Replace the spring.

Spring free length

74.3 mm (2.93 in)
<Limit>: 70.6 mm (2.78 in)

EAS00323

ASSEMBLING THE PRIMARY SHEAVE

1. Clean:
9 primary fixed sheave 9
primary sliding sheave 9
spacer
9 primary sheave weights

2. Install:
9 oil seal
3. Lubricate:
9 primary sliding sheave
9 spacer

Recommended lubricant
Shell Dolium Grease R®
NOTE:
Fill the notch of the primary sliding sheave with
grease. Apply grease to the inner surface of the
primary sliding sheave as shown.

cC
Do not get any grease on the surfaces of
the sheaves. If any grease gets on the
sheaves, be sure to wipe it off with alcohol,
etc.

4-
 BELT EN
1 1 3 4. Install:
4 9 primary sheave weights 1
9 spacer 2
9 plastic slider guides 3
9 slider 4

3 3
2
1

5. Install:
9 primary sliding sheave 1
NOTE:
1
When installing the primary sliding sheave, hold
the slider to prevent the primary sheave weights
from falling out of the primary sliding sheave.

6. Install:
9 washer 1
9 primary fixed sheave 2
4 5 9 claw washer 3
9 kickstarter one-way clutch 4
1
9 conical spring washer 5
3 9 primary sheave nut 6
2 4 5 48 Nm (4.8 m·kg, 35 ft·lb)
6
NOTE:
9 Install the conical spring washer 4 as shown in
the illustration.
9 While holding the primary fixed sheave with the
sheave holder, tighten the primary sheave nut.

Sheave holder
90890-01701

4-
 BELT EN
EAS00324

ASSEMBLING THE
1 SECONDARY SHEAVE
1. Lubricate:
2 9 secondary fixed sheave’s inner surface 1 9
secondary sliding sheave’s inner surface 2 9 oil
seals
9 bearings
(with the recommended lubricant)

Recommended lubricant
Shell Dolium Grease R®

cC
Do not get any grease on the surfaces of
the sheaves. If any grease gets on the
sheaves, be sure to wipe it off with alcohol,
etc.

2. Install:
9 oil seals 3
9 secondary sliding sheave 1
9 secondary fixed sheave 2
1 NOTE:
2 Install the secondary sliding sheave onto the
secondary fixed sheave 2 with the oil seal
guide 3.

Oil seal guide

90890-01384

3. Lubricate:
9 secondary sliding sheave’s inner surface (with
the recommended lubricant)

Recommended lubricant
Shell Dolium Grease R®
NOTE:
Apply 3 cc of Shell Dolium Grease R ® to the inner
surface of the secondary fixed sheave.

4-
 BELT EN
DRIVE
1 9 guide pin 1

5. Lubricate:
9 guide pin groove 1
9 O-rings 2
2 (with the recommended lubricant)
New
Recommended lubricant
Shell Dolium Grease R®
1 NOTE:
Apply 1 cc of Shell Dolium Grease R® to the guide
pin groove.

6. Install: a
9 spring seat 1

cC
Do not get any grease on the surfaces a
and b of the sheaves. If any grease gets on
the sheaves, be sure to wipe it off with
alco- hol, etc.
1
b

4-
 BELT EN
2 7. Install:
3 1 9 spring
9 clutch carrier 1
3 NOTE:
9 Attach the clutch spring holder 2 onto the
secondary sheave as shown. Then, com- press
the spring, and tighten the clutch carri- er nut 3.
1 9 Install the clutch carrier nut with the beveled side
of the nut facing the clutch carrier.

Clutch spring holder

90890-01337

EAS00325

2
a INSTALLING THE BELT DRIVE
For installation, reverse the removal procedure.
1 New 1. Install:
9 gasket 1
9 V-belt 2
9 secondary sheave 3
3 cC
Do not allow grease to contact the V-belt,
secondary sheave assembly.

NOTE:
9 The V-belt must be installed, with the arrows
a facing forward.
9 Install the V-belt on the primary sheave, then
install the secondary sheave 3 along with the
V-belt 2.
9 When installing the secondary sheave, do not get
grease from the inner surface of the sec- ondary
sheave on the primary drive gear.

4-
 BELT EN
DRIVE
9 clutch carrier nut
55 Nm (5.5 m·kg, 40 ft·lb)
NOTE:
While holding the clutch carrier with the rotor
holding tool 1, tighten the clutch carrier nut with
the socket wrench 2.

Rotor holding tool

90890-01235
Socket wrench
90890-01493

3. Position:
1 9 V-belt 1
2 NOTE:
3
Position the V-belt in the primary sheave 2
(when the sheave is at its widest position) and in
the secondary sheave 3 (when the sheave is at its
narrowest position), and make sure the V-belt is
tight.

4. Install:
1 9 clutch housing 1
3 9 secondary sheave nut 2
2
40 Nm (4.0 m·kg, 29 ft·lb)
9 O-ring
NOTE:
Tighten the secondary sheave nut with the
sheave holder 3.

Sheave holder
90890-01701

4-
 STARTER EN
EAS00341

STARTER CLUTCH
1 Idle gear plate
2 Idle gear
3 Idle gear shaft
4 Starter clutch assembly
5 circlip
6 Starter wheel gear
7 Bearing

10 Nm (1.0 m•kg, 7.2 ft•lb)

LS
3
2
1

6
5

4-
 ENG
STARTER CLUTCH
EAS00344

REMOVING THE STARTER CLUTCH

1. Remove:
9 V-belt case cover
Refer to “KICKSTARTER”.
9 primary sliding sheave
Refer to “BELT DRIVE”.

2. Remove:
2
9 starter clutch assembly 1
9 idle gear plate 2
9 washer
3 9 idle gear 3
1 9 washer

3. Remove:
9 circlip 1
2 9 starter wheel gear 2
1

EAS00348

CHECKING THE STARTER CLUTCH

1. Check:
9 idle gear
9 starter wheel gear
9 starter clutch assembly
Burrs/chips/roughness/wear  Replace the
defective part(s).

2. Check:
9 starter wheel gear contacting surface Damage/pitting/wear  Replace the
starter wheel gear.

4-
 STARTER EN
å ∫ 3. Check:
1 9 starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2 a. Install the starter wheel gear 1 onto the
starter clutch 2 and hold the starter
clutch.
b. When turning the starter wheel gear to
direction å, the starter clutch and the
starter wheel gear should engage, other- wise
the starter clutch is faulty and must be
replaced.
c. When turning the starter wheel gear to
direction ∫, it should turn freely, otherwise
the starter clutch is faulty and must be
replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00355

INSTALLING THE STARTER CLUTCH

1. Install:
9 starter wheel gear 1
9 starter clutch assembly 2
NOTE:
9 Pour a few drops of molybdenum disulfide oil on
the areas of the starter clutch shown.
9 When installing the starter clutch assembly, turn
the starter wheel gear in the direction of the
arrow shown.

Recommended lubricant
Molybdenum disulfide oil

2. Install:
9 idle gear plate
9 idle gear plate bolts
M
10 Nm (1.0 m·kg, 7.2 ft·lb)

4-
 A.C. EN
A.C. MAGNETO
1 Stator coil assembly
2 Pickup coil
3 Pickup coil bracket
4 A.C. magneto rotor

4-
 ENG
A.C. MAGNETO
EAS00346

REMOVING THE A.C. MAGNETO

1. Remove:
9 air filter case
Refer to “AIR FILTER CASE” in chapter 5.
2. Remove:
9 engine cooling fan cover
9 engine cooling fan
Refer to “CYLINDER HEAD”.
3. Remove:
9 A.C. magneto rotor nut 1
9 washer
NOTE:
While holding the A.C. magneto rotor 2 with
the rotor holding tool 3, loosen the A.C. mag- neto
rotor nut.

Rotor holding tool

90890-01235

4. Remove:
9 A.C. magneto rotor 1
(with the flywheel puller 2)
9 woodruff key

Flywheel puller
90890-01189

5. Remove:
9 stator coil assembly 1
9 pickup coil bracket 2
9 pickup coil 3

4-
 A.C. EN
EAS00354

INSTALLING THE A.C. MAGNETO

For installation, reverse the removal procedure.
1. Install:
9 stator coil assembly 1
9 stator coil assembly bolts
11 Nm (1.1 m·kg, 8.0 ft·lb)
9 pickup coil
9 pickup coil bracket 2
9 pickup coil bracket screws
7 Nm (0.7 m·kg, 5.1 ft·lb)
NOTE:
Pass the stator coil lead under the pickup coil
bracket.

2. Install:
9 woodruff key
9 A.C. magneto rotor 1
9 washer
9 A.C. magneto rotor nut
NOTE:
9 Clean the tapered portion of the crankshaft and
the A.C. magneto rotor hub.
9 When installing the A.C. magneto rotor, make
sure the woodruff key is properly seated in the
keyway of the crankshaft.

3. Tighten:
9 A.C. magneto rotor nut 1
70 Nm (7.0 m·kg, 50 ft·lb)
NOTE:
While holding the A.C. magneto rotor 2 with
the rotor holding tool 3, tighten the A.C. mag- neto
rotor nut.

Rotor holding tool

90890-01235

4-
 OIL EN
EASF0035

OIL PUMP
1 Oil pump cover 8 Engine oil strainer
2 Oil seal 9 Spring
3 O-ring 0 O-ring
4 Gasket q Engine oil drain plug
5 Dowel pin
6 Oil pump assembly
7 Gasket

4-
 OIL EN
REMOVING THE OIL PUMP
1. Drain:
9 engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
2. Remove:
9 footboard
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
3. Remove:
9 air filter case
Refer to “AIR FILTER CASE” in chapter 5.
4. Remove:
9 engine cooling fan cover
9 engine cooling fan
Refer to “CYLINDER HEAD”.
9 stator coil assembly
Refer to “A.C. MAGNETO”.
5. Remove:
9 oil pump cover 1
9 O-ring
9 gasket
9 dowel pin
Flywheel puller
90890-01362

70mm NOTE:
Use the flywheel puller with bolts (M670 mm) and
washers.

6. Remove:
9 oil pump assembly 1
9 gasket

DISASSEMBLING THE OIL PUMP

1. Remove:
9 oil pump housing cover 1
9 pin
9 oil pump driven gear 2
9 inner rotor 3
9 outer rotor 4
9 oil pump housing 5

4-
 OIL EN
EAS00364

CHECKING THE OIL PUMP

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

Inner-rotor-to-outer-rotor-tip clear-
ance
0.13 ~ 0.18 mm
(0.0051 ~ 0.0071 in)
<Limit>: 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing
clearance
0.13 ~ 0.18 mm
(0.0051 ~ 0.0071 in)
<Limit>: 0.25 mm (0.0098 in)
Oil-pump-housing-to-inner -
rotor and- outer-rotor clearance
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
<Limit>: 0.17 mm (0.0067 in)

3. Check:
9 oil pump operation
Rough movement  Repeat steps (1) and
(2) or replace the defective part(s).

4-
 OIL EN
EAS00368

CHECKING THE OIL STRAINER

1
1. Check:
9 oil strainer 1
Damage  Replace.
Contaminants  Clean with solvent.

EAS00375

ASSEMBLING THE OIL PUMP

1. Lubricate:
9 inner rotor
9 outer rotor
9 oil pump shaft (oil pump driven gear)
(with the recommended lubricant)

Recommended lubricant
Engine oil

2. Install:
9 oil pump driven gear 1
(to the oil pump housing 2)
9 outer rotor 3
9 inner rotor 4
9 pin 5
9 oil pump housing cover
NOTE:
9 Install the inner rotor and outer rotor with their
punch marks a facing away from the oil
pump housing.
9 When installing the inner rotor, align the pin in
the oil pump driven gear with the groove b in
the inner rotor.

3. Check:
9 oil pump operation
Refer to “CHECKING THE OIL PUMP”.

EAS00376

INSTALLING THE OIL PUMP

For installation, reverse the removal procedure.
1. Install:
9 gasket
9 oil pump assembly
9 oil pump assembly screws

4 Nm (0.4 m·kg, 2.9 ft·lb)

4-
 OIL EN
cC
After tightening the bolts, make sure the oil
pump turns smoothly.

2. Install:
9 gasket
9 O-ring
9 oil pump cover
9 oil pump cover bolts
10 Nm (1.0 m·kg, 7.2 ft·lb)

4-
 TRANSMISSIO EN
EASF0041

TRANSMISSION
1 Drive axle 8 Oil seal
2 Oil seal 9 Transmission case cover
3 Conical spring washer 0 Gasket
4 Drive axle gear q Primary drive gear
5 Main axle
6 Conical spring washer
7 Dowel pin

4-
 TRANSMISSIO EN
EASF0042

REMOVING THE TRANSMISSION

NOTE:
Prior to remove the transmission, remove the
muffler, rear wheel and secondary sheave.

1. Drain:
9 transmission oil
(completely from the transmission case) Refer to “CHANGING THE TRANSMIS-
SION OIL” in chapter 3.
2. Remove:
9 transmission case cover 1
1 (with primary drive gear, bearings)
9 gasket
9 dowel pins

1 3. Remove:
9 oil seal 1
9 circlip 2

4. Remove:
2 9 primary drive gear 1
9 retainer bolt 2
9 primary drive gear bearing 3
1

5. Remove:
9 washer 1
2 9 conical spring washer 9
drive axle gear 2 9
conical spring washer 9
main axle 3
3

4-
 TRANSMISSIO EN
6. Remove:
9 drive axle 1
1 (with circlip)

EAS00425

CHECKING THE TRANSMISSION

1. Check:
9 drive axle
9 main axle 9
primary drive gear 9
drive axle gear
Damage/wear  Replace.
2. Check:
9 bearings
Rough movement  Replace.
3. Check:
9 circlips
Bends/damage/looseness  Replace.

EAS00428

INSTALLING THE TRANSMISSION

1. Install: 9
drive axle 9
a circlip 1
New 1
NOTE:
Make sure the circlip 1 is inserted into the
groove a in the drive axle.

4 2. Install:
5
9 main axle 1
9 conical spring washer 2
3
9 drive axle gear 3
3 2 9 conical spring washer 4
9 washer 5
1 NOTE:
5
Install the conical spring washers as shown in the
illustration.

4-
 TRANSMISSIO EN
3. Install:
9 primary drive gear bearing
9 retainer bolt
LT

10 Nm (1.0 m·kg, 7.2 ft·lb)

4. Install:
9 primary drive gear
9 circlip
9 oil seal
9 dowel pins
9 gasket
9 transmission case cover
(with primary drive gear, bearings)
9 transmission case cover bolts
13 Nm (1.3 m·kg, 9.4 ft·lb)
5. Check:
9 transmission
Rough movement  Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.

6. Fill:
9 transmission case
Refer to “CHANGING THE TRANSMIS-
SION OIL” in chapter 3.

4-
 CRANKSHAF EN
EASF0037

CRANKSHAFT
1 Crankcase (right) 0 Collar
2 Crankshaft assembly q Engine bracket
3 Timing chain w Spacer
4 Timing chain guide (intake side) e Centerstand shaft r
5 Dowel pin
Centerstand spring t
6 Crankcase (left) Centerstand
7 Oil seal
8 Engine drain bolt
9 Rubber damper

4-
 CRANKSHAF EN
T
DISASSEMBLING THE CRANKCASE
1. Remove:
9 engine assembly
Refer to “REMOVING THE ENGINE”.
2. Remove:
9 cylinder head
9 cylinder
9 piston
Refer to “CYLINDER HEAD” and “CYLIN-
DER AND PISTON”.
3. Remove:
9 V-belt case cover
Refer to “KICKSTARTER”.
4. Remove:
9 secondary sheave
9 V-belt
9 primary sheave
Refer to “BELT DRIVE”.
5. Remove:
9 starter clutch
Refer to “STARTER CLUTCH”.
6. Remove:
9 starter motor
Refer to “STARTER MOTOR” in chapter 7.
7. Remove:
9 A.C. magneto rotor
Refer to “A.C. MAGNETO”.
8. Remove:
9 oil pump
Refer to “OIL PUMP”.
9. Remove:
9 rear wheel assembly
Refer to “REAR WHEEL AND BRAKE” in
chapter 6.
10. Remove:
9 upper mount nut 9
upper mount bolt 9
rubber dampers 1
9 collars
9 engine bracket 2
9 bracket
1 2 11. Remove:
9 circlip 1
9 washer
4 9 centerstand shaft 2
3
9 centerstand 3
9 centerstand spring 4

4-
 CRANKSHAF EN
12. Remove:
1 9 timing chain guide (intake side) 1

13. Remove:
9 crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stages
and in a crisscross pattern. After all of the bolts are
fully loosened, remove them.

14. Remove: 9
right crankcase 9
dowel pins

cC
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.

EASF0040

REMOVING THE CRANKSHAFT ASSEM-

BLY
1
1. Remove:
9 crankshaft assembly 1
2 9 timing chain 2
NOTE:
9 Before removing the crankshaft assembly, remove
the timing chain from the crankshaft drive
sprocket.
9 The crankshaft assembly cannot be removed if the
timing chain is attached onto the crank- shaft
drive sprocket.

4-
 CRANKSHAF EN
T
CHECKING THE TIMING CHAIN AND
TIMING CHAIN GUIDE
1. Check:
9 timing chain
Damage/stiffness  Replace the timing chain
and camshaft sprocket as a set.

2. Check:
9 timing chain guide (intake side) Damage/wear
 Replace.

EAS00394

CHECKING THE CRANKSHAFT AND CONNECTING ROD

1. Measure:
9 crankshaft runout 1
Out of specification  Replace the crank-
shaft, bearing or both.
NOTE:
Turn the crankshaft slowly.

Maximum crankshaft runout

0.03 mm (0.0012 in)

2. Measure:
9 big end side clearance 2
Out of specification  Replace the crank-
shaft.
Big end side clearance
0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)
3. Measure:
9 crankshaft width 3
Out of specification  Replace the crank-
shaft.
Crankshaft width
45.45 ~ 45.50 mm
(1.789 ~ 1.791 in)

4-
 CRANKSHAF EN
T
9 crankshaft drive sprocket 1
Damage/wear  Replace the crankshaft.
9 bearings 2
Cracks/damage/wear  Replace the
crankshaft.
9 oil pump drive gear 3
Damage/wear  Replace the crankshaft.

5. Check:
9 crankshaft journal
Scratches/wear  Replace the crankshaft.
9 crankshaft journal oil passage
Obstruction  Blow out with compressed air.

EAS00399

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
9 crankcase
Cracks/damage  Replace.
9 oil delivery passages
Obstruction  Blow out with compressed air.

EAS00401

CHECKING THE BEARINGS AND OIL

SEALS
1. Check:
9 bearings
Clean and lubricate the bearings, then rotate the
inner race with your finger.
Rough movement  Replace.
2. Check:
9 oil seals
Damage/wear  Replace.

4-
 CRANKSHAF EN
EAS00408

INSTALLING THE CRANKSHAFT

1. Install:
9 timing chain
9 crankshaft assembly

cC
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.

NOTE:
9 While expanding the timing chain and install in
to the left crankcase.
9 After installing the crankshaft to the left
crankcase, make sure that the timing chain
meshes with the camshaft drive sprocket and the
crankshaft turns smoothly.

EAS00416

ASSEMBLING THE CRANKCASE

1. Apply:
9 sealant
(onto the crankcase mating surfaces)
Yamaha bond No.
1215 90890-85505

NOTE:
Do not allow any sealant to come into contact with
the oil gallery.

2. Install:
1 9 dowel pins 1
3. Install:
1
9 right crankcase
(onto the left crankcase)
NOTE:
Tap lightly on the right crankcase with a soft- face
hammer.

4. Install:
9 crankcase bolts
10 Nm (1.0 m·kg, 7.2 ft·lb)
5. Install:
9 timing chain guide (intake side)
9 timing chain guide retainer bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)

4-
 CRANKSHAF EN
T
9 crankshaft operation
Rough movement  Repair.
7. Lubricate:
9 centerstand shaft
(with the recommended lubricant)
Recommended lubricant
Lithium-soap-based grease
8. Install: 9
centerstand spring 9
centerstand 9
centerstand shaft 9
washer
9 circlip

9. Install:
9 spacers
9 rubber dampers 1
9 engine bracket 2
9 lower engine mounting bolts 3
9 nuts 4
9 8 mm bolt 5
NOTE:
9 Do not fully tighten the lower engine mounting
bolts and nuts.
9 Insert an 8 mm bolt or similar rod into the hole in
the engine bracket and into the hole in the left
crankcase to ease the installation proce- dure.

10. Tighten:
9 nuts 4 35 Nm (3.5 m·kg, 26 ft·lb)

NOTE:
First tighten the nuts on the left crankcase side, and
then tighten the nuts on the right crankcase side.

11. Remove:
9 8 mm bolt 5

4-
 CRANKSHAF EN
12. Install:
9 upper engine mounting bolts 1
9 nuts 2
NOTE:
Push the engine bracket in the direction of the
arrow shown and install the upper engine mounting
bolts.

13. Tighten:
9 nuts 2 16 Nm (1.6 m·kg, 11 ft·lb)

4-
CARB

CHAPTER 5
CARBURETOR

CARBURETOR............................................................................................5-1
REMOVING THE CARBURETOR....................................................................5-2
DISASSEMBLING THE CARBURETOR.........................................................5-3
CHECKING THE CARBURETOR....................................................................5-5
ASSEMBLING THE CARBURETOR................................................................5-7
MEASURING AND ADJUSTING THE FUEL LEVEL....................................5-8
INSTALLING THE CARBURETOR.................................................................5-9
CHECKING THE FUEL COCK OPERATION..................................................5-9

FUEL TANK...............................................................................................5-10
REMOVING THE FUEL TANK......................................................................5-10
INSTALLING THE FUEL TANK....................................................................5-11

AIR FILTER CASE.....................................................................................5-11

REMOVING THE AIR FILTER CASE............................................................5-11
INSTALLING THE AIR FILTER CASE..........................................................5-12

AIR INDUCTION SYSTEM.........................................................................5-13

AIR INDUCTION.............................................................................................5-13
AIR CUT-OFF VALVE....................................................................................5-13
CHECKING THE AIR INDUCTION SYSTEM...............................................5-15
CARB
 CARBURETO CAR
EASF0480

CARBURETOR
CARBURETOR
1 Cylinder head breather hose 8 Coasting enricher set y Float
holder 9 Pilot screw set u Float pivot pin
2 Vacuum chamber cover 0 Needle valve i Gasket
3 Piston valve spring q Needle jet o Float chamber
4 Jet needle set w Cap p Fuel drain screw
5 Piston valve e Needle jet holder a Fuel overflow hose
6 Throttle stop screw set r Main jet
7 Starter plunger assembly t Pilot jet

4
2

t q
0
w e 9
r
y
u

i
a

5-
 CARBURETO CAR
EASF0481

REMOVING THE CARBURETOR

w
Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.

1. Remove:
9 air filter case
Refer to “AIR FILTER CASE”.
2. Loosen:
9 fuel drain screw 1
3. Drain:
9 fuel (from the float chamber)

1 4. Remove:
9 cylinder head breather hose (from the hose
holder) 1
9 vacuum hose 2

2 5. Remove:
9 air cut-off valve assembly 1
1 9 carburetor assembly 2

6. Disconnect:
9 fuel hose
7. Remove:
9 starter plunger assembly (from the carbu- retor
body) 1
9 fuel overflow hose (from the hose holder)
1 NOTE:
Slide the rubber cover back, and then remove the
starter plunger assembly.

5-
 CARBURETO CAR
8. Loosen:
9 locknut (throttle cable) 1
NOTE:
1 2 Slide the rubber cover 2 back, and then
loosen the locknut.

9. Disconnect:
9 throttle cable

10. Disconnect:
9 starter plunger assembly 1
(from the starter cable)

EASF0483

DISASSEMBLING THE CARBURETOR

NOTE:
The following parts can be cleaned and inspected
without disassembly.
9 Throttle stop screw
9 Pilot screw
9 Coasting enricher

1. Remove:
2 9 cylinder head breather hose holder 1
4 9 vacuum chamber cover 2
1
9 piston valve spring 3
9 piston valve 4

2. Remove:
9 jet needle holder 1
9 jet needle spring 2
4 9 jet needle 3
3 9 washer 4
2
1

5-
 CARBURETO CAR
3. Remove:
9 fuel overflow hose 1
9 float chamber 2
2 9 float chamber rubber gasket

4. Remove:
9 float pin screw 1
9 float pivot pin 2
3 9 float 3
9 needle valve 4
1
4
2

5. Remove:
9 main jet 1
9 needle jet holder 2
9 cap 3
4 9 needle jet 4
3 9 pilot jet 5
2
1
5

6. Remove:
9 coasting enricher cover 1
9 coasting enricher spring 2
9 coasting enricher 3
9 O-ring 4
4
1
3
2

7. Remove:
9 pilot screw set 1

5-
 CARBURETO CAR
R
CHECKING THE CARBURETOR
1. Check:
9 carburetor body
9 float chamber
9 jet housing
Cracks/damage  Replace.

2. Check:
9 fuel passages Obstruction  Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
9 float chamber body
Dirt  Clean.
4. Check:
9 float chamber rubber gasket Cracks/damage/wear
 Replace.

5. Check:
9 float
Damage  Replace.

6. Check:
9 needle valve 1
9 needle valve seat 2 Damage/obstruction/wear
 Replace the needle valve and carburetor
body as a set.

5-
 CARBURETO CAR
7. Check:
9 piston valve 1
Damage/scratches/wear  Replace.
2
9 piston valve diaphragm 2
Cracks/tears  Replace.
8. Check:
9 vacuum chamber cover
1 9 piston valve spring

9. Check:
1
9 jet needle holder 1
7 9 jet needle spring 2
2 5 9 jet needle 3
6 9 needle jet holder 4
8
4 9 needle jet 5
3
9 main jet 6
9 pilot jet 7
9 pilot screw 8 Bends/damage/wear  Replace. Obstruction  Clean.
Blow out the jets with compressed air.
10. Check:
9 piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness  Replace the piston valve.

11. Check:
9 starter plunger 1
1 2 9 starter plunger spring 2
Bends/cracks/damage  Replace.
12. Check:
9 coasting enricher 9
coasting enricher spring 9
coasting enricher cover
Clog/cracks/damage  Replace.
13. Check: 9
vacuum hose 9
fuel hose
Cracks/damage/wear  Replace.
Obstruction  Clean.
Blow out the hoses with compressed air.

5-
 CARBURETO CAR
R
ASSEMBLING THE CARBURETOR
For assembly, reverse the disassembly proce- dure.

cC
9 Before assembling the carburetor, wash
all of the parts in a petroleum-based sol-
vent.
9 Always use a new gasket and O-ring.

1. Install:
b 9 pilot screw
a

Pilot screw setting

2 turns out
2. Install:
9 washer
9 jet needle
9 jet needle spring
9 jet needle holder
NOTE:
When installing the jet needle holder, align the
notches a in the jet needle holder with the pro-
jections b on the piston valve.

3. Install:
9 piston valve 1
b
NOTE:
a 9 Match the tab a on the piston diaphragm to the
1
matching recess b in the carburetor body.
9 Make sure that the rim of the piston diaphragm is
installed in the groove in the carburetor body.

5-
 CARBURETO CAR
EAS00498

1 MEASURING AND ADJUSTING THE FUEL

LEVEL
1. Measure:
a
9 fuel level a
Out of specification  Adjust.
4
3 2 Fuel level (above the float cham-
ber mating surface)
7.0 ~ 9.0 mm (0.28 ~ 0.35 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the carburetor to a temporary fuel
tank and supply fuel to the carburetor.
b. Install the fuel level gauge 1 onto the fuel
drain pipe 2.

Fuel level gauge

90890-01312
c. Loosen the fuel drain screw 3.
d. Hold the fuel level gauge vertically next to
the float chamber 4.
e. Measure the fuel level a.
NOTE:
Make sure that the carburetor is level. The car-
buretor must be level to measure the fuel level
correctly.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Adjust:
9 fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the needle valve seat and needle
valve.
b. If either is worn, replace them as a set.
1
c. If both are fine, adjust the float level by
slightly bending the float tang 1.
d. Measure the fuel level again.
e. Repeat steps (a) to (d) until the fuel level is
within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5-
 CARBURETO CAR
R
a
b INSTALLING THE CARBURETOR
For installation, reverse the removal procedure.
1. Install:
9 carburetor assembly
NOTE:
When installing the carburetor assembly, align the
slot a in the carburetor assembly with the
projection b on the intake manifold.

2. Install:
9 fuel overflow hose
9 cylinder head breather hose (from
the hose holder)
9 fuel hose
9 throttle cable

w
Proper hose and cable routing are
essential to insure safe vehicle operation.
Refer to “CABLE ROUTING” in chapter 2.

3. Adjust:
9 engine idling speed
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” in chapter 3.

Engine idling speed

1,300 ~ 1,500 r/min
(New engine at set up)
1,450 ~ 1,650 r/min
(After engine brake-in)
4. Adjust:
9 throttle cable free play
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 7 mm (0.12 ~ 0.18 in)
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.

EAS00506

CHECKING THE FUEL COCK OPERATION

1. Place a container under the end of the fuel
hose 1.

5-
 CARB
CARBURETOR/FUEL TANK
2. Check:
9 fuel cock operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suck on the end of the vacuum hose 1.

Fuel flows. Fuel cock is OK.

1
Replace the fuel
Fuel does not flow.
cock.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EASF0006

FUEL TANK
REMOVING THE FUEL TANK
1. Remove:
9 side cover (left and right)
9 grab bar
Refer to “REMOVING THE SEAT AND
SIDE COVERS” in chapter 3.
9 storage box
Refer to “REMOVING THE ENGINE” in
chapter 4.
1
2. Disconnect:
9 fuel hose 1
NOTE:
Before disconnect the fuel hose, install the hose
clip to the fuel hose to stop the fuel sup- ply.

3. Remove:
9 fuel sender coupler 1
9 fuel tank 2

1
2

5-
 CARB
FUEL TANK/AIR FILTER CASE
INSTALLING THE FUEL TANK
For installation, reverse the removal procedure.
1. Install:
9 fuel tank 7 Nm (0.7 m·kg, 5.1 ft·lb)
9 grab bar 10 Nm (1.0 m·kg, 7.2 ft·lb)
Refer to “INSTALLING THE SEAT AND
SIDE COVERS” in chapter 3.
9 storage box 9 Nm (0.9 m·kg, 6.6 ft·lb)
Refer to “INSTALLING THE ENGINE” in
chapter 4.

2. Connect:
9 vacuum hose
9 fuel hose
9 fuel sender coupler
Refer to “CABLE ROUTING” in chapter 2.

EASF0009

AIR FILTER CASE

REMOVING THE AIR FILTER CASE
1. Remove:
9 footboard
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
2. Remove:
9 V-belt case air duct
Refer to “KICKSTARTER” in chapter 4.
3. Remove:
9 fuel tank
Refer to “FUEL TANK”.
3 4. Disconnect:
1 9 A.C. magneto couplers 1
9 ignition coil connector 2
9 cylinder head breather hose
5. Loosen:
4 2 9 carburetor joint screw (air filter case side)
3
6. Remove:
9 air filter case bolts 4
9 air filter case 5
9 collar
5 NOTE:
Unhook the mud flap 6 from the check cap, and
6 then remove the air filter case bolts.
4

5-
 CARB
AIR FILTER CASE
INSTALLING THE AIR FILTER CASE
For installation, reverse the removal procedure.
1. Install:
9 collar
9 air filter case
9 air filter case bolts
7 Nm (0.7 m·kg, 5.1 ft·lb)

1 2. Connect:
9 cylinder head breather hose 1
9 ignition coil connector
9 A.C. magneto couplers
Refer to “CABLE ROUTING” in chapter 2.
NOTE:
Install the cylinder head breather hose to the stay
of the carburetor.

5-
 AIR INDUCTION CAR
SYSTEM
AIR INDUCTION SYSTEM
AIR INDUCTION
The air induction system burns unburned exhaust
gases by injecting fresh air (secondary air) into the
exhaust port, reducing the emis- sion of
hydrocarbons.
When there is negative pressure at the exhaust
port, the reed valve opens, allowing secondary air
to flow into the exhaust port. The required
temperature for burning the unburned exhaust
gases is approximately 600 to 700 °C.

EAS00508

AIR CUT-OFF VALVE

The air cut-off valve is operated by the intake gas
ç 1 pressure through the piston valve diaphragm.
Normally, the air cut-off valve is open to allow
fresh air to flow into the exhaust port. During
å sudden deceleration (the butterfly valve suddenly
closes), negative pressure is generated and the air
cut-off valve is closed in order to prevent after-
burning.
Additionally, at high engine speeds and when the
pressure decreases, the air cut-off valve
automatically closes to guard against a loss of
∫
performance due to self-EGR (Exhaust Gas
Recirculation).
1 During normal operation, the air cut-off valve is
open.
2 During sudden deceleration (the butterfly valve
suddenly closes), the air cut-off valve closes.
2 3 3 At high engine speeds and when the pressure
decreases, the air cut-off valve is open.
å From the air filter case
∫ To the cylinder head
ç To the intake manifold

5-
 CARB
AIR INDUCTION SYSTEM
1 Air induction system pipe
2 Air induction system hose (air cut-off valve assembly to air induction system pipe)
3 Air cut-off valve assembly
4 Air induction system hose (air cut-off valve assembly to air filter case)
5 Vacuum hose (air cut-off valve assembly to 3-way joint)
6 3-way joint
7 Vacuum hose (3-way joint to intake manifold)

2 3

7 Nm (0.7 m·kg, 5.1 ft·lb)

5-
AIR INDUCTION CAR
SYSTEM
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
9 hoses
Loose connection  Connect properly.
Cracks/damage  Replace.
9 pipe
Cracks/damage  Replace.
2. Check:
9 air cut-off valve Cracks/damage
 Replace.

5-
CHAS

CHAPTER 6
CHASSIS

FRONT WHEEL AND BRAKE DISC...........................................................6-1

REMOVING THE FRONT WHEEL..................................................................6-2
CHECKING THE FRONT WHEEL...................................................................6-3
CHECKING THE BRAKE DISC........................................................................6-5
CHECKING THE SPEEDOMETER GEAR UNIT............................................6-6
INSTALLING THE FRONT WHEEL................................................................6-7

REAR WHEEL AND BRAKE.......................................................................6-9

REMOVING THE REAR WHEEL AND REAR BRAKE...............................6-10
CHECKING THE REAR WHEEL....................................................................6-11
CHECKING THE BRAKE................................................................................6-12
INSTALLING THE REAR WHEEL AND REAR BRAKE.............................6-13

FRONT BRAKE..........................................................................................6-15
FRONT BRAKE CALIPER..............................................................................6-15
REPLACING THE FRONT BRAKE PADS.....................................................6-16
DISASSEMBLING THE FRONT BRAKE CALIPER.....................................6-18
CHECKING THE FRONT BRAKE CALIPER................................................6-20
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER..........6-21
FRONT BRAKE MASTER CYLINDER..........................................................6-23
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER.................6-24
CHECKING THE FRONT BRAKE MASTER CYLINDER............................6-26
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER....................................................................................6-27

FRONT FORK............................................................................................6-31
REMOVING THE FRONT FORK LEGS.........................................................6-32
DISASSEMBLING THE FRONT FORK LEGS..............................................6-33
CHECKING THE FRONT FORK LEGS..........................................................6-34
ASSEMBLING THE FRONT FORK LEGS.....................................................6-35
INSTALLING THE FRONT FORK LEGS.......................................................6-38
HANDLEBAR.............................................................................................6-39
REMOVING THE HANDLEBAR....................................................................6-40
CHECKING THE HANDLEBAR.....................................................................6-42
INSTALLING THE HANDLEBAR..................................................................6-42

STEERING HEAD......................................................................................6-45
REMOVING THE LOWER BRACKET...........................................................6-46
CHECKING THE STEERING HEAD..............................................................6-47
INSTALLING THE STEERING HEAD...........................................................6-48
 CHAS

REAR SHOCK ABSORBER ASSEMBLY.................................................6-50

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY........................6-51
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY........................6-52
CHECKING THE CRANKCASE (LEFT)........................................................6-52
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY.....................6-52
 FRONT WHEEL AND BRAKE CHA
EASF0044

CHASSIS
FRONT WHEEL AND BRAKE DISC
1 Front wheel axle 8 Front wheel
2 Brake disc
3 Spacer
4 Oil seal
5 Bearing
6 Spacer
7 Speedometer gear unit

6-
 FRONT WHEEL AND BRAKE CHA
EAS00519

REMOVING THE FRONT WHEEL

1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there
is no danger of it falling over.

2. Remove:
9 speedometer cable 1
9 wheel axle nut 2
9 washer 3
3. Elevate:
9 front wheel
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.

4. Remove:
9 front wheel axle 1
9 spacer 2
9 speedometer gear unit 3
9 front wheel

5. Remove:
9 brake disc 1

6-
 FRONT WHEEL AND BRAKE CHA
EAS00526

CHECKING THE FRONT WHEEL

1. Check:
9 wheel axle
Roll the wheel axle on a flat surface. Bends 
Replace.

w
Do not attempt to straighten a bent wheel
axle.

Wheel axle bending limit

0.25 mm (0.0098 in)

2. Check:
9 tire
9 front wheel
Damage/wear  Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Check:
9 spokes
Bends/damage  Replace. Loose
 Tighten.
Tap the spokes with a screwdriver.
Refer to “CHECKING AND TIGHTENING
THE SPOKES” in chapter 3.

4. Measure:
9 radial wheel runout a
9 lateral wheel runout b
Over the specified limits  Replace.

Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)

6-
 FRONT WHEEL AND BRAKE CHA
5. Check:
9 spacers
Damage/wear  Replace.

w
9 After mounting a new tire, ride conserva-
tively for a while to become accustomed
to the “feel” of the new tire and to allow
the tire to seat itself properly in the rim.
Failure to do so could lead to an accident
with possible injury to the rider or
damage to the vehicle.
9 After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 properly.

6. Check:
9 wheel bearings
Front wheel turns roughly or is loose 
Replace the wheel bearings.
9 oil seal
Damage/wear  Replace.

2 7. Replace:
9 wheel bearings
9 oil seal
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Clean the outside of the front wheel hub.
New b. Remove the oil seal 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel sur- face.

c. Remove the wheel bearings 3 with a gen-

eral bearing puller.
d. Install the new wheel bearings and oil seal in
the reverse order of disassembly.

6-
 FRONT WHEEL AND BRAKE CHA
cC
Do not contact the wheel bearing inner race 4 or balls 5. Contact should be made only with
the outer race 6.

NOTE:
Use a socket 7 that matches the diameter of the
wheel bearing outer race and oil seal.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00527

CHECKING THE BRAKE DISC

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

Brake disc deflection limit

(maximum)
0.15 mm (0.006 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the vehicle on a suitable stand so that the
front wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is sta-
tionary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against the
brake disc surface.
e. Measure the deflection 1.5 mm (0.059 in)
below the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6-
 FRONT WHEEL AND BRAKE CHA
3. Measure:
9 brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace.

Brake disc thickness limit

(minimum)
3.0 mm (0.12 in)

4. Adjust:
9 brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc 1.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.

Brake disc bolt

23 Nm (2.3 m · kg, 17 ft · lb)
LOCTITER
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjust- ment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00535

CHECKING THE SPEEDOMETER GEAR

UNIT
1. Check:
9 speedometer gear Bends/damage/wear
 Replace.

6-
 FRONT WHEEL AND BRAKE CHA
EAS00542

INSTALLING THE FRONT WHEEL

1. Lubricate:
9 wheel axle
9 wheel bearings
9 oil seal lips
9 speedometer gear unit
Recommended lubricant
Lithium-soap-based grease

2. Install:
9 speedometer gear unit 1
NOTE:
9 Make sure that the speedometer gear unit and the
wheel hub are installed with the pro- jection a of
the wheel hub inserted in a slot b of the
speedometer gear unit.
9 When installing the speedometer gear unit, make
sure that the projection on the wheel hub does not
damage the lip of the speedometer gear unit oil
seal.

3. Install:
9 brake disc
Refer to “CHECKING THE BRAKE DISC”.
4. Install:
9 speedometer gear unit
9 spacer
9 front wheel 9
front wheel axle 9
washer
NOTE:
Make sure the projection a on the speedome- ter
gear unit fits over the stopper on the outer tube.

6-
 FRONT WHEEL AND BRAKE CHA
5. Tighten:
9 wheel axle nut
40 Nm (4.0 m·kg, 29 ft·lb)

w
Make sure the brake hose is routed proper-
ly.

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

6. Connect:
9 speedometer cable

6-
 REAR WHEEL AND CHA
EASF0049

REAR WHEEL AND BRAKE

1 Axle nut 0 Brake camshaft lever
2 Rear wheel q Adjusting nut
3 Brake shoe spring (brake camshaft side) w Pin
4 Brake shoe spring (pivot side) e Rear brake cable spring
5 Brake shoe r Rear brake cable
6 Brake camshaft
7 O-ring
8 Brake shoe wear indicator
9 Wave washer

6-9
 REAR WHEEL AND CHA
BRAKE
REMOVING THE REAR WHEEL AND
REAR BRAKE
1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there
is no danger of it falling over.

NOTE:
Place the vehicle on a suitable stand so that the
rear wheel is elevated.

2. Remove:
9 muffler
Refer to “REMOVING THE ENGINE” in
chapter 4.

3. Remove:
9 wheel axle nut 1
9 washer
9 rear wheel 2

4. Remove: 9
adjusting nut 1 9 rear brake cable 2 9 pin 3
9 brake camshaft lever bolt 4
9 brake camshaft lever 5

5. Remove:
9 wave washer 1
9 brake shoe wear indicator 2

6-
 REAR WHEEL AND CHA
6. Remove:
9 brake shoes 1
9 brake shoe spring (brake camshaft side) 2
3 9 brake shoe spring (pivot side) 3

1
2

7. Remove:
9 brake camshaft 1
9 washer 2

EAS00566

CHECKING THE REAR WHEEL

1. Check:
9 tire
9 rear wheel
Damage/wear  Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
2. Check:
9 spokes
Bends/damage  Replace. Loose
 Tighten.
Tap the spokes with a screwdriver.
Refer to “CHECKING AND TIGHTENING
THE SPOKES” in chapter 3.
3. Measure:
9 radial wheel runout
9 lateral wheel runout
Refer to “CHECKING THE FRONT
WHEEL”.

6-
 REAR WHEEL AND CHA
EAS00569

CHECKING THE BRAKE

The following procedure applies to all of the
brake shoes.
1. Check:
9 brake shoe lining Glazed
areas  Repair.
Sand the glazed areas with course sand-
paper.
NOTE:
After sanding the glazed areas, clean the brake shoe
with a cloth.

2. Measure:
9 brake shoe lining thickness a
Out of specification  Replace.

Brake shoe lining thickness limit

2.0 mm (0.079 in)

w
Do not allow oil or grease to contact the
brake shoes.

NOTE:
Replace the brake shoes as a set, if either is worn
to the wear limit.

3. Check:
9 brake drum inner surface Oil
deposits  Clean.
Remove the oil with a rag soaked in lac-
quer thinner or solvent.
Scratches  Repair.
Lightly and evenly polish the scratches with
an emery cloth.

4. Measure:
9 brake drum inside diameter a
Out of specification  Replace the wheel.

Brake drum inside diameter limit

131 mm (5.16 in)
5. Check:
9 brake camshaft Damage/wear
 Replace.

6-
 REAR WHEEL AND CHA
EAS00573

INSTALLING THE REAR WHEEL AND

REAR BRAKE
1. Lubricate:
9 brake camshaft
Recommended lubricant
Lithium-soap-based grease
2. Install:
9 washer
9 brake camshaft 1

w
After installing the brake camshaft, remove
any excess grease.

NOTE:
Install the brake camshaft 1 with the punch mark
a toward the outside.

3. Install:
9 brake shoe wear indicator 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the brake camshaft so its punch mark
a is positioned as shown.
b. Align the projection b on the brake shoe
wear indicator with the notch in the brake
shoe camshaft.
c. Check that the brake shoes are properly
positioned.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
9 brake shoe spring (brake camshaft side) 1
9 brake shoe spring (pivot side) 2
9 brake shoes
NOTE:
9 Do not to damage the springs during installa- tion.
9 Install the brake shoe spring as shown.

6-
 REAR WHEEL AND CHA
5. Install:
9 brake camshaft lever 1
9 brake camshaft lever bolt 2
9 pin 3
9 rear brake cable 4
9 adjusting nut 5
NOTE:
9 Align the punch mark on the brake camshaft with
the mark on the brake camshaft lever positioned
as shown a.
9 Lubricate the brake camshaft 6 and pin 3
with lithium-soap-based grease.

6. Tighten:
9 brake camshaft lever bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
9 wheel axle nut
135 Nm (13.5 m·kg, 100 ft·lb)
7. Adjust:
9 rear brake lever free play
Rear brake lever free play
(lever end)
10 ~ 20 mm (0.39 ~ 0.79 in)
Refer to “ADJUSTING THE REAR
BRAKE” in chapter 3.

6-
 FRONT CHA
FRONT BRAKE
EASF0052

FRONT BRAKE CALIPER

1 Brake pad retaining pin
2 Air bleed screw 9 Brake pad
3 Brake caliper 0 Brake pad spring
4 Brake caliper bracket
5 Lower brake caliper retaining bolt
6 Brake caliper piston
7 Brake caliper dust seal
8 Brake caliper piston seal

6 Nm (0.6 m•kg, 4.6 ft•lb)

S

S
5

7
9
8
0

BF S

35 Nm (3.5 m•kg, 26 ft•lb)

6-
 FRONT CHA
EAS00579

cC
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
9 Never disassemble brake components
unless absolutely necessary.
9 If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
9 Never use solvents on internal brake com-
ponents.
9 Use only clean or new brake fluid for
cleaning brake components.
9 Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
9 Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
9 Flush with water for 15 minutes and get
immediate medical attention.

EAS00581

REPLACING THE FRONT BRAKE PADS

NOTE:
When replacing the brake pads, it is not nec- essary
to disconnect the brake hose or disas- semble the
brake caliper.

1. Remove:
9 brake caliper bolts
9 brake caliper 1

6-
 FRONT CHA
BRAKE
9 clips
9 brake pad retaining pin
9 brake pads 1
9 brake pad spring

3. Measure:
9 brake pad wear limit a a
Out of specification  Replace the brake pads
as a set.
Brake pad wear limit
0.8 mm (0.031 in)

4. Install:
9 brake pad spring
9 brake pads

NOTE:
Always install new brake pads and a new brake pad
spring as a set.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2. Put the other end of the hose
1 into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with your
finger.
2 c. Tighten the bleed screw.

Bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
d. Install new brake pads and a new brake pad spring.
NOTE:
Make sure the brake pad spring is installed
correctly as shown.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6-
 FRONT CHA
5. Lubricate:
9 brake pad retaining pin
Recommended lubricant
Silicone grease

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

6. Install:
9 brake caliper bolts
35 Nm (3.5 m·kg, 26 ft·lb)

7. Check:
9 brake fluid level
a Below the minimum level mark a  Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
9 brake lever operation
Soft or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

EAS00618

DISASSEMBLING THE FRONT BRAKE

CALIPER
NOTE:
Before disassembling the brake caliper, drain the
brake fluid from the entire brake system.

6-
 FRONT CHA
1. Remove:
9 union bolt 1
9 copper washers 2
9 brake hose
1
NOTE:
Put the end of the brake hose into a container and
2
pump out the brake fluid carefully.

2. Remove:
9 brake caliper 1
9 pin
9 brake pad retaining pin
1
9 brake pads
9 brake pad spring

3. Remove:
1 9 brake caliper bracket 1

4. Remove:
9 brake caliper piston 1
2 9 brake caliper piston seal 2
9 brake caliper dust seal 3
3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
opening to force out the piston from the brake
1
caliper.

w
9 Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton are
expelled from the brake caliper.
9 Never try to pry out the brake caliper pis- ton.

b. Remove the brake caliper piston seal and

brake caliper dust seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6-
 FRONT CHA
EAS00631

CHECKING THE FRONT BRAKE

CALIPER

Recommended brake component

replacement schedule
Brake pads If necessary
Piston seal Every two years
Brake hose Every four years
Every two years
Brake fluid and whenever the
brake is
disassembled

1. Check:
3
9 brake caliper piston 1 Rust/scratches/wear 
Replace the brake caliper pistons.
2 9 brake caliper cylinder 2
Scratches/wear  Replace the brake caliper
assembly.
9 brake caliper body 3
1 Cracks/damage  Replace the brake caliper
assembly.
9 brake fluid delivery passages
(brake caliper body)
Obstructions  Blow out with compressed
air.

w
Whenever a brake caliper is disassembled,
replace the piston seals.

2. Check:
9 brake caliper bracket 1
Cracks/damage  Replace.

6-
 FRONT CHA
EAS00634

ASSEMBLING AND INSTALLING THE

FRONT BRAKE CALIPER
w
9 Before installation, all internal brake com-
ponents should be cleaned and
lubricated with clean or new brake fluid.
9 Never use solvents on internal brake com-
ponents as they will cause the piston
seals to swell and distort.
9 Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.

Recommended brake fluid

DOT 4

NOTE:
If DOT 4 brake fluid is not available, DOT 3 brake
fluid can be used.

1. Install:
2 9 brake caliper 1
1 (temporarily)
9 copper washers
a 9 brake hose 2
b
9 union bolt 3 26 Nm (2.6 m·kg, 19 ft·lb)
3
w
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING”.

cC
When installing the brake hose onto the
brake caliper 1, make sure the brake pipe
a touches the projection b on the
brake caliper.

2. Remove:
9 brake caliper
3. Install:
9 brake pad springs
9 brake pads
9 brake pad retaining pin
9 brake caliper 35 Nm (3.5 m·kg, 26 ft·lb)
Refer to “REPLACING THE FRONT
BRAKE PADS”.

6-
 FRONT CHA
4. Fill:
9 brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)

Recommended brake fluid

DOT 4

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

cC
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

NOTE:
If DOT 4 brake fluid is not available, DOT 3
a brake fluid can be used.

5. Bleed:
9 brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
9 brake fluid level
Below the minimum level mark a  Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
9 brake lever operation
Soft or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6-22
 FRONT CHA
EASF0050

FRONT BRAKE MASTER CYLINDER

1 Brake master cylinder 9 Front brake light switch
2 Brake lever 0 Copper washer
3 Brake master cylinder kit q Union bolt
4 Brake master cylinder reservoir cap w Brake hose
5 Brake master cylinder reservoir diaphragm holder
6 Brake master cylinder reservoir diaphragm
7 Plate
8 Brake master cylinder bracket

6-
 FRONT CHA
EAS00588

DISASSEMBLING THE FRONT BRAKE

MASTER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire brake
system.

1. Remove:
9 front cowling
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.

2. Remove:
1 1
9 rear view mirrors (left and right) 1
9 handlebar cover 2
2 NOTE:
Slide the rubber cover and lessen the nut before
removing each rear view mirror.

8 7 4 5 3. Remove: 9
speedometer cable 1 9
starter cable 2
9 speedometer assembly screw
9 left handlebar switch bracket 3

4. Disconnect:
9 speedometer assembly coupler 4
1 2 6 3 9 left handlebar switch coupler 5
9 left handlebar switch connecter 6
9 right handlebar switch coupler 7

5. Remove:
9 speedometer assembly 8
(with left and right handlebar switches)

6-
 FRONT CHA
6. Remove:
9 union bolt 1
9 copper washers 2
9 brake hose 3
9 brake lever 4
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end of
the brake hose.

7. Remove:
9 front brake light switch 1

8. Remove:
9 brake master cylinder bracket 1
9 brake master cylinder 2

9. Remove:
9 dust boot 1
9 brake master cylinder kit 2

10. Remove:
9 brake master cylinder reservoir cap 1
9 brake master cylinder reservoir diaphragm
holder 2
9 brake master cylinder reservoir diaphragm 3
9 plate 4

6-
 FRONT CHA
1 11. Remove:
9 brake hose holder 1
2 9 brake hose 2
1

EAS00590

CHECKING THE FRONT BRAKE MAS- TER CYLINDER

1. Check:
9 brake master cylinder 1
Damage/scratches/wear  Replace.
9 brake fluid delivery passages 2
(brake master cylinder body)
Obstruction  Blow out with compressed air.
2. Check:
9 brake master cylinder kit Damage/scratches/wear  Replace.

3. Check:
9 brake master cylinder reservoir 1
Cracks/damage  Replace.
9 brake master cylinder reservoir diaphragm 2
Damage/wear  Replace.

4. Check:
9 brake hose 1
Cracks/damage/wear  Replace.

6-
 FRONT CHA
EAS00598

ASSEMBLING AND INSTALLING THE

FRONT BRAKE MASTER CYLINDER
For assembly and installation, reverse the dis-
assembly and removal procedure.
w
9 Before installation, all internal brake com-
ponents should be cleaned and
lubricated with clean or new brake fluid.
9 Never use solvents on internal brake com-
ponents.

Recommended brake fluid

DOT 4
NOTE:
If DOT 4 brake fluid is not available, DOT 3
brake fluid can be used.

1. Install:
9 brake hose
9 brake hose holder
7 Nm (0.7 m·kg, 5.1 ft·lb)
2. Install:
9 plate 1
9 brake master cylinder reservoir diaphragm
9 brake master cylinder reservoir diaphragm
holder
9 brake master cylinder reservoir cap
NOTE:
Install the plate in the direction shown.

3. Install:
9 brake master cylinder 1
1 9 brake master cylinder bracket
9 brake master cylinder bracket upper bolt
11 Nm (1.1 m·kg, 8.0 ft·lb)
9 brake master cylinder bracket lower bolt
(temporarily)
a
NOTE:
9 Install the brake master cylinder bracket with the “UP” mark facing up.
9 Install the brake master cylinder within 10
from the horizontal line shown in illustration.
9 Install the brake master cylinder bracket as
shown.
9 First, tighten the upper bolt, then the lower bolt.

a 171 mm (6.76 in)

6-
 FRONT CHA
4. Install:
9 brake lever 1
9 copper washers 2
9 brake hose 3
9 union bolt 4 26 Nm (2.6 m·kg, 19 ft·lb)

w
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“ CABLE ROUTING” in chapter 2.

NOTE:
Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts (e.g.,
wire harness, cables, leads). Correct if necessary.

5. Fill:
9 brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)

Recommended brake fluid

DOT 4

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

cC
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

6-
 FRONT CHA
NOTE:
If DOT 4 brake fluid is not available, DOT 3
brake fluid can be used.

6. Bleed:
9 brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7. Check:
9 brake fluid level
Below the minimum level mark a  Add the recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
a
LEVEL” in chapter 3.
8. Check:
9 brake lever operation
Soft or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

9. Install:
9 speedometer assembly 1
(with left and right handlebar switches)
NOTE:
When installing the meter assembly cover, make
sure that the gap between the brake master
a cylinder bracket 2 and the handlebar lower cover
1 2 is uniform. If the gap is not uniform, loosen the
bolt in the hole a in the meter assembly cover
and adjust the position of the brake master
cylinder bracket.

6-
 FRONT CHA
1 4 2 6 10. Connect:
9 right handlebar switch coupler 1
9 left handlebar switch coupler 2
9 left handlebar switch connecter 3
9 speedometer assembly coupler 4
Refer to "CABLE ROUTING" in chapter 2.
11 .Install:
9 left handlebar switch bracket 5
8 7 3 5 9 left handlebar switch bracket screw 6
4 Nm (0.4 m·kg, 2.9 ft·lb)
9 speedometer assembly screw
9 starter cable 7
9 speedometer cable 8
Refer to "CABLE ROUTING" in chapter 2.

NOTE
First, tighten the lower left handlebar switch
bracket screw, then the upper left handlebar switch
bracket screw.

12. Tighten:
9 rear view mirror nuts (left and right)
32 Nm (3.2 m·kg, 23 ft·lb)
13. Install:
9 handlebar cover
9 handlebar cover screw

6-
 FRONT CHA
EASF0054

FRONT FORK
1 Front fork cap bolt 0 Outer tube
2 O-ring
3 Fork spring
4 Damper rod
5 Rebound spring
6 Inner tube
7 Dust seal 8
Oil seal clip 9
Oil seal

20 Nm (2.0 m•kg, 14 ft•lb)

6
1
2
7
8
9

23 Nm (2.3 m•kg, 17 ft•lb)

6-
 FRONT CHA
FORK
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there
is no danger of it falling over.

NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.

2. Remove:
9 front cowling
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
3. Remove:
9 front wheel
Refer to “FRONT WHEEL AND BRAKE
DISC”.
4. Remove:
9 brake hose holder
5. Remove:
9 lower bracket upper pinch bolt 1
6. Loosen:
9 front fork cap bolt 2
(with a 10-mm hexagonal wrench)
9 lower bracket lower pinch bolt 3

w
Before removing the lower bracket lower pinch bolts, support the front fork leg.

7. Remove:
9 front fork leg 4

6-
 FRONT CHA
1
FORK
DISASSEMBLING THE FRONT FORK
LEGS
The following procedure applies to both of the front
fork legs.
1. Remove:
9 cap bolt
9 fork spring
2. Drain:
9 fork oil
NOTE:
Stroke the inner tube 1 several times while draining the fork oil.
3. Remove:
9 dust seal 1
9 oil seal clip 2
(with a flat-head screwdriver)
cC
Do not scratch the inner tube.

4. Remove:
9 damper rod assembly bolt 1
9 copper washer
NOTE:
While holding the damper rod assembly with the
hexagon socket wrench (10 mm) 2 and the T-
handle 3, loosen the damper rod assem- bly bolt 1.

T-handle
90890-01326

5. Remove:
9 inner tube
9 damper rod
9 rebound spring
NOTE:
Pull out the inner tube and damper rod togeth- er.

6. Remove:
9 oil seal 1

cC
Never reuse the oil seal.
2 Rag

6-
 FRONT CHA
EAS00657

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Check:
9 inner tube 1
9 outer tube 2
Bends/damage/scratches  Replace.

w
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.

2. Measure:
9 fork spring free length a
Out of specification  Replace.

Fork spring free length

266.7 mm (10.50 in)
<Limit>: 261.4 mm (10.29 in)

3. Check:
9 damper rod 1
1
Damage/wear  Replace.
Obstruction  Blow out all of the oil pas-
2 sages with compressed air.
9 rebound spring 2
Wear/cracks  Replace.

cC
9 The front fork leg has a built-in damper
adjusting rod and a very sophisticated
internal construction, which are particu-
larly sensitive to foreign material.
9 When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.

6-
 FRONT CHA
EAS00659

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the front
fork legs.

w
9 Make sure the oil levels in both front fork
legs are equal.
9 Uneven oil levels can result in poor han-
dling and a loss of stability.

NOTE:
9 When assembling the front fork leg, be sure to
replace the following parts:
- oil seal
- dust seal
- gasket
9 Before assembling the front fork leg, make sure
all of the components are clean.

1. Install:
2 9 damper rod assembly 1
9 rebound spring
9 inner tube 2
1
cC
Allow the damper rod assembly to slide
slowly down the inner tube 2 until it pro-
trudes from the bottom of the inner tube.
Be careful not to damage the inner tube.

2. Lubricate:
9 inner tube’s outer surface

Recommended lubricant
Fork oil 10 W or equivalent
3. Install:
9 outer tube

6-
 FRONT CHA
4. Tighten:
LT
9 damper rod assembly bolt 1
23 Nm (2.3 m·kg, 17 ft·lb)
NOTE:
LT While holding the damper rod assembly with the
hexagon socket wrench (10 mm) 2 and T-
1
handle 3, tighten the damper rod assembly bolt.
New

T-handle
90890-01326

5. Install:
9 oil seal 1
(with the fork seal driver attachment 2 and
fork seal driver weight 3)
Fork seal driver weight
90890-01184
Fork seal driver attachment
90890-01186

cC
Make sure the numbered side of the oil seal faces up.

NOTE:
9 Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
9 Lubricate the outer surface of the inner tube with
fork oil.
9 Before installing the oil seal, cover the top of the
front fork leg with a plastic bag 4 to pro- tect
the oil seal during installation.

6-
 FRONT CHA
6. Install:
9 oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.

7. Install:
9 dust seal 1
(with the fork seal driver weight 2)
Fork seal driver weight
90890-01184

8. Fill:
9 front fork leg
(with the specified amount of the recom-
mended fork oil)
Quantity (each front fork leg)
57 cm3 (2.01 Imp oz, 1.93 US oz)
Recommended oil
Fork oil 10 W or equivalent

Front fork leg oil level a (from

the top of the inner tube, with the
inner tube fully compressed and
without the fork spring)
88 mm (3.46 in)
NOTE:
9 While filling the front fork leg, keep it upright.
9 After filling, slowly pump the front fork leg up and
down to distribute the fork oil.

9. Install:
9 fork spring 1
NOTE:
Install the fork spring with the smaller pitch fac- ing
up.

6-
 FRONT CHA
EAS00663

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
For installation, reverse the removal procedure.
1. Install:
9 front fork leg 1
9 lower bracket lower pinch bolt 2
9 O-ring
9 cap bolt 3
9 lower bracket upper pinch bolt 4
NOTE:
Install the front fork leg with the groove a in
the inner tube aligned with the hole b for the
lower bracket upper pinch bolt.

2. Tighten:
9 lower bracket lower pinch bolt
38 Nm (3.8 m·kg, 27 ft·lb)

9 cap bolt 20 Nm (2.0 m·kg, 14 ft·lb)

9 lower bracket upper pinch bolt
38 Nm (3.8 m·kg, 27 ft·lb)

6-
 HANDLEBA CHA
EASF0055

HANDLEBAR
1 Rear view mirror 0 Starter cable q
2 Throttle grip Throttle cable w
3 Throttle cable housing 4 Starter lever
Right handlebar switch 5 e Handlebar cover
Handlebar r Speedometer assembly
6 Left handlebar switch
7 Handlebar grip 8
Rear brake lever 9
Rear brake cable

32 Nm (3.2 m•kg, 23 ft•lb) 32 Nm (3.2 m•kg, 23 ft•lb)

2 1 1
4

3
r

q
5
7
w
53 Nm (5.3 m•kg, 39 ft•lb)
9 8

6-
 HANDLEBA CHA
EAS006
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there
is no danger of it falling over.

2. Remove:
9 front cowling
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
3. Remove:
9 handlebar cover
9 speedometer assembly
Refer to “DISASSEMBLING THE FRONT
BRAKE MASTER CYLINDER”.
4. Remove:
9 brake master cylinder assembly
Refer to “FRONT BRAKE” .
5. Remove:
9 throttle cable housing (rear side) 1

6. Remove:
9 throttle cable 1
9 throttle grip 2
9 throttle cable housing (front side) 3

7. Remove:
1 9 handlebar grip 1
NOTE:
Blow compressed air between the handlebar and
the handlebar grip, and gradually push the grip off
the handlebar.

6-
 HANDLEBA CHA
8. Disconnect:
9 rear brake light switch connector 1
9. Remove:
9 rear brake cable 2
9 rear brake lever assembly 3

10. Remove: 9
speedometer cable 9
1 front brake hose 9
wireharness 9 throttle
cable
9 rear brake cable
9 starter cable
NOTE:
9 Remove the speedometer cable and front brake
hose from the holder, then remove the
wireharness, throttle cable, rear brake cable, and
starter cable from the guide.
9 Unhook the plastic strap 1 attached to the
wireharness from the projection on the han-
dlebar, and then remove the wireharness.

11. Remove: 9
handlebar nut 1 9
handlebar bolt 2 9
handlebar 3
3

6-
 HANDLEBA CHA
EAS00668

CHECKING THE HANDLEBAR

1. Check:
1 9 handlebar 1
Bends/cracks/damage  Replace.

w
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.

EAS00673

INSTALLING THE HANDLEBAR

For installation, reverse the removal procedure.
1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there
is no danger of it falling over.

2. Install:
9 handlebar 1
NOTE:
Align the pipe a on the handlebar with the slit
b on the lower bracket.

3. Tighten:
9 handlebar nut
53 Nm (5.3 m·kg, 39 ft·lb)

4. Install:
9 starter cable 9
1 rear brake cable 9
throttle cable
9 wireharness
9 front brake hose
9 speedometer cable
Refer to “CABLE ROUTING” in chapter 2.
NOTE:
Hook the plastic strap 1 attached to the wire
harness from the projection on the handlebar, and
then install the wireharness.

6-
 HANDLEBA CHA
5. Install:
9 rear brake lever assembly 1
7 Nm (0.7 m·kg, 5.1 ft·lb)
9 rear brake cable
NOTE:
9 Install the rear brake lever within 10 from the
horizontal line shown in the illustration.
9 After installing the rear brake lever assembly, make
sure that the clearance a between the center of
the hole b in the handlebar and the rear brake
lever assembly 1 is 10.3 mm (0.41 in).

6. Connect:
9 rear brake light switch connector

7. Install:
9 handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

8. Install:
9 throttle cable 1
9 throttle grip 2
9 throttle cable housing (front side) 3
NOTE:
9 Lubricate the inside of the throttle grip with a thin
coat of lithium-soap-based grease and install it
onto the handlebar.
9 Align the projection a on the throttle cable
housing (front side) with the hole b on the
handlebar.

6-
 HANDLEBA CHA
9. Install:
9 throttle cable housing (rear side) 1
4 Nm (0.4 m·kg, 2.9 ft·lb)

w
Make sure the throttle grip operates
smoothly.

10. Adjust:
9 throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 7 mm (0.12 ~ 0.28 in)

11. Adjust:
9 brake lever free play
Refer to “ADJUSTING THE REAR
BRAKE” in chapter 3.
Brake lever free play (lever end)
10 ~ 20 mm (0.39 ~ 0.79 in)

6-
 STEERING CHA
EASF0057

STEERING HEAD
1 Upper ring nut 0 Speedometer cable guide
2 Lower ring nut q Front fender
3 Ball race cover w Stay
4 Bearing inner race e Guide
5 Upper bearing
6 Bearing outer race
7 Lower bearing
8 Lower bracket
9 Brake hose holder bracket

1
2 75 Nm (7.5 m•kg, 54 ft•lb)
3
4 30 Nm (3.0 m•kg, 22 ft•lb)
5
6

38 Nm (3.8 m•kg, 29 ft•lb)

7 Nm (0.7 m•kg, 5.1 ft•lb) 4

7 Nm (0.7 m•kg, 5.1 ft•lb)

6
7
9 e
8

7 Nm (0.7 m•kg, 5.1 ft•lb)

7 Nm (0.7 m•kg, 5.1 ft•lb)

6-
 STEERING CHA
EAS00679

REMOVING THE LOWER BRACKET

1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there
is no danger of it falling over.

2. Remove:
9 front cowling
9 leg shield
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
3. Remove:
9 front wheel
Refer to “REMOVING THE WHEEL”.
9 front fender

4. Remove:
9 front fork
Refer to “FRONT FORK”.
5. Remove:
9 handlebar
Refer to “HANDLEBAR”.

6. Remove:
9 brake hose holder bracket 1
9 speedometer cable guide 2

2
1

7. Remove:
9 upper ring nut 1
9 lower ring nut 2
9 lower bracket
NOTE:
Hold the lower ring nut with the ring nut wrench 3,
and then remove the upper ring nut with the
steering nut wrench 4.

6-
 STEERING CHA
Steering nut wrench
90890-01403
Ring nut wrench
90890-01268

w
Securely support the lower bracket so that
there is no danger of it falling.

EAS00681

CHECKING THE STEERING HEAD

1. Clean:
9 bearings
9 bearing races
Recommended cleaning solvent
Kerosene

2. Check:
9 bearings 1
2 1 9 bearing races 2
Damage/pitting  Replace.

3. Replace:
9 bearings
9 bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steer- ing
head pipe with a long rod 1 and ham- mer.
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install the new bearing races.

cC
If the bearing race is not installed properly, the steering head pipe could be damaged.

NOTE:
Always replace the bearings and bearing races as a
set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6-
 STEERING CHA
4. Check:
9 lower bracket 1
(along with the steering stem)
Bends/cracks/damage  Replace.

EAS00683

INSTALLING THE STEERING HEAD

For installation, reverse the removal procedure.
1. Lubricate:
9 upper bearing
9 lower bearing
9 bearing races
Recommended lubricant
Lithium-soap-based grease
2. Install:
9 upper bearing 1
9 lower bearing 2
NOTE:
Install the upper and lower bearings with the
projection a on each bearing facing up.

3. Install:
9 cover
9 lower ring nut
9 upper ring nut
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.

4. Install:
9 speedometer cable guide
7 Nm (0.7 m·kg, 5.1 ft·lb)
9 brake hose holder bracket
7 Nm (0.7 m·kg, 5.1 ft·lb)

6-
 STEERING CHA
5. Install:
9 front fender 7 Nm (0.7 m·kg, 5.1 ft·lb)

6. Install:
9 front wheel
Refer to “INSTALLING THE WHEEL”.

7. Install:
9 leg shield
9 front cowling
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.

6-
 REAR SHOCK ABSORBER CHA
EASF0058

REAR SHOCK ABSORBER ASSEMBLY

1 Boot
2 Rear shock absorber

2
32 Nm (3.2 m•kg, 23 ft•lb)

16 Nm (1.6 m•kg, 11 ft•lb)

6-
 CHAS
REAR SHOCK ABSORBER ASSEMBLY
EAS00690

REMOVING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there
is no danger of it falling over.

NOTE:
Place the vehicle on a suitable stand so that the
rear wheel is elevated.

2. Remove:
9 side cover (left and right)
Refer to “REMOVING THE SEAT AND
SIDE COVER” in chapter 3.

3. Remove:
9 fuel tank
Refer to “FUEL TANK” in chapter 5.

4. Remove:
9 V-belt case air filter assembly
Refer to “KICKSTARTER” in chapter 4.

5. Remove:
9 boots

6. Remove:
9 rear shock absorber bolt 1
9 rear shock absorber nut 2
3
9 washer
1 9 rear shock absorber assembly 3
9 washer

6-
 REAR SHOCK ABSORBER CHA
EAS00695

CHECKING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Check:
9 rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
9 rear shock absorber
Oil leaks  Replace the rear shock
absorber assembly.
9 spring
Damage/wear  Replace the rear shock
absorber assembly.
9 bushings
Damage/wear  Replace.
9 bolts
Bends/damage/wear  Replace.

CHECKING THE CRANKCASE (LEFT)

1 1. Check:
9 bushing (rear shock absorber assembly) 1
Damage/wear  Replace.

EAS00697

INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
For installation, reverse the removal procedure.
1. Install:
9 washer
9 rear shock absorber assembly
9 washer
9 rear shock absorber assembly nut
32 Nm (3.2 m·kg, 23 ft·lb)
9 rear shock absorber assembly bolt
16 Nm (1.6 m·kg, 11 ft·lb)
2. Install:
9 boots
9 V-belt case air filter assembly
Refer to “KICK STARTER” in chapter 4.
9 fuel tank
Refer to “FUEL TANK in chapter 5.
9 side cover
Refer to “INSTALLING THE SEAT AND
SIDE COVER” in chapter 3.

6-
ELEC

CHAPTER 7
ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS....................................................................7-1

CHECKING SWITCH CONTINUITY.............................................................7-3

CHECKING THE SWITCHES......................................................................7-5

CHECKING THE BULBS AND BULB SOCKETS.......................................7-7

TYPES OF BULBS.............................................................................................7-7
CHECKING THE CONDITION OF THE BULBS.............................................7-8
CHECKING THE CONDITION OF THE BULB SOCKETS............................7-9

IGNITION SYSTEM....................................................................................7-10
CIRCUIT DIAGRAM.......................................................................................7-10
TROUBLESHOOTING.....................................................................................7-11

ELECTRIC STARTING SYSTEM...............................................................7-15

CIRCUIT DIAGRAM.......................................................................................7-15
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION..............................7-16
TROUBLESHOOTING.....................................................................................7-17

STARTER MOTOR....................................................................................7-20
REMOVING THE STARTER MOTOR...........................................................7-21
DISASSEMBLING THE STARTER MOTOR.................................................7-21
CHECKING THE STARTER MOTOR............................................................7-22
ASSEMBLING THE STARTER MOTOR.......................................................7-24
INSTALLING THE STARTER MOTOR.........................................................7-25

CHARGING SYSTEM.................................................................................7-26
CIRCUIT DIAGRAM.......................................................................................7-26
TROUBLESHOOTING.....................................................................................7-27

LIGHTING SYSTEM...................................................................................7-29
CIRCUIT DIAGRAM.......................................................................................7-29
TROUBLESHOOTING.....................................................................................7-30
CHECKING THE LIGHTING SYSTEM..........................................................7-32

SIGNALING SYSTEM................................................................................7-34
CIRCUIT DIAGRAM.......................................................................................7-34
TROUBLESHOOTING.....................................................................................7-35
CHECKING THE SIGNALING SYSTEM.......................................................7-36
ELEC
 ELEC
ELECTRICAL COMPONENTS
EAS00729

ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1 Fuse 8 Turn signal relay
2 Starter relay
3 Fuel sender
4 C.D.I. unit
5 Rectifier/regulator
6 Ignition coil
7 Horn

1
2

5
4

7-
 ELEC
ELECTRICAL COMPONENTS
1 Main switch
2 Fuse
3 Positive battery lead
4 Battery
5 Negative battery lead
6 Wireharness

1
6

7-
 ELEC
CHECKING SWITCH CONTINUITY
EAS00730

CHECKING SWITCH CONTINUITY

Check each switch for continuity with the pock- et
tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace
the switch.

cC
Never insert the tester probes into the cou-
1 pler terminal slots 1. Always insert the
probes from the opposite end of the cou-
pler, taking care not to loosen or damage
the leads.

Pocket tester
90980-03112

NOTE:
9 Before checking for continuity, set the pocket tester to “0” and to the “  1” range.
9 When checking for continuity, switch back and forth between the switch positions a few times.
b The terminal connections for switches (e.g., main
Br R
OFF
switch, engine stop switch) are shown in an
a illustration similar to the one on the left.
ON
The switch positions a are shown in the far left
column and the switch lead colors b are
Br R shown in the top row in the switch illustration.
NOTE:
“1——1” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit at
the respective switch position).

The example illustration on the left

shows that:
There is continuity between red and brown when
the switch is set to “ON”.

7-
 ELEC
CHECKING SWITCH CONTINUITY

7-
 ELEC
CHECKING THE SWITCHES
EAS00731

CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals.
Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear  Repair or replace.
Improperly connected  Properly connect. Incorrect
continuity reading  Replace the switch.

1 2 3 4
P B Y L/ G Ch Br/W Dg P Dg
OFF B L B Br/W
PUSH HI N L/B Ch
LO R

5 6 7
L Y/ R
Y/R L L/B L/ B
L/B
OFF W
B PO OFF
L/W
ON START
B
B

(BLACK)

8
Br R
OFF R
ON Br

7-
 ELEC
CHECKING THE SWITCHES
1 Rear brake light switch
2 Horn switch
3 Dimmer switch
4 Turn signal switch
5 Front brake light switch
6 Light switch
7 Start switch
8 Main switch
9 Fuse

7-
 CHECKING THE BULBS AND BULB ELE
EAS00732

CHECKING THE BULBS AND

BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for con- tinuity
between the terminals.
Damage/wear  Repair or replace the
bulb, bulb socket or both.
Improperly connected  Properly connect. No
continuity  Repair or replace the bulb, bulb
socket or both.

TYPES OF BULBS
The bulbs used on this vehicle are shown in the illustration on the left.
9 Bulb a is used for the headlights and usu-
ally use a bulb holder that must be detached
before removing the bulb. The majority of
these types of bulbs can be removed from
their respective socket by turning them
counterclockwise.
9 Bulbs b is used for turn signal and tail/ brake lights and can be removed from the socket by pushing
and turning the bulb counterclockwise.
9 Bulbs c and d are used for meter lights and indicator lights and can be removed from their respective
socket by carefully pulling them out.

7-
 CHECKING THE BULBS AND BULB SOCKETS ELEC

CHECKING THE CONDITION OF THE

BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
9 bulb

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

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

2. Check:
9 bulb (for continuity)
(with the pocket tester)
No continuity  Replace.
Pocket tester
90890-03112

NOTE:
Before checking for continuity, set the pocket tester
to “0” and to the “  1” range.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to termi- nal 2 and the negative tester probe to ter- minal 1, and check
the continuity.
b. Connect the positive tester probe to termi- nal
3 and the negative tester probe to ter- minal
1, and check the continuity.
c. If either of the readings indicate no conti-
nuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7-
CHECKING THE BULBS AND BULB ELE
CHECKING THE CONDITION OF THE
BULB SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:
9 bulb socket (for continuity)
(with the pocket tester) No
continuity  Replace.

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

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of
the readings indicate no continuity, replace the
bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7-
 CIRCUIT DIAGRAM
IGNITION SYSTEM
EAS00734
Br B O
W/R W/
W B
L
R Y (BLACK)

OFF R R
ON Br Br
W W W/L W/L O O
1 R 2 Y/R
3 W/R W/R 9 B 0
Br B
R W W
Y/R Y/R
Br
R
Y
B B B
q
B
W/L W/R W/RW/L

5 R R/W Gy Gy B
Gy L/W L/W L/W

R
Gy Gy
R R

7
R/W R/W
R R/W R/W L/W L/W
Y/R L/W

R
4 R
R/
Gy
L/W
e r t
L Y/ R Y/ R L
B Br
6 w OFF
PO
OFF
START
L/B L/B
B G/Y

L/ L/W (BLACK) (BLACK)

B ON
B B
B 8 L /B B Br G/Y
B B
L
7-10

Br

Br

IGNITION SYSTEM
i Br/W
Br u y
Br
Br/W
P

Br Ch Dg Y g P L Br/W G/Y

o /B
k
Y Br
Dg Ch
h j
B G Br Y
Ch Dg
a a s d f OFF HI L

G B PUSH LO N
Dg P P Dg R
(RED) (RED)
p Br/W B
Ch Y /R
B Br/W
L/B Ch

B Ch Dg

ELEC
G B Y G
q Spark plug
0 Ignition coil
9 C.D.I. unit
8 Negative lead
5 Fuse
4 Battery
3 A.C. magneto
1 Main switch

Ch Dg L G/Y
G

n L Ch Y G Dg
z ; l
G
B L B
G
B G Y b c v x B L
Y G/Y

(BLACK) (BLACK) Y G
B L L B Ch Dg Dg Ch
Dg Ch Ch Dg

B
 IGNITION ELE
EAS007
SYSTEM
TROUBLESHOOTING 1. Fuse
The ignition system fails to operate (no 9 Check the fuse for continuity.
spark or intermittent spark). Refer to “CHECKING THE FUSE” in chap-
ter 3.
Check: 9 Is the fuse OK?
1. fuse
2. battery YES NO
3. spark plug
4. ignition spark gap Replace the fuse.
5. spark plug cap resistance
EAS00739
6. ignition coil resistance
7. pickup coil resistance 2. Battery
8. main switch 9 Check the condition of the battery.
9. wiring connections (of the entire ignition Refer to “CHECKING AND CHARGING
system) THE BATTERY” in chapter 3.
NOTE: Minimum open-circuit voltage
9 Before troubleshooting, remove the following 12.8 V or more at 20 C (68 F)
part(s):
1. seat 9 Is the battery OK?
2. center cover
YES NO
3. right side cover
4. front cowling
9 Troubleshoot with the following special tool(s). 9 Clean the battery
terminals.
9 Recharge or replace
Ignition checker the battery.
90890-06754
Pocket tester EAS00740

90890-03112
3. Spark plug
9 Check the condition of the spark plug.
9 Check the spark plug type.
9 Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
in chapter 3.
Standard spark
plug C7HSA
(NGK)
Spark plug gap
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
9 Is the spark plug in good condition, is it of the
correct type, and is its gap within spec-
ification?

YES NO

Re-gap or replace
the spark plug.

7-
 IGNITION ELE
EAS00742 EAS00744

4. Ignition spark gap 5. Spark plug cap resistance

9 Disconnect the spark plug cap from the 9 Remove the spark plug cap from the spark
spark plug. plug lead.
9 Connect the ignition checker 1 as shown. 9 Connect the pocket tester (  1k) to the
2 Spark plug cap spark plug cap as shown.
9 Set the main switch to “ON”. 9 Measure the spark plug cap resistance.
9 Measure the ignition spark gap a.
9 Crank the engine by pushing the starter switch
and gradually increase the spark gap until a
misfire occurs. 1k

Spark plug cap

resistance 5 k at 20 C
(68 F)
9 Is the spark plug cap OK?
Minimum ignition spark
gap 6 mm (0.24 in) YES NO

9 Is there a spark and is the spark gap within

specification? Replace the spark
plug cap.
NO YES

The ignition system is

OK.

7-
 IGNITION ELE
EAS007
SYSTEM

6. Ignition coilcoil
7. Pickup resistance
resistance
9 Disconnect
9 Disconnectthe the
ignition
A.C.coil connector
magneto from
coupler from the
the ignition coil
wire harness. terminal.
9 Connect the the
9 Connect pocket tester
pocket ((
tester  1)100)
to the
to the
ignition coil as shown.
pickup coil terminal as shown.
Positive tester
Positive probe
tester  terminal
probe 1
 white/blue 1
Negative tester probe  ignition coil
Negative tester probe  white/red base
2
2

B Y/R W W/R W/L

1
2 1
9 Measure the pickup coil resistance.
9 Measure the primary coil resistance.
Pickup coil resistance
Primary
248 coil resistance
~ 372  at 20 C (68 F)
0.32 ~ 0.48  at 20 C (68 F)
9 Is the pickup coil OK?
9 Connect the pocket tester (  1k) to the
ignition coil as shown.
YES NO
Negative tester probe  terminal 1
Positive tester probe  spark plug lead 2
Replace the pickup
coil/stator assembly.
EAS00749

8. Main switch
9 Check the main switch for continuity. Refer
1 to “CHECKING THE SWITCHES”.
2 9 Is the main switch OK?

YES NO
9 Measure the secondary coil resistance.
Secondary coil resistance
Replace the main
5.68 ~ 8.52 k at 20 C (68 F)
switch.
9 Is the ignition coil OK?

YES NO

Replace the ignition 7-

coil.
 IGNITION ELE
EAS00754

9. Wiring
9 Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the ignition system’s wiring properly
connected and without defects?

YES NO

Replace the C.D.I. Properly connect or

unit. repair the ignition
system’s wiring.

7-
 CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
EAS00755
Br B O
W B W/R W/L
R Y (BLACK)

OFF R R
ON Br Br
W W W/L W/L O O
1 R 2 Y/R
3 W/R W/R 9 B 0
Br B
R W W
Y/R Y/
Br
R
Y B B B
q
B
W/L W/R W/RW/L

5 R R/W
Gy L/W Gy
Gy L/W L/W

R Gy Gy B
R R

7
R/W R/W
R R/W R/W L/W L/W
Y/R L/W

R
4 R
R/
Gy
L/W
e r t

ELECTRIC STARTING SYSTEM

L Y/ R Y/ L
R
6
OFF OFF L/B L/B B (BLACK)
START
B
PO
B ON L/ (BLACK)
L/W
B B Br
B 8 Br G/Y
G/Y
L/ B
B B B
L
7-15

Br

Br

i Br/W
Br u y
Br
Br/W
P

Br Ch Dg Y g P L Br/W G/Y

o /B
k
Y Br
Dg Ch
h j
B G Br Y
Ch Dg
a a s d f OFF HI L

G B PUSH LO N
Dg P P Dg R
y Rear brake light switch
t Front brake light switch
r Start switch
8 Negative lead
7 Starter relay
6 Starter motor
5 Fuse
4 Battery
1 Main switch

(RED) (RED)
p Br/W B
Ch Y /R
B Br/W
L/B Ch

ELEC
B Ch Dg
G B
Y G

Ch Dg L G/Y
G

n
G
L Ch Y G Dg
z ; l
G
B B
L B
(BLACK) (BLACK) G Y Y G b c v x B L
Y G/Y
B L L B Ch Dg Dg Ch
Dg Ch Ch Dg

B
 ELECTRIC STARTING ELE
EAS00756

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

8 If the main switch is set to “ON” (switch is
M closed), the starter motor can only operate if at
least one of the following conditions is met:

9 The front brake lever is pulled to the handle- bar

7 (the front brake light switch is closed).
9 The rear brake lever is pulled to the handle- bar
(the rear brake light switch is closed).
1
1 Battery
2 Fuse
3 Main switch
2 4 Front brake light switch
5 Rear brake light switch 6
Start switch
7 Starter relay
3 8 Starter motor

4 5

7-
 ELECTRIC STARTING ELE
EAS007
SYSTEM
TROUBLESHOOTING 1. Fuse
The starter motor fails to turn. 9 Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chap-
Check: ter 3.
1. fuse 9 Is the fuse OK?
2. battery
3. starter motor YES NO
4. starter relay
5. main switch Replace the fuse.
6. start switch
EAS00739
7. front brake light switch
8. rear brake light switch 2. Battery
9. wiring connections 9 Check the condition of the battery.
(of the entire starting system) Refer to “CHECKING AND CHARGING
NOTE: THE BATTERY” in chapter 3.
9 Before troubleshooting, remove the following Minimum open-circuit voltage
part(s): 12.8 V or more at 20 C (68 F)
1. seat
9 Is the battery OK?
2. center cover
3. side cover (left and right)
YES NO
4. front cowling
5. leg shield
6. handlebar cover 9 Clean the battery
9 Troubleshoot with the following special tool(s). terminals.
9 Recharge or replace
Pocket tester the battery.
90890-03112

7-
 ELECTRIC STARTING ELE
EAS00758
EAS00761

4. Starter
3. Starter relay
motor
9 Disconnect
9 Connect the starter
the positive relayterminal
battery coupler 1from
and the
starter
starter relay.lead 2 with a jumper lead 3.
motor
9 Connect the pocket tester (  1) and bat-
tery (12 V) to the starter relay terminal as
shown.
Positive battery terminal  blue/white 1
Negative battery terminal  gray 2
Positive tester probe  red 3
Negative tester probe  red/white 4

R
WARNING
R R/W
9 A wire that is used as a jumper lead
Gy L/W
must have at least the same capacity or
R/W
more as that of the1battery 2 lead, other-
wise the jumper lead may burn.
9 This check 4 is likely to produce sparks,
9 Does the
therefore startersure
make relaynothing
have continuity between
flammable
is inred
theand red/white?
vicinity.

9 Does the starter motor turn? YES NO

YES NO Replace the starter

relay.

Repair or replace the

starter motor.

7-
 ELECTRIC STARTING ELE
EAS007
EAS007
5. Main switch 9. Wiring
9 Check the main switch for continuity. Refer 9 Check the entire starting system’s wiring.
to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”.
9 Is the main switch OK? 9 Is the starting system’s wiring properly
connected and without defects?
YES NO
YES NO
Replace the main
switch.
The starting system Properly connect or
EAS00764 circuit is OK. repair the starting
system’s wiring.
6. Start switch
9 Check the start switch for continuity. Refer
to “CHECKING THE SWITCHES”.
9 Is the start switch OK?

YES NO

Replace the
right
handlebar switch.
7. Front brake light switch
9 Check the front brake light switch for conti-
nuity.
Refer to “CHECKING THE SWITCHES”.
9 Is the front brake light switch OK?

YES NO

Replace the
front brake
light switch.
8. Rear brake light switch
9 Check the rear brake light switch for conti-
nuity.
Refer to “CHECKING THE SWITCHES”.
9 Is the rear brake light switch OK?

YES NO

Replace the rear

brake light switch.

7-
 STARTER ELE
EASF0767

STARTER MOTOR
1 Starter motor rear cover
2 Starter motor yoke
3 Armature
4 Bush set
5 Starter motor front cover assembly

BRUSH LENGTH LIMIT:

A
3.5 mm (0.14 in)
COMMUTATOR WEAR LIMIT:
B
21 mm (0.83 in)
MICA UNDER CUT:
C
1.5 mm (0.06 in)
ARMATURE COIL RESISTANCE:
D
0.0315 ~ 0.0385  at 20 C (68 F)

7-
 STARTER ELE
REMOVING THE STARTER MOTOR
1. Remove:
9 footboard
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
2. Remove:
9 battery
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
3. Remove:
9 storage box
Refer to “FUEL TANK” in chapter 5.
9 air filter case
Refer to “AIR FILTER CASE” in chapter 5.

4. Disconnect:
2 9 battery negative lead 1
5. Remove:
9 starter motor 2

DISASSEMBLING THE STARTER

2
MOTOR
3
1. Remove:
9 starter motor lead 1
9 starter motor front cover bolts (with
washer and O-ring)
2. Remove:
1
9 starter motor front cover 2
9 washer 3

3. Remove:
1
9 starter motor yoke 1
9 O-rings 2

7-
 STARTER ELE
4. Remove:
9 armature 1
1

EAS00770

CHECKING THE STARTER MOTOR

1. Check:
9 commutator
Dirt  Clean with 600-grit sandpaper.

2. Measure:
9 commutator diameter a
Out of specification  Replace the starter
motor.

Commutator wear limit

21 mm (0.83 in)

3. Measure:
9 mica undercut a
Out of specification  Scrape the mica to the
proper measurement with a hacksaw blade that
has been grounded to fit the commutator.
Mica undercut
1.5 mm (0.06 in)

NOTE:
The mica of the commutator must be undercut to
ensure proper operation of the commutator.

7-
 STARTER ELE
4. Measure:
9 armature assembly resistances (commuta- tor and insulation)
Out of specification  Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances with
the pocket tester.

Pocket tester
90890-03112

Armature coil
Commutator resistance 1
0.0315~ 0.0385  at 20 °C (68
°F)
Insulation resistance 2
Above 1 M at 20 °C (68 °F)
b. If any resistance is out of specification,
replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Measure:
9 brush length a
Out of specification  Replace the brush- es as
a set.
Brush length wear limit
3.5 mm (0.14 in)
a

7-
 STARTER ELE
6. Measure:
9 brush spring force
Out of specification  Replace the brush
springs as a set.

Brush spring force

5.52 ~ 8.28 N
(563 ~ 844 gf, 19.87 ~ 29.80 oz)

7. Check:
9 gear teeth
Damage/wear  Replace the gear.
8. Check:
9 bearing
9 oil seal
Damage/wear  Replace the defective part(s).

EAS00772
b
ASSEMBLING THEaSTARTERbMOTOR
1
w
Always use a new O-ring.

1. Install:
9 washer
3 New (to armature)
2
9 armature
(in starter motor front cover 1)
9 O-rings
(to starter motor yoke) 9
starter motor yoke 9
starter motor rear cover 2
NOTE:
Align the match mark a on the starter motor
yoke with the match marks b on the front and
starter motor rear cover.

9 starter motor rear cover bolts (with

O-ring and washer)
9 O-ring 3
(to starter motor front cover)
9 starter motor lead

7-
 STARTER ELE
INSTALLING THE STARTER MOTOR
1 For installation, reverse the removal procedure.
1. Install:
9 starter motor 1
9 negative battery lead 2
2 9 starter motor bolts
7 Nm (0.7 m·kg, 5.1 ft·lb)

7-
 CIRCUIT DIAGRAM
CHARGING SYSTEM
EAS00773
Br B O
W/R W/
W B L
R Y (BLACK)

OFF R R
ON Br Br
W W W/L W/L O O
1 R R 2 Y/R 3 W/R W/R 9 B 0
Br B
Y W W
Br
Y/R Y/R
R

B
B B B
q

5 W/L W/R W/RW/L

Gy Gy
R R/W L/W L/W
Gy L/W B
R
Gy Gy
R R

7
R/W R/W
R R/W R/W L/W L/W
Y/R L/W

R
4 R
R/
Gy
L/W
e r t
L Y/ R Y/ L
R B
6 OFF

PO
OFF
START
L/B L/
B
B (BLACK)

B ON L/ L/W (BLACK)
B B Br
B 8 Br G/Y
G/Y
L/ B
B B B
L
7-26

Br

CHARGING SYSTEM
Br

i Br/W
Br u y
Br
Br/W
P

Br Ch Dg Y g P L Br/W G/Y

o /B
k
h j
Y Br
Dg Ch
Br Y a a s d f OFF HI L
Ch Dg PUSH LO N
B G G B
P Dg P Dg R
(RED) Br/W B B Br/W
(RED)
p Ch Y /R L/B Ch

B Ch Dg

ELEC
G B
Y G

5
4
3
2
8
Negative lead
Fuse
Battery
A.C. magneto
Rectifier/regulator
Ch Dg L G/Y
G

n L Ch Y G Dg
z ; l
G
B
G
B
G Y Y G b c v x B L
Y
L B
G/Y

(BLACK) (BLACK)
B L L B Ch Dg Dg Ch
Dg Ch Ch Dg
B

B
 ELEC
CHARGING SYSTEM
EAS00774
EAS00738
TROUBLESHOOTING
1. Fuse
The battery is not being charged. 9 Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chap-
Check: ter 3.
1. fuse 9 Is the fuse OK?
2. battery
3. charging voltage YES NO
4. charging coil resistance
5. wiring connections
Replace the fuse.
(of the entire charging system)
EAS00739
NOTE:
9 Before troubleshooting, remove the following 2. Battery
part(s): 9 Check the condition of the battery.
1. seat Refer to “CHECKING AND CHARGING
2. center cover THE BATTERY” in chapter 3.
3. right side cover
Minimum open-circuit voltage
9 Troubleshoot with the following special tool(s). 12.8 V or more at 20 C (68 F)

9 Is the battery OK?

Engine tachometer YES NO
90890-03113
Pocket tester
90890-03112 9 Clean the battery
terminals.
9 Recharge or replace
the battery.

7-
 ELEC
CHARGING SYSTEM
EAS00775 EAS00776
3. Charging voltage
4. Charging coil resistance
9 Connect the engine tachometer to the spark
plug lead. 9 Disconnect the A.C. magneto coupler from the
9 Connect the pocket tester (DC 20 V) to the wire harness.
battery as shown. 9 Connect the pocket tester (  1) to the
charging coil as shown.
Positive tester probe 
positive battery terminal 1 Positive tester probe  white 1
Negative tester probe  Negative tester probe  black 2
negative battery terminal 2

B Y/R W/R W/L

W
2 1
9 Measure the charging coil resistances.
9 Start the engine and let it run at approxi- Charging coil resistance
mately 5,000 r/min. 0.32 ~ 0.48  at 20 C (68 F)
9 Measure the charging voltage.
9 Is the charging coil OK?
Charging voltage
14 V at 5,000 YES NO
r/min
NOTE: Replace the pick up
Make sure the battery is fully charged. coil/stator coil assem-
bly.
9 Is the charging voltage within specifica- EAS00779

tion?
5. Wiring

NO 9 Check the wiring connections of the entire

YES
charging system.
Refer to “CIRCUIT DIAGRAM”.
The charging circuit is 9 Is the charging system’s wiring properly
OK. connected and without defects?

YES NO

Replace the rectifier/ Properly connect or

regulator. repair the charging
system’s wiring.

7-
 CIRCUIT DIAGRAM
LIGHTING SYSTEM
EAS00780
5
4
3
2
1
e Light switch
8 Negative lead
Br B O
W B W/R W/
L
R Y

Fuse
Battery
A.C. magneto
Rectifier/regulator
Main switch
(BLACK)

OFF R R
ON Br Br
W W W/L W/L O O
1 R R 2 Y/R 3 W/R W/R 9 B 0
Br B
Y W
Br W
Y/R Y/R
R

B
B B
B
q
W/L W/R
5 Gy Gy
W/RW/L

R R/W L/W L/W

Gy B
R L/W
Gy Gy
R R

7
R/W R/W
R R/W R/W L/W L/W
Y/R L/W

b Auxiliary light
v Headlight
l Tail/brake light
j Dimmer switch

f High beam indicator

a Meter light
R
4 R
R/
Gy
L/W
e r t

light
L Y/ R Y/ R L
B Br
6 w OFF
PO
OFF
START
L/B L/B
B G/Y

L/ L/W (BLACK) (BLACK)

B ON
B B
B 8 Br G/Y
L /B B
B B L
7-29

Br

Br

LIGHTING SYSTEM
i Br/W
Br u y
Br
Br/W

g h
P
P
j Br/W
Br Ch Dg L /B G/Y
Y
o k
Y Br Br Y a a sdf Dg P
Br/W B OFF HI L
Dg Ch Ch Dg Ch Y /R
PUSH LO N
BG G B
P Dg Br/W R
(RED) BL/B Ch
(RED)
p
B
Ch Dg
B
G Y G

ELEC
Ch Dg L G/Y
G

n
G
L Ch Y G Dg
z ; l
GB
B
(BLACK) (BLACK)
G Y Y G b c v x B
L B
Y
L

B L L B Ch Dg
G/Y
Dg Ch Ch Dg
B Dg Ch

B
 LIGHTING ELE
EAS00781 EAS00738

TROUBLESHOOTING
1. Fuse
Any of the following fail to light: head- 9 Check the fuse for continuity.
light, high beam indicator light, Refer to “CHECKING THE FUSE” in chap-
taillight or meter light. ter 3.
9 Is the fuse OK?
Check:
YES NO
1. fuse
2. battery
3. main switch Replace the fuse.
4. light switch 2. Battery
EAS00739

5. dimmer switch 9 Check the condition of the battery.

6. lighting coil resistance Refer to “CHECKING AND CHARGING
7. wiring connections THE BATTERY” in chapter 3.
(of the entire lighting system)
Minimum open-circuit voltage
NOTE: 12.8 V or more at 20 C (68 F)
9 Before troubleshooting, remove the following
9 Is the battery OK?
part(s):
1. seat
YES NO
2. center cover
3. right side cover
4. headlight assembly
5. front cowling
6. leg shield 9 Clean the battery
7. handlebar cover terminals.
9 Troubleshoot with the following special tool(s). 9 Recharge or replace
EAS00749 the battery.

3. Main switch
Pocket tester 9 Check the main switch for continuity. Refer
90890-03112 to “CHECKING THE SWITCHES”.
9 Is the main switch OK?
YES NO

Replace switch.
the main
EAS00783

4. Light switch
9 Check the light switch for continuity. Refer
to “CHECKING THE SWITCHES”.
9 Is the light switch OK?

YES NO

The light switch is

faulty. Replace the
right handlebar switch.

7-
 LIGHTING ELE
EAS00784
7. Wiring
5. Dimmer switch 9 Check the entire lighting system’s wiring.
9 Check the dimmer switch for continuity. Refer to “CIRCUIT DIAGRAM”.
Refer to “CHECKING THE SWITCHES”. 9 Is the lighting system’s wiring properly
9 Is the dimmer switch OK? connected and without defects?

YES NO YES NO

The dimmer switch is Check the condition of Properly connect or

faulty. Replace the left each of the lighting repair the lighting
handlebar switch. system’s circuits. system’s wiring.
EAS00776
Refer to “CHECK-
ING THE LIGHTING
6. Lighting coil resistance SYSTEM”.
9 Disconnect the A.C. magneto coupler from the
wire harness.
9 Connect the pocket tester (  1) to the
lighting coils as shown.
Positive tester probe  yellow/red 1
Negative tester probe  black 2

B Y/R W W/R W/L

2 1
9 Measure the lighting coil resistances.
Lighting coil resistance
0.24 ~ 0.36  at 20 C (68 F)
9 Is the lighting coil OK?
YES NO

Replace the pickup

coil/stator coil
assembly.

7-
 LIGHTING ELE
EAS00788
High beam indicator light
CHECKING THE LIGHTING SYSTEM
Positive tester probe  yellow 4
1. The headlight and the high beam indicator
Negative tester probe  black 5
light fail to come on.

1. Headlight bulb and socket

9 Check the headlight bulb and socket for AC20V
continuity.
Refer to “CHECKING THE BULBS AND
4
BULB SOCKETS”.
Y Br
9 Are the headlight bulb and socket OK?
5 Dg Ch
B G
YES NO
9 Set the main switch to “ON”.
9 Start the engine.
Replace the head- light
9 Set the dimmer switch to “LO” or “HI”.
bulb, socket or both.
9 Measure the voltage (AC 12 V) of green 1 or
yellow 2 on the headlight coupler (wire
2. Voltage harness side) and yellow 4 on the meter
light coupler.
9 Connect the pocket tester (AC 20 V) to the
9 Is the voltage within specification?
headlight coupler and meter light coupler as
shown.
YES NO
Headlight
Positive tester probe 
This circuit is OK. Replace the rectifier/
green 1 or yellow
2 regulator.
Negative tester probe  black 3
å When the dimmer switch is set to “LO”
∫ When the dimmer switch is set to “HI”

AC20V

1 2
G Y
B
Dg Ch
3

7-
 LIGHTING ELE
EAS00789 EAS00790

2. The meter light fails to come on. 3. The tail/brake light fails to come on.

1. Meter light bulb and socket 1. Tail/brake light bulb and socket
9 Check the meter light bulb and socket for 9 Check the tail/brake light bulb and socket for
continuity. continuity.
Refer to “CHECKING THE BULBS AND Refer to “CHECKING THE BULBS AND
BULB SOCKETS”. BULB SOCKETS”.
9 Are the meter light bulb and socket OK? 9 Are the tail/brake light bulb and socket
OK?
YES NO
YES NO

Replace the meter light

bulb, socket or both. Replace the tail/ brake
light bulb, socket or
both.
2. Voltage 2. Voltage
9 Connect the pocket tester (DC 20 V) to the
9 Connect the pocket tester (AC 20 V) to the tail/brake light couple
meter light coupler (wire harness side) as
shown.
Positive tester probe  brown 1
Positive tester probe  blue 1
Negative tester probe  black 2
Negative tester probe  black 2

1
1 2
Br Y Y Br
Ch Dg
B L L B
Dg Ch
G B B G Y G/Y
Ch Dg Dg Ch

9 Set the main switch to “ON”.

9 Measure the voltage (DC 12 V) of brown 1 9 Set the main switch to “ON”.
9 Start the engine.
on the meter light coupler (wire harness side).
9 Measure the voltage (AC 12 V) of blue 1 on the tail/brake light co
9 Is the voltage within specification? 9 Is the voltage within specification?

YES NO

YES NO
This circuit is OK. The wiring circuit
from the main switch
to the meter light This circuit is OK. Replace the rectifier/
coupler is faulty and regulator.
must be repaired.

7-
 CIRCUIT DIAGRAM
SIGNALING SYSTEM
EAS00793
u Turn signal relay
y Rear brake light switch
t Front brake light switch
8 Negative lead
5 Fuse
4 Battery
1 Main switch
Br B O
W B W/R W/L
R Y (BLACK)

OFF R R
ON Br Br
W W W/L W/L O O
1 R R 2 Y Y/R
3 W/R W/R 9 B 0
Br B
Br W W
R B Y/R
B
Y/R
B
B
q

5 R R/W Gy Gy W/L W/R W/RW/L

L/W L/W
Gy L/W

R Gy Gy B
R R

7
R/W R/W
R R/W R/W L/W L/W
Y/R L/W

R
4 R
R/
Gy
L/W
e r t
L Y/ R Y/ R L

w
OFF OFF L/B L/B B Br
6

d Turn signal

s Turn signal
h Horn switch

p Fuel gauge
i Horn
PO START B G/Y
B
ON L/W L/W (BLACK) (BLACK)

(right)

(left)
B
B 8 L/ B Br G/Y
B B B
L
7-34

SIGNALING SYSTEM
Br

Br

indicator

indicator
i Br/W
Br
u y
Br
Br/W
P

Br Ch Dg Y g P L Br/W G/Y

light

light
o /B
k
h j
Y Br Br Y a a s d f OFF HI L
Dg Ch Ch Dg
PUSH LO N
BG G B

Fuel sender
Front turn signal light (left) n
Front turn signal light (right) c
z Rear turn signal light (left) x
; Rear turn signal light (right)
l Tail/brake light
k Turn signal switch
Dg P P Dg R
(RED)
Br/W B B Br/W
(RED)
p Ch Y /R L/B Ch

ELEC
B Ch Dg
G B
Y G

Ch Dg L G/Y
G

n L Ch Y G Dg
z ; l
G
B B
G
b c v x B L L B
(BLACK) (BLACK) G Y Y G Y G/Y
B L L B Ch Dg Dg Ch
Dg Ch Ch Dg
B

B
 SIGNALING ELE
EAS00794 EAS00738

TROUBLESHOOTING
1. Fuse
9 Any of the following fail to light: turn 9 Check the fuse for continuity.
signal light, brake light or an indica- Refer to “CHECKING THE FUSE” in chap-
tor light. ter 3.
9 The horn fails to sound. 9 Is the fuse OK?
Check:
1. fuse YES NO
2. battery
3. main switch Replace the fuse.
4. wiring connections
EAS00739
(of the entire signaling system)
2. Battery
NOTE:
9 Before troubleshooting, remove the following 9 Check the condition of the battery.
part(s): Refer to “CHECKING AND CHARGING
1. seat THE BATTERY” in chapter 3.
2. center cover Minimum open-circuit voltage
3. right side cover 12.8 V or more at 20 C (68 F)
4. front cowling
9 Is the battery OK?
5. leg shield
6. handlebar cover
YES NO
9 Troubleshoot with the following special tool(s).

Pocket tester 9 Clean the battery

90890-03112 terminals.
9 Recharge or replace
the battery.

EAS00749

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

YES NO

Replace the main

switch.

7-
 SIGNALING ELE
EAS00795 EAS00796

CHECKING THE SIGNALING SYSTEM

4. Wiring
1. The horn fails to sound.
9 Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”. 1. Horn switch
9 Is the signaling system’s wiring properly
9 Check the horn switch for continuity. Refer
connected and without defects?
to “CHECKING THE SWITCHES”.
9 Is the horn switch OK?
YES NO
YES NO
Check the condition of Properly connect or
each of the signal- ing repair the signaling
The horn switch is
system’s circuits. system’s wiring.
faulty. Replace the left
Refer to “CHECK-
handlebar switch.
ING THE SIGNAL-
ING SYSTEM”.
2. Voltage
9 Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as shown.

Positive tester probe  brown 1

Negative tester probe  ground

Br P

9 Set the main switch to “ON”.

9 Push the horn switch.
9 Measure the voltage (DC 12 V) of brown at
the horn terminal.
9 Is the voltage within specification?

YES NO

The wiring circuit

from the main switch
to the horn connector
is faulty and must be
repaired.

7-
 SIGNALING ELE
EAS00798
3. Horn 2. The tail/brake light fails to come on.
9 Disconnect the pink connector at the ho rn
terminal. 1. Tail/brake light bulb and socket
9 Connect a jumper lead 1 to the horn ter- 9 Check the tail/brake light bulb and socket for
minal and ground the jumper lead. continuity.
9 Set the main switch to “ON”. Refer to “CHECKING THE BULBS AND
9 Does the horn sound? BULB SOCKETS”.
9 Are the tail/brake light bulb and socket
Br OK?

YES NO
1
Replace the tail/ brake
light bulb, socket or
both.
2. Brake light switches
NO YES 9 Check the brake light switches for continu-
ity.
The horn is OK. Refer to “CHECKING THE SWITCHES”.
9 Is the brake light switch OK?
4. Voltage
9 Connect the pocket tester (DC 20 V) to the YES NO
horn connector at the pink terminal as
shown.
Replace the brake
Positive tester probe  pink 1 light switch.
Negative tester probe  ground

Br P

9 Set the main switch to “ON”.

9 Measure the voltage (DC 12 V) of pink 1
at the horn terminal.
9 Is the voltage within specification?

YES NO

Repair or replace the Replace the horn.

pink lead or ground
lead.

7-
 SIGNALING ELE
EAS00799

3. 3.The
Voltage
turn signal light, turn signal indicator light or both fail to blink.
9 Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side) as 1. Turn signal indicator light bulb and socket
shown. 9 Check the turn signal light bulb and socket for
Positive tester probe  green/yellow 1 continuity.
Negative tester probe  black 2 Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
9 Are the turn signal light bulb and socket
1 2 OK?

B L L B YES NO
Y G/Y
Ch Dg Dg Ch

Replace the turn sig-

nal light bulb, socket
or both.
9 Set the main switch to “ON”.
9 Pull in the brake levers. 2. Turn signal switch
9 Measure the voltage (DC 12 V) of green/ 9 Check the turn signal switch for continuity.
yellow 1 on the tail/brake light coupler Refer to “CHECKING THE SWITCHES”.
(wire harness side). 9 Is the turn signal switch OK?
9 Is the voltage within specification?
YES NO YES NO

This circuit is OK. The wiring circuit from

the main switch to the
tail/brake light coupler
is faulty and must be
repaired.

The turn
signal
switch is faulty.
Replace the

7-
 SIGNALING ELE
3. Voltage
9 Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
Positive tester probe  brown 1
Negative tester probe  ground

Br/W
1 Br

9 Set the main switch to “ON”.

9 Measure the voltage (DC 12 V) on brown
1 at the turn signal relay coupler (wire
harness side).
9 Is the voltage within specification?

4. Voltage
9 Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
Positive tester probe  brown/white 1
Negative tester probe  ground

1 Br/W
Br

9 Set the main switch to “ON”.

9 Measure the voltage (DC 12 V) on brown/
white 1 at the turn signal relay coupler
(wire harness side).
9 Is the voltage within specification?

YES NO YES NO

The wiring circuit The turn signal relay is

from the main switch faulty and must be
to the turn signal replaced.
relay coupler is faulty
and must be repaired.

7-
 SIGNALING ELE
5. Voltage 9 Set the main switch to “ON”.
9 Set the
9 Connect the pocket tester (DC 20 V) to the turn signal light coupler turnharness
(wire signal side)
switchas to “L” or “R”.
shown.
9 Measure the voltage (DC 12 V) of the
chocolate 1 or dark green 2 at the turn
signal light coupler (wire harness side) and
å Rear turn signal light
∫ Front turn signal light Left turn signal light chocolate 3 or dark green 4 at the turn
Positive tester probe  chocolate 1 signal indicator light coupler (wire harness
Negative tester probe  ground Right turn signal light side).
Positive tester probe  dark green 2 9 Is the voltage within specification?
Negative tester probe  ground
YES NO

This circuit is OK. The wiring circuit

ç Turn signal indicator light from the turn signal
Positive tester probe  chocolate 3 Negative tester probe  ground Positive tester probe  dark green 4 N
switch to the turn sig-
nal light coupler is
faulty and must be
repaired.

B L L B
Y G/Y
Ch Dg Dg Ch

2 1

Y GG Y
BB
Ch DgDg Ch

21

4 3
Br YY Br
Ch DgDg Ch
G BB G

7-
 SIGNALING ELE
EAS00804

4. The fuel level gauge fails to operate. 2. Voltage

9 Connect the pocket tester (DC 20 V) to the
1. Fuel sender meter light coupler (wire harness side) as
9 Remove the fuel sender from the fuel tank. 9 shown.
Connect the pocket tester to the fuel sender
Positive tester probe  brown 1
coupler (wire harness side) as
Negative tester probe  green 2
shown.
Positive tester probe  green 1
Negative tester probe  black 2
2 1
1
B G Br Y Y Br
Ch Dg Dg Ch
G B B G

2
å
9 Set the main switch to “ON”.
9 Measure the voltage (DC 12 V) of brown 1
∫ on the meter light coupler (wire harness side).
9 Measure the fuel sender resistances. 9 Is the voltage within specification?
Fuel sender resistance (up
posi- tion “full” å)
(  1) YES NO
4 ~ 10  at 20 C (68 F)
Fuel sender resistance
Check the wiring
(down position “empty” ∫)
connections of the
(  10)
entire signaling sys-
90 ~ 100  at 20 C (68 F)
tem.
9 Is the fuel sender OK?

YES NO

Replace the fuel

sender.

7-
 SIGNALING ELE
3. Fuel level gauge
9 Set the main switch to “ON”.
9 Move the float up 1 or down 2.
9 Check that the fuel level gauge needle
moves to “F” or “E”.

NOTE:
Before reading the fuel level gauge, leave the
float in one position (either up or down) for at
least three minutes.

9 Does the fuel level gauge needle move

appropriately?

YES NO

Replace the meter

assembly.

4. Wiring
9 Check the entire signaling system’s wiring.

7-
 SHTG
TRB
CHAPTER 8
TROUBLESHOOTING

TROUBLESHOOTING.................................................................................8-1
ELECTRICAL SYSTEM....................................................................................8-1
COMPRESSION SYSTEM................................................................................8-2
INTAKE AND EXHAUST SYSTEM................................................................8-3
TRB
SHTG
 TRB
TROUBLESHOOTIN L
EASF0062

TROUBLESHOOTING
TROUBLESHOOTING
ELECTRICAL SYSTEM

8-
 TRB

COMPRESSION SYSTEM
TROUBLESHOOTING SHTG

WEAR/SCRATCH/DAMAGE

WEAR/STICK/BROKEN

INSUFFICIENT TIGHTENING TORQUE

WEAR/SCRATCH

WEAR/CARBON DEPOSITS DAMAGE

DAMAGE

INSUFFICIENT TIGHTENING TORQUE

8-
 TRB
TROUBLESHOOTIN L
INTAKE AND EXHAUST SYSTEM

FUEL TANK CAP AIR FILTER ELEMENT

8 Clogged 8 Dirty or clogged

FUEL COCK
8 Clogged

FUEL HOSE
8 Clogged,
damaged or
kinked

EXHAUST PIPE
SILENCER
8 Cracked or broken
8 Clogged 8 Carbon deposits

8-
 YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
AL115C WIRING DIAGRAM
1 Main switch
Br B O 2 Rectifier/ regulator
W B
W/R W/L
3 A. C. magneto
R Y
(BLACK) 4 Battery
OFF ON R R 5 Fuse
1 Br Br
W W W/LW/L OO 6 Starter motor
2 Y Y/R 3 9 B
0
R R W/R W/R
Br B
7 Starter relay
Br W W
B 8 Negative lead
R B Y/R B Y/R
B
q 9 C. D. I. unit
0 Ignition coil
Gy L/W Gy
5 R R/W L/W
W/L W/R W/RW/L
q Spark plug
Gy L/W
w Handlebar switch (right)
Gy Gy R B
R
R
7 e Light switch
R/W L/W r Start switch
R
R/W t Front brake light switch
R/W R/W L/W
Y/RL/W
y Rear brake light switch u
4
R/ Gy
L/W
Turn signal relay
R R
e r t
OFF PO OFF START
L Y/ R
Y/ R L
L/B i Horn
L/B B
6
Br
w ON B G/Y o Meter assembly
B L/W
L/W
B B
(BLACK) (BLACK)
p Fuel gauge
B 8 L /B B Br G/Y
a Meter light
B B L s Turn signal indicator light (left) d
Turn signal indicator light (right) f
High beam indicator light
Br
g Handlebar switch (left)
Br
h Horn switch
j Dimmer switch
Br/ W
i u k Turn signal switch
Br
y l Tail/brake light
Br ; Rear turn signal light (right) z
P
Br/W
Rear turn signal light (left) x
Br Ch DgY g P
L /B Br/W G/Y Front turn signal light (right) c
o Front turn signal light (left) v
Y Br h j k Headlight
Dg Ch
B G
Br Y
Ch Dg aasdf OFF PUSH HI LO LN
G B
(RED)
R
b Auxiliary light
(RED)
Dg P
Br/W B Ch Y /R
P Dg B Br/W L/B Ch
n Fuel sender
p

B Ch Dg
G B
Y G

Ch DgL G/Y
G

n
G
G
LChY GDg
z; l
B LL B
B B
(BLACK) (BLACK) G Y Y G b cv x YG/Y
Ch DgDg Ch
B L L B
Dg Ch Ch Dg

COLOR CODE
B...................Black
P....................Pink R/W...............Red/White
Br..................Brown
R....................Red W/L................White/Blue
Ch..................Chocolate
W..................White W/R...............White/Red
Dg..................Dark green
Y...................Yellow Y/R................Yellow/Red
G...................Green
Br/W..............Brown/White
Gy.................Gray
G/Y................Green/Yellow
L....................Blue
L/B.................Blue/Black
O...................Orange
L/W................Blue/White