Yamaha VMX12H Supplementary Service Manual

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VMXl2N,

NC~K, KC

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Troubleshooting

Summary of Contents for Yamaha VMX12H

Page 1 VMXl2N, NC~K, KC...
Page 2 LIT-1 161 6-1 0-12...
Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the VMX12H/VMX12HC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. VMX12N SERVICE MANUAL: 2WE-28197-10...
Page 4 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the cus- tomer with the most satisfaction from his motorcycle and to conform with federal envi- ronmental quality objectives.
Page 5: How To Use This Manual
HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See "Illustrated sym- bo Is" 1st title This is a chapter with its symbol on the upper right of each page. 2nd title This title appears on the upper of each page on the left of the chapter symbol.
Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols are printed on top right of each page and indicate the sub- ject of each chapter. General information Specifications Periodic inspections and adjustments Engine Cooling system Carburetion Chassis Electrical Troubleshooting Illustrated symbols are used to identify the specifications appearing in the text.
Page 7: Table Of Contents
CONTENTS ................GENERAL INFORMATION ............MOTORCYCLE IDENTIFICATION ..........VEHICLE IDENTIFICATION NUMBER ..............FRAME SERIAL NUMBER ..............ENGINE SERIAL NUMBER ..................SPECIAL TOOLS .................... SPECIFICATIONS ..............GENERAL SPECIFICATIONS ............MAINTENANCE SPECIFICATIONS ....................ENGINE ..................ELECTRICAL ..........PERIODIC INSPECTION AND ADJUSTMENT ....................ENGINE ..............
Page 8: General Information
MOTORCYCLE IDENTIFICATION GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFlCATlON NUMBER The vehicle identification number stamped into the right side of the steering pipe. Starting serial number: JYA2WEE0 TA050101 (USA) JYA2WFC0 TA012101 (California) The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licens- ing authority in your state.
Page 9 SPECIAL TOOLS SPECIAL TOOLS Refer to the list provided to avoid errors when placing an order. The proper special tools are necessary for complete and accurate tune-up and assem- bly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.
Page 10: Vehicle Identification Number
GENERAL SPECIFICATIONS/ MAINTENANCE SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model VMX12 Model code: 3JPM (USA) 3JPN (California) 3LRA (EUR) Engine starting number: 2WE-050101 (USA) 2WF-012101 (California) 2EN-042101 (EUR) JYA2WEE0*TA050101 (USA) Vehicle identification number: JYA2WFC0 * TA012 1 0 1 California) 2EN-042101 (EUR) Frame starting number: Basic weight: 283 kg (624 Ib) (USA)
Page 11: Electrical
MAINTENANCE SPECIFICATIONS ELECTRICAL Model VMX12 Rectifier: Model manufacturer SH662-12 SHINDENGEN Capacity 25 A Withstand Voltage Electric starter system: Constant mesh type TYPe Starter motor: Model manufacturer SM-13 MITSUBA output 0.65 kW Brush overall length 12.5 mm (0.49 in) <Lim it> <5.0 mm (0.20 in) Commutator diameter...
Page 12: Periodic Inspection And Adjustment
ENGINE OIL REPLACEMENT PERIODIC INSPECTION AND ADJUSTMENT ENGINE ENGINE OIL REPLACEMENT 1.Start the engine and let warm up for severa I mi n 2.Stop the engine and place an oil pan under the drain bolt. 3.Remove: Oil filler cap Remove: Drain bolt (with gasket) Drain the crankcase of its oil.
Page 13 ENGINE OIL REPLACEMENT Drain bolt: 43Nm(4.3m-kg,31ft• Ib) NOTE: Always use a new gasket. 7.Fill: Crankcase 60" F Recommended oil: At 5°C (40°F)or higher SAE 20W40 type SE motor oil At 15°C (60°F)or lower SAE 10W30 type SE motor oil Oil quantity: 15°C 15°C Total amount:...
Page 14: Engine Overhaul
INSPECTION AND REPAIR ENGINE OVERHAUL INSPECTION AND REPAIR CRANKSHAFT AND CONNECTING ROD 1.Measure: Runout (crankshaft) Out of specification Replace. Runout: Less than 0.03 mm (0.0012 in) 2.1 nspect: Main journal surfaces Crank pin surfaces Bearing surfaces Wear/Scratches Replace. Measure: Oil clearance (main journal) Out of specification Replace bearing.
Page 15 I N SPEC TI O N A N D R EPA I R a pi ece of Pl ast i gauge® on each m ai n j our nal . N O TE: D o not put t he Pl ast i gauge® over t he oi l hol e i n t he m ai n j our nal of t he cr ankshaf t , i nst al l t he l ow er hal f of t he bear i ngs i nt o...
Page 16 INSPECTION AND REPAIR the bearings, crank pins and bear- ing portions of the connecting rods. the upper half of the bearing into the connecting rod and lower half of the bearing into the connecting rod cap. NOTE: Align the projection of the bearing with the /--- notch of the cap and connecting rod.
Page 17 I N SPEC TI O N A N D R EPA I R M ai n j our nal bear i ng J, ) C r ank pi n bear i ng P, ) Sel ect i on of beari ngs: Exam pl e 1: M ai n j ournal beari ng “...
Page 18: Balancer Shaft
INSPECTION AND REPAIR BALANCER SHAFT 1.Measure: Oil clearance (balancer shaft bearing) Out of specification Replace bearing. Oil clearance: 0.020 0.048 mm (0.0008 0.002 in) Measurement steps: the bearings, balancer shaft and bearing portions of the crankcase. the crankcase (upper) a bench in an upside down position.
Page 19 INSPECTION AND REPAIR 2.Select: Balancer shaft bearing J5 J6 Selection of bearings: Example: o n the crankcase is "6" and "2" o n the balancer shaft, then the bearing size for "J," is: Bearing size of Balancer shaft No. Crankcase (Green) BEARING COLOR CODE Blue...
Page 20: Middle Gear Service
MIDDLE GEAR SERVICE Damper spring Universaljoint Damper cam Dust seal Middle drive pinion gear Housing O-ring @Thrust washer Bearing Retainer Collapsible collar Bearing Middle drive shaft Middle driven pinion gear Spring seat...
Page 21: Shaft Drive
SHAFT DRIVE CHASSIS SHAFT DRIVE Dust cover Bearing 27Washer Bearing housing Bearing Circlip Ring gear stopper shim Drive pinion gear Bearing Ring gear stopper Final drive gear shim Circlip O-ring Bearing Universal joint Oil seal Bearing retainer Ring gear shim O-ring Bearing Oil seal...
Page 22 VAMAHA MOTOR CO.,LTD. PRINTED U.S.A.
Page 23 LIT-1161 6-08-77...
Page 24 VMX12S/VMX12SC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-04-98 VMX12U/VMX12UC SUPPLEMENTARY SERVICE MANUAL: LIT-I1616-06-08 VMXl2E/VMXl2EC SUPPLEMENTARY SERVICE MANUAL 1992 Yamaha Motor Co., Ltd. © 1st Edition, November 1992 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
Page 25 NOTICE This manual was written by Yamaha Motor Company Ltd. primarilyfor use by Yamaha dealers / - - and qualified mechanics. is not possible to put an entire mechanic's education into one manual, so persons using this book to perform maintenance and repairs on Yamaha motor- cycles should have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology.
Page 26 HOW TO USE THIS MANUAL CONSTRUCTION THIS MANUAL This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols") This is a chapter with its symbol on the upper right of each page. 1 st title This title appearsonthe upper of each page the left of the chapter symbol.
Page 27 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols are designed as thumb tabs to indicate the chapter's number and content. General information Specifications Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Troubleshooting Illustrated symbols are used to iden- tify the specifications appearing in the text.
Page 28 CONTENTS ................GENERAL INFORMATION .............. MOTORCYCLE IDENTIFICATION ..........VEHICLE IDENTIFICATION NUMBER ..............ENGINE SERIAL NUMBER ................... SPECIAL TOOL ............... FOR CHASSIS SERVICE .................... SPECIFICATIONS ..............GENERAL SPECIFICATIONS ............MAINTENANCE SPECIFICATIONS ....................ENGINE ....................CHASSIS ..................ELECTRICAL ......................CHASSIS ................ FRONT AND REAR BRAKE ....................
Page 29: General Information
MOTORCYCLE IDENTIFICATION GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number stamped into the steering head pipe. Starting serial number: ... PA035101 ..PA008101 NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state.
Page 30: Special Tool
SPECIAL TOOLS Referto the list providedto avoid errorswhen TOOLS SPECIAL placing an order. The proper special tools are necessary for complete and accurate tune-up and California, Using the correct special tool will help prevent damage caused by the use of im- proper tools or improvised techniques.
Page 31: Specifications
GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number: Engine starting number: 2WE-035101 2WF-008101 Vehicle identification number: Minimum turning radius: Carburetor: Ty p e/Manufacturer BDS 35 x 4/MlKUNl Tire: Tubeless Type Size (F) 110/90V 18 B RI DGESTONE G525AW/DUNLOP F20 Size (R) 150/90V 15 BRIDGESTONE G526BW/DUNLOP K525...
Page 32: Maintenance Specifications Engine
MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE VMX12E VMX12EC Carburetor: I.D. Mark 1FK01 2WE01 Main jet (M.J.) #152.5 Main air jet (M.A.J.) 02.0 Jet needle (J.N.) 5EZ43 5EZ50 Needle jet (N.J.) #37.5 Pilot jet (P.J.) Pilot air jet (P.A.J.1) #100 Preset Pilot screw (P.S.) Pilot outlet (P.O.)
Page 33: Electrical
MAINTENANCE SPECIFICATIONS LECTRICAL VMX12E/EC Model T.C.I.: at 20°C (68°F) (Black- Orange) Pickup coil resistance (color) TID14-93/HITACHI T.C.I. Unit-modeI/Manufacturer A.C. magneto: M o d e l / Ma n ufacturer F L 1 3 Normal output 14V, 25A at 5,000 r/min Engine speed Stater coil resistance 0.26...
Page 34: Chassis
FRONT A N D REAR BRAKE CHASSIS FRONT AND REAR BRAKE Air bleed screw Pad spring Retaining pin Caliper assembly Dust seal Brake disc Piston seat The arrow mark on the pad spring must Piston point in the disc rotating direction. Brake pad...
Page 35: Front Fork
Seal spacer Cap bolt Slide metal Fork cap CAPACITY: (21.8 Imp oz, 20.9 US Yamaha Fork Oil 1Owt or equivalent STD. AIR PRESSURE: 23 N m (2.3 m kg, 17 5.7 psi) 39.2 (0.4 r - - - - - - - MIN.
Page 36: Removal
FRONT FORK REMOVAL Securely support t h e motorcycle so there is no danger it falling over. 1. Place the motorcycle on a level place. 2.Elevate the front wheel by placing suitable stand under the engine. Remove: Caliper assembly Brake hose holder 4.
Page 37: Disassembly
FORK FRONT 9. Loosen: Pinch bolt (handle crown) Cap bolt Pinch bolts (under bracket) Support the fork before loosening the pinch bolts. DISASSEMBLY 1. Remove: Cap bolt Spacer Spring seat Spring 2. Drain: Fork oil 3. Remove: Dust seal Retaining clip Use a thin slotted head screw driver.
Page 38: Inspection
FRONT FORK Removal steps: Hold the fork leg horizontally. • Clamp the caliper mounting boss of the • outer tube securely in a vise with soft jaws. Pull out the inner fork tube from the outer tube by forcefully, but carefully, with draw- ing the inner tube.
Page 39: Assembly
FRONTFORK 3. Inspect: Damper rod Wear/Damage Replace. Blow out all oil passages Contamination with compressed air. 4. Inspect: Oil lock piece O-ring (cap bolt) Wear/Damage Replace. ASSEMBLY Reverse the "DISASSEMBLY" procedure. Note the following points. NOTE: In front fork reassembly, be sure to use following new parts.
Page 40 FRONTFORK 2. Lubricate: Inner fork tube (outer surface) Recommended lubricant: Fork oil or equivalent 3. Install: Piston metal Oil lock piece 4. Tighten: Bolt (damper rod) Bolt (damper rod): m kg, (6.2 45 ft LOCTITE® NOTE: Tighten the bolt (damper rod) while holding ‘...
Page 41 FRONT FORK 6.Install: Retaining clip NOTE: Fit the retaining clip correctly in the groove in the outer tube. 8.Fill: Fork oil (21.8 Imp oz,20.9 Fork oil or equivalent after filling, slowly pump the fork up and down to distribute oil. Oil level: 123 mm (4.8 in) from the top of inner fork tube...
Page 42 FRONT FORK IN STALL Reverse the “REMOVAL” procedure. Note the following points. Front Temporary tighten the pinch bolts. NOTE: Be sure the inner fork tube end is flush with the top of the handle crown. 2. Tighten Pinch bolts (under bracket) Cap bolt (front fork) •...
Page 43 FRONT FORK Install: Caliper assembly Brake hose holder Speedometer cable Bolt (caliper bracket): (3.5 m kg, 25 ft Ib) Make sure that the brake hose are routed properly. -15-...
Page 44: Electrical
CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM...
Page 45 CIRCUIT DIAGRAM Reed switch A.C. Magneto generator Rectifier/Regulator "TURN" switch "TURN" indicator light Main fuse Front/Rear brake switch Main switch TaiI/Brake light Fuse (IGNITION) Horn "ENGINE STOP" switch "HORN" switch Ignitor unit Temperature meter Pick up coil Thermo unit Pressure sensor "FUEL"...
Page 46: Ignition System
SYSTEM IGNITION IGNITION SYSTEM DIGITAL IGNITION CONTROL SYSTEM DESCRIPTION The electronic ignition that sparksthe engine is computer controlled and operated by the digital CPU (microprocessor). It has a pre- programed ignition advance curve. This programed advance curve closely matches the spark timing to the engine's ignition requirements.
Page 47 VMX12E/EC WIRING DIAGRAM Clutch switch 'LIGHTS' (Dimmer) switch 'HORN' switch 'TURN' switch Temp. meter Tachometer Meter light "HIGH BEAM' 'TURN' 'FUEL' 'OIL LEVEL' 'NEUTRAL' Front flasher light Headlight Front flasher light 'START' switch 'ENGINE STOP' switch 'FUEL' switch Front brake switch Speedometer Meter light switch...
Page 48 VAMAHA MOTOR CO.,LTD. PRINTED IN U.S.A.
Page 49 LIT-I1616-06-08...
Page 50 Service Manual together with following manual: VMX12N/NC Service Manual: LIT-11616-04-67 VMX12S/SC Supplementary Service Manual: LIT-11616-04-98 VMX12U/UC SUPPLEMENTARY SERVICE MANUAL 1987 by Yamaha Motor Corporation U.S.A. © 1st Edition, August 1987 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A,...
Page 51 It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor- cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology.
Page 52 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols are designed as thumb tabs t o indicate the chapter‘s number and content. General information Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Appendices Illustrated symbols are used t o iden- tify the specifications appearing.
Page 53 MOTORCYCLE IDENTIFICATION GENERAL I N FORM AT I ON MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number i s stamped into the steering head pipe. NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state.
Page 54 SPECIF APPENDICES FICATIONS GENERAL Model Model Code Number Engine Starting Number 2WE-000101 2WF-000101 Vehicle Identification Number JYA2W E EO Basic Weight: Weight Oil and Full Fuel Tank (624 (626 Tire Pressure (Cold Tire): Basic Weight: With Oil and Full Fuel Tank (624 (626 Maximum Load*...
Page 55 SPECIFICATION Model Exhaust "A" 36.25 36.35 mm (1.427 1.431 in) < > < > Limit 36.15 mm (1.423 in) Exhaust 28.02 28.12 mm (1.103 1.107 in) < > < > Limit 27.92 mm (1.099 in) 27.97- 28.07 mm (1.101 1.105 in) >...
Page 56 IWATA, JAPAN PRINTED IN U.S.A.
Page 57 LIT-1...
Page 58 FOREWORD Service Manual: LIT-11616-04-67 VMX 1 SUPPLEMENTARY SERVICE MANUAL 1985 by Yamaha Motor Corporation U.S.A. 1 Edition, September 1985 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in U.S.A.
Page 59 If there is any question about a service procedure, is impera- tive that you contact a Yamaha dealer for any service information changes that apply t o this model. This policy is intended to provide the customer with the most satisfaction from his motorcycle and to conform with federal environmental quality objectives.
Page 60 ILLUSTRATED SYMBOLS (Refer to the illustration) designed as Illustrated symbols tabs to indicate the chapter's t h u m b number and content. General information Periodic inspection and adjustment Engine system Carburetion @Electrical are used Illustrated symbols identify t h e specifications appearing. fluid clearance speed...
Page 61 MOTORCYCLE I GENERAL INFORMATION I DENT I F RCYCLE VEHICLE IDENTIFICATION NUMBER T h e vehicle identification number is stamped into t h e steering head pipe. NOTE: T h e vehicle identification number is used t o i d e n t i f y your motorcycle and m ay be used to register your motorcycle with t he licensing a u t h o r i t y in your state.
Page 62 SPECIFICATIONS APPENDICES SPECIFICATIONS GENERAL FICATIONS Model Model Code Number Engine Starting Number 1UT-000101 Vehicle Identification Dimensions: Overall Length 2,300 mm (90.6 in) Overall Width 795 mm (31.3 in) Height 1,160 mm (45.7 in) Seat Height 765 mm (30.1 in) Wheelbase 1,590 mm (62.6 in) Minimum Ground Clearance 145 mm...
Page 63 Model BDS 34 x Spark Plug: G K , anufacturer DP R I PPOND E NSO 0.9 mm (0.031 0.035 in) Type: multiple-disc Wet, Transmission : Spar gear Primary Reduction System Primary Reduction Ratio 87/49 1.775) Secondary Reduction System Shaft drive Secondary Reduction Ratio 21/27 x (2.851)
Page 64 I W A T A . JAPAN PRINTED IN U.S.A.
Page 65 Serr-ice 1616-04-67...
Page 67 If there is any question about a service procedure, it is impera- tive that you contact a Yamaha dealer for any service information changes that apply t o this model. This policy i s intended t o provide the customer with the most his motorcycle and t o conform with federal environmental quality objectives.
Page 68 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated designed as thumb tabs to indicate the chapter's number and content. General information Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Appendices Illustrated are used to identify the specifications appearing in the text. Filling fluid Lubricant Tightening...
Page 69 Being a Yamaha owner, you obviously prefer a quality product. Authentic, not artificial Yamaha. PARTS ACCESSORIES Don’t compromise the quality and performance of your Yamaha with off-brand alternatives. You’ll be getting exactly what you’re paying for.
Page 70 /--- GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM CARB U RETION CHASSIS ELECTRICAL APPENDICES...
Page 71 CHAPTER 1 GENERAL INFORMATION ....... . MOTORCYCLE IDENTIFICATION ......VEHICLE IDENTIFICATION NUMBER .
Page 72: Chapter 1 . General Information
MOTORCYCLE IDENTIFICATION GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the steering head pipe. NOTE: The vehicle identification number is used to identify your motorcycle and may be used t o register your motorcycle with the licensing authority in your state.
Page 73: Important Information
IMPORT A NT INFORMATION IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assem- bly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled.
Page 74 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a make sure that the sharp-edged corner positioned opposite to the thrust receives. See the sectional view. Shaft SPECIAL TOOLS The proper special tools are necessary for com- plete and accurate tune-up and assembly.
Page 75: For Engine Service
4. Fuel Level Gauge P/N YM-01312-A This gauge is used to measure the fuel level in the float chamber. 5. Vacuum Gauge P/N YU-08030 This gauge is needed for carburetor nization. 6. Radiator Cap Tester P/N YU-24460 This tester is needed for checking the cooling system.
Page 76: Special Tools
SPECIAL TOOLS 3. Valve Spring Compressor P/N YM-04019 This tool is needed t o remove and install the valve assemblies. 4. Valve Guide Remover (5.5 mm) P/N YM-01122 This tool is used t o remove the valve guides. 5. Valve Guide Reamer (5.5 mm) P/N YM-01196 This tool i s used t o new valve guide.
Page 77 SPECIAL TOOLS 8. Flywheel Puller P/N YU-33270 Adapter P/N YM-33282 These tools are used to remove the flywheel. 9.8 mm Wrench Adapter P/N YM-28897 This tool is used to loosen or tighten thecylinder head securing nut. 10. Piston Ring Compressor P/N YM-8037 This tool is used when installing the piston into the cylinder.
Page 78 SPECIAL TOOLS 13. #40 Torx Driver P/N YU-29843-7 This tool is used to loosen or tighten the middle gear bearing retainer bolt. 14. #30 Torx Driver P/N YU-29843-6 This tool i s used to loosen or tighten the drive axle bearing retainer bolt. 15.
Page 79: For Chassis Service
SPECIAL TOOLS 18. Sealant (Quick Gasket@) This sealant (bond) is used for crankcase mating surfaces, etc. FOR CHASSIS SERVICE 1. T-Handle P/N YU-01326 Damper Rod Holder (24 mm) P/N YM-01328 This tool is used to loosen and tighten the front fork cylinder holding bolt. 2.
Page 80: For Middle Gear Service
SPECIAL TOOLS FOR MIDDLE GEAR SERVICE Universal Joint Holder YM-04062 i s used when adjusting the gear lash This tool in the middle gear. Middle Drive Gear Holder YM-33222 This tool is needed when measuring the middle gear lash. Damper Spring Plate YM-33286 This tool is used with a middle drive gear holder t o disassemble and reassemble the middle gear...
Page 81: For Electrical Components
SPECIAL TOOLS Final Drive Shaft Holder P/N YM-01229 This tool is used when the gear lash for the final gear. / - - 7. Final Drive Shaft Bearing Retainer Wrench P/N YM-04050 This tool i s used to remove and install the bearing retainer, Gear Lash Measurement Tool P/N YM-01230...
Page 82 CHAPTER 2 PERIODIC INSPECTIONS AND ADJUSTMENTS ..........INTRODUCTION ......
Page 83 ......... . ELECTRICAL.
Page 84: Periodic Inspections And Adjustments
INTERVALS CHARTS PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary t o perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale.
Page 85 Check oil level and leakage. Final gear Check "G L-4" Replace Replace every 24,000 km or gear months. Yamaha chain and Apply chain Control cable lube lube and meter cable 1OW30 motor oil Check bearing Medium assembly for...
Page 86 MAINTENANCE INTERVALS CHARTS Initial Odometer reading 25,000 km 31,000 Remarks 25 months 31 months (600 mi) Check bearings assembly for Medium looseness. weight Steering Moderately wheel bearings repack every bearing 24,000 km grease (15,200 mi). Check bearings for smooth rotation. Check specific gravity and breather pipe...
Page 87: Engine
VALVE CLEARANCE ADJUSTMENT ENGINE VALVE CLEARANCE ADJUSTMENT Removal 1. Remove: cover ( l e f t and right) Remove: .Electrical components board 3. Disconnect: electrical component leads 4. Remove: covers (radiator) (radiator) NOTE: It is not necessary t o remove the radiator completely from the motorcycle.
Page 88 VALVE CLEARANCE ADJUSTMENT Remove: *Crankcase cover plate *Special washer plug NOTE: Check for clog of oil passage in the bolt. If any, clean the oil passage. Inspection and Adjustment 1. Measure: *Valve clearance NOTE: Be sure piston is at Top Dead Center when measuring clearance.
Page 89 VALVE CLEARANCE ADJUSTMENT 540' 720' 360' 180' Crankshaft degree Cylinder *Measure the valve clearance, in sequence, for Nor. and No. cylinders. Out of specification Adjust clearance. Front Firing Sequence: 1 - 3 - 4 - 2 Adjust: *Valve clearance By the following adjustment steps. Valve clearance adjustment steps: the valve lifter slots (intake and exhaust side) opposite each other.
Page 90 VALVE CLEARANCE ADJUSTMENT Remove the pads from the lifters. Use a small screwdriver and a magnetic rod for removal. pad numbers. the proper valve adjusting pad from the chart below: Pad Availability : Pad range 25 increments mm (0.002 in) incre- Hundredths Rounded valve or 2...
Page 91 VALVE CLEARANCE ADJUSTMENT INTAKE INSTALLED PAD NUMBER MEASURED 0121 220122512301235 250125512601265 1270127512801 0.00-0.05 0.11 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 0.21- 0.25 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 295 300 305 310 315 320...
Page 92: System Inspection
CRANKCASE VENTILATION SYSTEM INSPECTION/ FUEL LINE INSPECTION Assembly When installing the top cover, reverse the removal procedure. Note the following points. 1. Install: head covers NOTE: sure all cam caps are coverd with oil plug *Arrow mark on the cover should face toward the exhaust side.
Page 93: Fuel Filter Replacement
FUEL FILTER REPLACEMENT/ INTAKE MANIFOLD INSPECTION/ EXHAUST SYSTEM INSPECTION FUEL FILTER REPLACEMENT Remove: Bracket filter 2. Inspect: filter Replace. Install: .Components in above list (step "1") INTAKE MANIFOLD INSPECTION Tighten Carburetor clamps joint bolts Carburetor joint nuts Inspect: joint Gaskets Replace EXHAUST SYSTEM INSPECTION 1.
Page 94: Canister Inspection
CANISTER I R ETOR SYNCHRONIZATION CANISTER INSPECTION (FOR CALIFORNIA ONLY) 1. Inspect: Hose connection Poor condition Correct. Hoses Canister Replace. Clogs Clean. To carburetor From fuel tank Canister To atmosphere CARBURETOR SYNCHRONIZATION OPEN CLOSE 2-1 1...
Page 95: Carburetor Synchronization
CARBURETOR SYNCHRONIZATION NOTE: Valve clearance must be set properly before synchronizing the carburetors. 1. Remove: Carburetor joint covers (left and right) plugs (left and right) hose Attach: Gauge (YU-08030) To the vacuum plugs. 3. Start the engine and let it warm up. 4.
Page 96: Idling Speed Adjustment
I D LI N G SPEED A D JU STM EN T/ TH R O TTLE C A B LE A D JU STM EN T V acuum S ynchronous D ifference: 2. 66 kPa ( 30 m m H g, 0. 79 i n H g) * R epeat t he above st eps t o synchr oni ze car bur et or N o.
Page 97: Enginel Level Inspection
EN G I N E O I L LEVEL I N SPEC TI O N / EN G I N E O I L R EPLA C EM EN T EN G I N E O I L LEVEL I N SPEC TI O N 1.
Page 98 EN G I N E O I L R EPLA C EM EN T D o not allow foreign m aterial to enter the crank- case. 6. I nst al l : 7. I nspect : l eaks * O i l l evel Engi ne O i l R epl acem ent ( W i t h O i l Fi l t er) 1.
Page 99: Coolant Level Inspection
COOLANT LEVEL SYSTEM INSPECTION 7. Install: f i l t e r cap 8. Inspect: leaks level COOLANT LEVEL INSPECTION 1. Remove: Top cover Inspect: *Coolant level (reservoir t a n k ) Add t a p water (soft water). Level low Change t h e Coolant every two years.
Page 100: Compression Pressure Measurement
COMPRESSION PRESSURE MEASUREMENT COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in performance loss. 1. Measure: clearance Out of specification Adjust. Warm up the engine. Remove: plugs Measure: pression pressure By the following measurement steps. Compression pressure measurement steps: the Compression 33223) using an adapter.
Page 101: Chassis
FINAL GEAR OIL LEVEL INSPECTION OIL REPLACEMENT Defective valves, cylinder head Same as without oil gasket or piston is possible. Inspect cylinder head, valve surfaces, or Above maximum level piston crown for carbon deposits. NOTE: The difference between the highest and lowest cylinder compression readings must not vary more than the specified value.
Page 102: Air Filter Cleaning
AIR FILTER CLEANING Install: plug Drain Plug (Final Gear): (2.3 4. Fill: gear case Oil Capacity: 0.2 L (0.18 Imp qt, 0.21 US qt) Final Gear Oil: SAE 80 API "GL-4" Hypoid Gear Oil I f desired, an SAE Hypoid gear oil may be used for all conditions.
Page 103: Brake Fluid Level Inspection
BRAKE FLUID LEVEL INSPECTION Eliminate: *Dust Use the compressed air. Blow out dust in the element from the outer surface. 4. Inspect: / -- Damage Replace. 5. Install: filter case cover cover BRAKE FLUID LEVEL INSPECTION Brake Inspection 1. Inspect: fluid level (brake master cylinder) Level low Replenish fluid.
Page 104: Front And Rear Brake Pad Inspection
FRONT AND REAR BRAKE PAD INSPECTION Clutch Inspection This motorcycle has a hydraulic clutch. There are no adjustments t o perform, but the clutch system must be inspected periodically for fluid level and leakage. 1. Inspect: fluid level (clutch master cylinder) Level low Replenish fluid.
Page 105: Front Brake Adjustment
FRONT BRAKE ADJUSTMENT/REAR BRAKE ADJUSTMENT FRONT BRAKE ADJUSTMENT 1. Loosen: Lockunt Adjust: *Free play Turn the adjuster until the free is within the specified limits. Proper lever free play is essential to avoid excessive brake drag. A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system.
Page 106: Cable Inspection And Lubrication
Replace any corroded or obstructed cables. *Lubricate any cables that do not operate smoothly Yamaha Chain and Cable Lube or SAE 10W30 Motor Oil BRAKE AND CHANGE PEDALS/BRAKE AND CLUTCH LEVERS LUBRICATION Lubricate pivoting parts of each lever and pedal.
Page 107: Front Fork Oil Change
FRONT FORK ADJUSTMENT FRONT FORK OIL CHANGE • Fork oil leakage can cause loss of stability and safe handling. Have any problem corrected before operating the motorcycle. the motorcycle there is support no danger of it falling over. 1. Elevate the front wheel by placing a suitable stand under the engine.
Page 108 FRONT FORK ADJUSTMENT 8. Install: Drain screws 9. Fill: forks Each Fork: 451 cm³ (15.9 Imp oz. 15.3 US oz) Yarnaha Fork Oil 10wt or Equivalent After filling, pump the forks slowly up and down to distribute the oil. 10. Tighten: bolts Use the Front Fork Cap Socket (YM- 01 104).
Page 109: Rear Shock Absorber Adjustment
REAR SHOCK ABSORBER ADJUSTMENT By the following adjustment steps. Air pressure adjustment steps: Remove the valve cap. the air check gauge check and adjust the air pressure. Stiffer Increase the air pressure. (Use an air pump or pressurized air supply.) Softer Decrease the air pressure.
Page 110 REAR SHOCK ABSORBER ADJUSTMENT the following adjustment steps. Spring preload adjustment steps: *Using the screwdriver, adjust the spring preload. Stiffer Increase the spring preload. (Turn the spring seat clock- wise.) Softer Decrease the spring preload. (Turn the spring seat counter- clockwise.) Position: 5 (Maximum)
Page 111: Recommended Combinations Of The Front Fork
RECOMMENDED COMBINATIONS THE FRONT FORK AND THE REAR SHOCK ABSORBER SETTINGS/ STEERING HEAD I NSPECTION/STEE R I NG HEAD ADJUSTMENT RECOMMENDED COMBINATIONS OF THE FRONT FORK AND THE REAR SHOCK ABSORBER S ETTlNGS Use this table as guidance to meet specific riding conditions and motorcycle load. Loading condition With accessory With...
Page 112 ING HEAD ADJUSTMENT 2. Remove: lens unit Disconnect: leads (in the headlight body) 4. Remove: Bolt (headlight body bracket) Emblem 5. Remove: *Flasher light bracket assembly Remove: holder assembly 7. Loosen: *Pinch bolts (steeringcrown) Remove: (steering stem) *Steering crown 2-29...
Page 113 STEERING H E A D ADJUSTMENT 9. Remove: washer (ring nut) nut (upper) nut (lower) Support the under bracket so that it may not fall down. 10. Tighten: nuts (lower and upper) By the following tightening steps. Ring nuts tightening steps: the ring nut (lower) The tapered side of ring nut must face down- ward.
Page 114: Wheel Bearings Check
WHEEL BEARINGS CHECK/TIRES CHECK the lock washer NOTE: Make sure the lock washer tab i s placed in the slots. the steering crown and tighten the steering stem nut to specification. Nut (Steering Stem) : 110 Nm (1 1.0 m-kg, 80 ft-lb) 11.
Page 115: Tires Check
TIRES CHECK Be sure to install the correct tube when using tube tires. type Tire Tubeless tire Wheel Tube type tire Air valve Aluminum wheel (tubeless type) Tube Aluminum wheel (tube type) This motorcycle is fitted with "V" range tires (for super high speed running).
Page 116 TIRES CHECK inflation pressure should b e checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted ac- cording to total weight of cargo, rider, pas- senger, and accessories (fairing, saddlebags, this etc.
Page 117: Wheels Check
WHEELS CHECK/IGNITION TIMING CHECK WHEELS CHECK Inspect: nu m wheels Damage/Bends Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. Never attempt even small repairs to the wheel. Tighten: stem locknut Valve Stem Locknut: 1.5 Nm (0.15 rn-kg, 1.1 ft-lb) Ride conservatively after installing a tire to allow it to seat itself properly on the rim.
Page 118 BATTERY INSPECTION BATTERY INSPECTION 1. Inspect: fluid level Battery fluid level low Fill. Fluid level should be between upper and lower level marks. U p p e r level L o w e r level Refill with distilled water only; tap water contains minerals harmful to a battery.
Page 119 BATTERY INSPECTION Remove: Inspect: Battery fluid specific gravity of specification Charge. Always charge a new battery before using it to ensure maximum performance. 1.4 amps/10 hrs Specific Gravity: Install: Battery Connect: Breather hose Be sure the hose is properly attached and routed.
Page 120 BRAKE LIGHT SWITCH ADJUSTMENT/ SPARK PLUG INSPECTION BRAKE LIGHT SWITCH ADJUSTMENT 1. Adjust: light operating timing Hold the main body of the switch with your hand so it does not rotate, and turn the adjuster until the operating timing is correct. SPARK PLUG INSPECTION 1.
Page 121 HEADLIGHT BULD REPLACEMENT NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turns part finger tight. Have the spark plug torqued to the correct value as soon as possible with a torque wrench.
Page 122 HEADLIGHT BEAM ADJUSTMENT/FUSE INSPECTION HEADLIGHT BEAM ADJUSTMENT 1. Adjust: Headlight beam (horizontally) Horizontal Adjustment Right Turn adjusting screw clockwise Turn adjusting screw counter- Left clockwise Adjust: beam (vertically) Vertical Adjustment Turn the adjusting screw clock- Turn the adjusting screw counter- Lower clockwise.
Page 123 CHAPTER 3 ENGINE OVERHAUL ......... . . ENGINE REMOVAL .
Page 124 ......ENGINE ASSEMBLY AND ADJUSTMENT ........LOWER CRANKCASE TRANSMISSION .
Page 125: Engine Overhaul
ENGINE REMOVAL ENGINE OVERHAUL ENGINE REMOVAL NOTE: It i s not necessary t o remove the engine in order t o remove the following components: .Clutch Carburetor pump magneto PREPARATION FOR REMOVAL Remove all dirt, mud, dust, and foreign material before removal and disassembly. Use proper tools and cleaning equipment.
Page 126: Carburetor
ENGINE REMOVAL CARBURETOR 1. Remove: (left and right) Remove: (carburetor overflow hose) Loosen: (air cleaner joint) 4. Remove: hose (crankcase) cleaner assembly Disconnect: hose 6. Disconnect: hose (ignition advance) 7. Loosen: (carburetor joint) 8. Remove: joint cover (left and right)
Page 127: Radiator
ENGINE REMOVAL Electrical components board cable cylinder 10. Disconnect: leads and cables 11. Remove: assembly NOTE: Cover the carburetor with clean rag t o prevent dirt or foreign matter into the carburetor. RADIATOR 1. Remove: *Radiator covers Remove: *Bolts (radiator) Disconnect: *Upper hose Lower hoses...
Page 128: V-Boost Control Cable And Air Baffle Plate
ENGINE REMOVAL 6. Disconnect: hoses and leads (conduit) 7. Remove: *Screws (conduit) V-BOOST CONTROL CABLE BAFFLE PLATE 1. Disconnect: *Control cable (V-boost) Disconnect: *Spark plug caps Straighten: *Tabs (front baffle plate) 4. Remove: baffle plate (front) baffle plate (rear) FOOTREST (RIGHT) AND BRAKE PEDAL 1.
Page 129: Footrest (Left) And Clutch Release Cylinder
lead Remove: Rear brake switch FOOTREST (LEFT) AND CLUTCH RELEASE CYLINDER 1. Remove: Footrest (left) pedal assembly gear case cover Remove: Seat cover (left) 3. Disconnect: leads (engine) 4. Remove: 5. Remove: release cylinder 6. Remove: 7. Disconnect: Rubber boot...
Page 130: Exhaust Pipe And Muffler
ENGINE REMOVAL EXHAUST PIPE AND MUFFLER 1. Remove: Flange bolts (front exhaust pipe) Loosen: *Bolts (front exhaust pipe) Remove: Front exhaust pipes Remove: *Bolt (muffler chamber) 5. Loosen: *Bolts (muffler) 6. Remove: *Bolts (muffler bracket) 7. Remove: *Screws (rear exhaust protector) (rear exhaust) 8.
Page 131: Servo Motor
ENGINE REMOVAL SERVO MOTOR 1. Remove: *Screws (servo motor bracket) *Servomotor Disconnect: *Servo motor coupler ENGINE REMOVAL 1. Place suitable stand under the engine. Remove: *Bolt (engine) *Bolts (down tube) *Down tube frame (right) Remove: *Engine assembly from right side. NOTE: Remove the rear cylinder head cover if diffi- culties are encountered with any of the previous...
Page 132: Engine Disassembly
ENGINE DISASSEMBLY ENG I N E DISASSEMBLY CYLINDER HEAD AND CAMSHAFT Rear Cylinder Head 1. Remove: Cylinder head covers (rear and front) Gaskets plugs Front Front cylinder Rear cylinder 2. Remove: cover plate washer plug NOTE: Check for clog of oil passage in the bolt.
Page 133 ENGINE DISASSEMBLY 6. Remove: (cam chain sprocket) Use 22 mm wrench t o hold camshaft. 7. Remove: *Camshaft caps NOTE: When loosing camshaft cap bolts, be sure cam- shaft cam lobes do not touching valve lifters. 8. Remove: Camshafts Sprockets Slip the sprockets from mounting boss on camshaft.
Page 134 I N E DISASSEMBLY 11. Remove: delivery pipe NOTE: When removing the pipe, be sure not to lose the washers that may fall out. head R emove chain guide (rear) Gasket pins Front Cylinder Head When removing the front cylinder head, repeat the rear cylinder head removal procedure.
Page 135 1. Remove: *Crankcase cover (left) Dowel pins 2. Remove: *Starter idle gears 3. Remove: Bolt (flywheel) Plain washer NOTE: Check for clog of oil passage in the bolt. If any, clean the oil passage. 4. Remove: Flywheel Use the Flywheel Puller (YU-33270) with the Puller Adapter (YM-33282) NOTE: When removing the flywheel, do not allow the...
Page 136: Clutch And Oil Pump Drive Gear
ENGINE DISASSEMBLY 5. Remove: Woodruff key Starter clutch gear 6. Remove: Oil baffle plate CLUTCH AND OIL PUMP DRIVE GEAR 1. Remove: Crankcase cover (right) NOTE: Working in a crisscross pattern, loosen the bolts 1/4 turn each. Remove them after all are loosened.
Page 137: Water Pump And Thermostatic Valve
Straighten the lock washer tabs. 4. Loosen: (clutch boss) Use the Clutch Holder (YM-91042) hold the clutch boss. 5. Remove: (clutch boss) washer boss washer housing 6. Remove: pump drive gear WATER PUMP AND THERMOSTATIC VALVE 1. Remove: pump cover Water pump cable Gasket pins...
Page 138: Starter Motor And Breather Cover
ENGINE DISASSEMBLY STARTER MOTOR AND BREATHER COVER 1. Remove: motor 2. Remove: Breather cover Breather cover spacer pipe OIL PAN AND OIL PUMP 1. Remove: filter cover Remove: Gasket pins 3. Remove: pump assembly pins 3-14...
Page 139: Crankcase Disassembly
ENGINE DISASSEMBLY 4. Straighten the bracket tabs 5. Remove: pipe oil gallery pipe 6. Remove: (oil pump pipe) pump pipe CRANKCASE DISASSEMBLY 1. Remove: (main axle bearing) (middle gear bearing) Use the # 4 0 Torx Driver (YU-29843-7).
Page 140: Upper Crankcase
ENGINE DISASSEMBLY 3. Remove: (crankcase) NOTE: Remove the bolts starting with the highest numbered one. embossed numbers in the crankcase designate the crankcase tightening sequence. W i t h washer UPPER CASE LOWER CASE 3. Remove: (upper) Use a soft hammer. NOTE: Pull out the crankcase (upper) while pulling up the cam chain.
Page 141: Lower Crankcase
ENGINE DISASSEMBLY Remove: Plane bearings (crankshaft/connecting rods/ balancer shaft) NOTE: Identify each plane bearing position very care- fully so that it can be reinstalled in i t s original Iace. Remove: pin clip *Piston TRANSM I 1. Remove: shaft *Main axle assembly *Drive axle assembly driven gear assembly Plane bearings...
Page 142 Unhook: spring Remove: cam stopper lever 4. Remove: retainer (shift cam) bars forks NOTE: Note the position of each part. Pay particular attention to the location and direction of shift forks. 5. Remove: pump idle gear 3-18...
Page 143: Inspection And Repair
INSPECTION A N D REPAIR INSPECTION A N D REPAIR CYLINDER HEAD 1. Remove: Valve pads Lifters Spark plugs NOTE: Identify each lifter and pad position very care- fully so that it can be reinstalled in its original place. Attach: Valve Spring Compressor Remove: retainers...
Page 144: Valve, Valve Guide. And Valve Seat
INSPECTION AND REPAIR 5. Measure: head Under specification Resurface. Over specification Replace. Cylinder Head Warp Limit: Less than 0.03 mm (0.0012 in) VALVE, VALVE GUIDE, AND VALVE SEAT Intake and Exhaust Valve 1. Inspect: *Valve face *Stem end of specification Replace.
Page 145 INSPECTION A N D REPAIR 3. Inspect: stem end Mushroom diameter than rest of stem Replace valve, valve guide, and oil seal. Measure: Valve stem O u t of specification Replace. M a x i m u m 0.01 mm (0.0004 i n ) Valve Guide NOTE: replace valve guide if valve is replaced.
Page 146 I NSPECTI O N AND REPAI R NO TE: Af t er i nst al l i ng val ve gui de: * U se t he 5. 5 m m Val ve G ui de R eam er ( YM - 01196) t o obt ai n pr oper val ve gui de/ val ve st em...
Page 147 I NSPECTI O N AND REPAI R 6. M easur e: seat w i dt h O ut of speci f i cat i on/ R em ai ni ng pi t t i ng/ Var i at i on of val ve seat w i dt h Cut val ve f ur t her .
Page 148 INSPECTION AND REPAIR seat is too narrow and is located down near the bottom edge of the valve face (see diagram "d"). Desired Result Valve Seat Cutter Set to increase its width 45° cutter / - - Valve/Valve Seat Assembly Lapping Apply: Coarse lapping compound (small amount) To valve face.
Page 149 INSPECTION AND REPAIR Apply: .Solvent Into each intake and exhaust port. Pour solvent into intake and exhaust ports only after completion of all valve work and assembly of all head parts. 11. Check: .valve seals Leakage past valve seat Replace valve. (See procedure below) Valve guide Relapping steps:...
Page 150 INSPECTION AND REPAIR Measure: force (installed length) Out of specification Replace. Valve Compressed Force: Outer: 13.3 15.7 34.6 at 33.8 mm (1.331 in) 16.3 Inner: 6.29 -7.39 (13.9 at 31.8 mm (1.75 in) Valve Lifter 1. Inspect: lifter wall Replace both lifter Scratches/Damage and cylinder head.
Page 151: Camshaft. Cam Chain. And Cam Sprocket
I NSPECTI O N AND REPAI R C A M S H A F T , C A M C H A IN , A N D C A M SPR O C K ET C am shaft 1. I nspect : l obes Pi t t i ng/ Scr at ches/ Bl ue di scol or at i on...
Page 152 INSPECTION A N D REPAIR 6. Remove: caps 7. Measure: W i d t h of specification F o l l o w step 8. Camshaft-to-cap Clearance: Standard: 0.020 0.054 (0.0008 0.0021 i n ) M a x i m u m : 0.160 (0.006 in) 8.
Page 153: Piston. Piston Ring. And Piston Pin
I NSPECTI O N AND REPAI R C am C hai n Tensi oner 1. Check: cam oper at i on Unsm oot h oper at i on Repl ace. 2. I nspect : * Al l par t s Dam age/ W ear Repl ace.
Page 154 INSPECTION A N D REPAIR NOTE: Measurement should be made a t a point 6.2 mm (0.244 in) above the bottom edge of the piston. Size 75.905 75.955 mm Standard (2.9884 2.9903 in) Oversize 1 76.25 mm (3.002 in) Oversize 2 76.50 mm (3.012 in) Measure: clearance...
Page 155 I NSPECTI O N AND REPAI R 2. P osi ti on: Pi st on r i ng I nt o cyl i nder . Push t he r i ng w i t h t he pi st on cr ow n, 3.
Page 156: Starter Drives
INSPECTION AND REPAIR 3. Check: Free play Free play Inspect connecting rod for wear. Wear Inspect connecting rod and piston pin. 4. Position: Into piston. 5. Check: play When pin i s in place in piston. Free play Replace piston pin and/or piston.
Page 157: Primary Gears
INSPECTION A N D REPAIR Starter Gears 1. Inspect: gear surfaces R ep lace. Pi tting/Wear/Damage PRIMARY GEARS The drive gear is mounted on the crankshaft; the driven gear is mounted on the transmission and is intergrated with the clutch assembly. 1.
Page 158 INSPECTION AND REPAIR 1. Inspect: Clutch boss splines Scoring/Wear/Damage Replace clutch boss assembly. NOTE: Scoring on the clutch plate splines will cause erratic operation. Friction Plates Inspect: Friction plate Replace friction plate as a Damage/Wear set. Measure: Friction plate thickness Measure a t all four points.
Page 159: Oil Pump
INSPECTION A N D REPAIR Clutch Bearing 1. Inspect: Pitting/Damage Replace. Clutch Spring 1. Inspect: .Clutch spring Wear/Bends/Cracks Replace. Measure: spring free height O u t of specification Replace. Clutch Spring Minimum Height: 6.5 mm (0.26 in) 3. Measure: spring warpage Use a surface plate and the Feeler Gauge O u t of specification Replace.
Page 160: Oil Gallery Pipe
INSPECTION AND REPAIR Measure: /Inner rotor clearance rotor Use t h e Feeler Gauge. O u t of specification Replace oil pump assemb I Tip Clearance Limit: 0.17 (0.0067 in) O I L GALLERY PIPE 1. Inspect: Wear/Cracks/Damage Replace. pipe Cracks/Damage Replace.
Page 161 INSPECTION A N D REPAIR 4. Attach: (YU-33210) O n t o t h e crankshaft journal surface. NOTE: not turn t h e crankshaft until clearance measurement has been completed. 5. Install: Bearings lower crankcase. 6. Tighten: Tighten to full torque in torque sequence as shown.
Page 162 INSPECTION AND REPAIR Connecting Rod Bearing Clearance Measurement 1. Clean all parts. 2. Install: *Connecting rod bearings Into connecting rod and cap. 3. Attach: (YU-33210) Onto the crank pin. 4. Install: Connecting rod *Connecting rod cap NOTE: Be sure the letter on both components align t o form perfect character.
Page 163 INSPECTION A N D REPAIR 7. Remove: rod cap Use care in removing. 8. Measure: Width of Plastigage® Out of specification Replace bearings and/or replace crankshaft if necessary. Connecting Rod Bearing Clearance: 0.021 -0.045 (0.0008 0.0018 in) Crankshaft Main and Connecting Rod Bearing Selection used to indicate crankshaft journal sizes are stamped on the crankweb.
Page 164: Bearing
I NSPECTI O N AND REPAI R Exam pl e 1: Sel ect i on of t he crankshaf t m ai n beari ngs; t he cr ankcase J 1 and cr ankshaf t J 1 si zes ar e No. 4 and No. 1, r espect i vel y, t he bear i ng si ze N o.
Page 165 INSPECTION A N D REPAIR 3. Install: Bearings Into the upper crankcase. 4. Install : Balancer shaft Into the upper crankcase. Attach: Onto the balancer shaft journal surface. NOTE: Do not move balancer shaft until clearance measurement has been completed. 6.
Page 166 I NSPECTI O N AND REPAI R B alancer S haft B earing S election • Num ber s used t o i ndi cat e bal ancer shaf t j our nal si zes ar e st am ped on t he R H bal ancer w eb cor ner , st ar t i ng w i t h t he l ef t j our nal .
Page 167 INSPECTION AND REPAIR Shift Cam 1. Inspect: cam grooves Wear/Damage/Scratches Replace. Shift cam segment Damage/Wear Replace. *Shift cam bearing Pitting/Damage Replace. Main and Drive Axles 1. Measure: runout Use the centering device and Dial Gauge (YU-03097) O u t of specification Replace.
Page 168: Middle Gear Service
MIDDLE GEAR SERVICE MIDDLE GEAR SERVICE joint @Middle drive pinion gear Dust seal washer Retainer @Collapsible collar @Middle drive shaft @Middle driven pinion gear Spring seat Damper spring Damper cam 3-44...
Page 169 MIDDLE GEAR SERVICE Drive axle seal Drive pinion gear shim Bearing retainer Bearing Bearing housing Middle drive pinion gear Driven pinion gear shim Collapsible collar Nut (drive pinion gear) (Always use a new one) Nut (driven pinion gear) Spacer @Bearing stopper Middle driven pinion gear O-ring Universal joint...
Page 170: Drive Axle Positioning
MIDDLE GEAR SERVICE DRIVE AXLE POSITIONING When the crankcase assembly and/or the drive axle are replaced, you must position the drive axle in place. Refer to "Drive Pinion Gear Shim Selection and Middle Gear Lash Adjustment" section. Drive pinion gear Driven pinion gear A Drive pinion gear shim Driven pinion gear shim...
Page 171 M I DDLE G EAR SERVI CE Exam pl e: Sel ect i on of t he dri ve pi ni on gear shi m ; Shi m Thi ckness = Di st ance “A ” - D i st ance “B ” I f t he dr i ve pi ni on gear i s st am ped “...
Page 172 MIDDLE GEAR SERVICE Middle Gear Lash Adjustment 1. Attach: Middle Drive Gear Holder (YM-33222) This tool will prevent the drive axle from turning. 2. Install: Bolts (three) On driven bearing housing. nger-tighten the bolts. NOTE: Clearance between the crankcase and driven bear- ing housing should be about 2 mm.
Page 173 MIDDLE GEAR SERVICE 6. Tighten: Bolt (Three) Tighten carefully one-threadturn only. Push in bearing housing and hold in position while tightening bearing housing bolts. Do not overtighten bearing housing bolts or you may obtain too little gear lash and cause damage to gears.
Page 174: Removal
MIDDLE GEAR SERVICE Tighten: Bolts (bearing housing) Bolts (Bearing Housing): (3.0 NOTE: Before tightening the bolts, make sure that the arrow on the bearing housing points to the upper crankcase. 11. Measure: Gear lash REMOVAL 1. Remove: Drive axle assembly 2.
Page 175: Inspection
MIDDLE GEAR SERVICE 6. Remove: Nut (drive gear) (YM-04054). Use the Offset Wrench Bearing INSPECT ION 1. Inspect: Damper cam surfaces Replace damper and drive pinion gear as set. Inspect: Damper spring Replace. ASSEMBLY 1. Install: Shim Bearing Nut (drive gear) (YM-04054).
Page 176: Middle Driven Gear Bearings
MIDDLE GEAR SERVICE 4. Attach: Damper Spring Plate (YM-33286) Drive Gear Holder (YM-33222) 5. Position: Drive axle shaft assembly Onto Hydraulic Press. 6. Compress the damper spring on the drive axle assembly. 7. Install: Retainers drive axle shaft groove. Drive axle shaft assembly Onto the crankcase.
Page 177 MIDDLE GEAR SERVICE Remove: Nut (driven pinion gear) Washer *Yoke Bearing Bearing housing *Collapsible collar Spacer Inspection 1. Inspect: Gear teeth Replace middle gear as a set. Bearings Replace. 2. Check: U-joint movement Roughness Replace U-joint. Assembly 1. Install: Bearing outer race the bearing housing.
Page 178 M I DDL E GEAR SERVICE 5. Measure: *Starting torque (driven pinion gear) Repeat steps from 4. Under specification Starting Torque (Driven Pinion Gear): 0.5 Nm (0.04 0.05 0.29 0.36 Never exceed the standard starting torque. *Be sure to tighten the driven pinion gear nut slowly, carefully checking measurements each time.
Page 179: Engine Assembly And Adjustment
ENGINE ASSEMBLY AND ADJUSTMENT ENG IN E ASSEMBLY AND ADJUSTMENT LOWER CRANKCASE 1. Install: pump idle gear 2. Install : Shift forks (No. 1 Guide bars NOTE: All numbers should face the left side and be in sequence (1, 2, begining from the left.
Page 180 ENGINE ASSEMBLY AND ADJUSTMENT Piston ring “Y” mark Matching mark Connecting rod bearing size Projection Washer Journal bearing size Crank pin size Balancer matching mark 3-56...
Page 181 TRANSMISSION 2nd wheel gear Bearing 3rd pinion gear 1st wheel gear 5th pinion gear 4th wheel gear 5th wheel gear @Washer Bearing Washer Bearing 3rd wheel gear axle Drive axle pinion gear Plug 3-57...
Page 182 ENGINE ASSEMBLY AND ADJUSTMENT Install: shaft assembly lever Shift lever TRANSMISSION 1. Install: Plane bearings shaft) Identify each plane bearing position very carfuly so that it can be reinstalled in i t s original palce. Install: *Main axle assembly Drive axle assembly NOTE: the bearing circlips completely into...
Page 183 ENGINE ASSEMBLY AND ADJUSTMENT Check: *Transmission and shifter operation Unsmooth operation Repair. NOTE: Oil each gear and bearingthoroughly. 6. Install: *Crankshaft with cam chains Balancer shaft NOTE: Align the mark on the balancer shaft gear with the mark on the crankshaft gear. UPPER CRANKCASE 1.
Page 184 ENGINE ASSEMBLY AND ADJUSTMENT Install: *Piston Piston pin pin clip NOTE: sure the piston i s positioned correctly as shown. *Always install new piston pin clips. Plane bearings (connecting rods) Onto the connecting rod and cap. Mark "EX" Exhaust side "IN"...
Page 185 CRANKCASE ASSEMBLY 1. Apply: Sealant (Quick Gasket@) To the mating surfaces of both case halves. NOTE: DO NOT ALLOW any sealant to come in contact with the oil gallery O-ring, or crankshaft bear- ings. Do not apply sealant to within (0.08 0.12 in) of the bearings.
Page 186 ENGINE ASSEMBLY AND ADJUSTMENT 6. Tighten: Nuts (connectingrod cap) Nut (Connecting Rod): (3.6 kg, 25 NOTE: Molybdenum disulfide grease to the rod cap bolt threads and nut surfaces. projection on the connecting rod cap should faces the crankshaft web. When tightening the rod cap, apply continuous 3 .
Page 187 Crankshaft Unsmooth operation Repair. Bolts (middle driven gear housing) The arrow mark on the bearing housing points to the upper crankcase. 10. Install: Retainer (main axle bearing) NOTE: Be sure that the groove in the shaft mesh with the slot in the retainer. Retainer (Main Axle Bearing): 7 Nm (0.7 11.
Page 188 ENGINE ASSEMBLY AND ADJUSTMENT Install: Main oil gallery pipe pipe NOTE: Make sure the correct O-rings are installed on gallery pipe. Tighten: (main oil gallery pipe) 6 mm Flange Bolt 12 Nm (1.2 8 mm Union Bolt 18 Nm (1.8 4.
Page 189 ENGINE ASSEMBLY AND ADJUSTMENT 8. Install: filter cover NOTE: Be sure that the projections on the filter cover mesh with the slots on the crankcase. Oil Filter Cover: 32 Nrn (3.2 kg, 23 BREATHER COVER AND STARTER MOTOR 1. Install: pipe Breather cover spacer Breather cover...
Page 190 ENGINE ASSEMBLY AND ADJUSTMENT CLUTCH AND OIL PUMP DRIVE GEAR 1. Install: pump drive gear Install: Clutch housing Thrust washer Clutch boss Lock washer (new) (clutch boss) 3. Tighten: (clutch boss) Use the Clutch Holder hold the clutch boss. Nut (Clutch Boss): 70 Nm (7.0 4.
Page 191 ENGINE ASSEMBLY A N D ADJUSTMENT CLUTCH AND OIL PUMP D R I V E GEAR Ball @Clutch spring @Push rod (No. 2) @Spring seat pump @Pressure plate washer pump driven gear @Friction plate pcs) boss plate (7 pcs) @Thrust washer @Friction plate (6 pcs) tch housing @Bearing...
Page 192 ENGINE ASSEMBLY AND ADJUSTMENT Friction plates and clutch plates installation steps: Install the six friction plates (with the double semi-circular slots) and the six clutch plates. NOTE: Be sure the double semi-circular slots the friction plate is aligned with the clutch housing embossed match marks Install the clutch plate and the friction plate (with the wide square slot).
Page 193 ENGINE ASSEMBLY AND ADJUSTMENT Install: Pressure plate NOTE: Be sure t h e m atch mark on t h e c lut c h boss i s aligned with t h e m a t c h m a r k on t h e pressure plate.
Page 194 ENGINE ASSEMBLY AND ADJUSTMENT Install: clutch gear Woodruff key Be sure t o remove any and or grease from the tapered portion of the crankshaft and rotor with / - - a thinner. Install: Flywheel NOTE: When installing the flywheel, do not allow the oil baffle plate t o touch the projections on the flywheel.
Page 195 ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER HEAD AND CAMSHAFT Rear Cylinder Head 1. Install: Dowel pins Gasket Rear cam chain guide NOTE: gasket "HEAD" mark should the upward. lower end of chain guide must rest in the cam chain guide slot in the crankcase. Cylinder head Pass cam chain through cam chain cavity.
Page 196 ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER HEAD AND CAMSHAFT Washer seal Valve Rubber washer Gasket Valve lifter plug Valve retainer @Joint O-ring Spring seat spring plug Valve guide Outer spring Spring seat CYLINDER HEAD WARP LIMIT: 0.03 mm (0.0012 in) 15 Nm (1.5 3-72...
Page 197 ENGINE ASSEMBLY AND ADJUSTMENT 4. Install: Camshafts By the following installation steps. instal lation steps : mark on the flywheel with the stationary pointer on the crank- case cover use mm wrench. Never turn the flywheel installing bolt. Rotating the bolt may loosen it, causing the rotor fall out.
Page 198 ENGINE ASSEMBLY AND ADJUSTMENT Tighten the cap bolts. NOTE: First tighten the No. 3, 1 and 4 cap bolts in that order, then the No. 2 cap bolts, Camshaft Cap: 10 Nm (1.0 Install: Cam chain sprockets By the following installation steps. :am chain sprockets installationsteps: mark on the flywheel...
Page 199 ENG I NE ASSEMBLY AND ADJUSTMENT Force the intake camshaft counterclockwise to remove the cam chain slack. the cam chain onto the exhaust sprocket. Install the sprocket with the punched mark " REAR" facing outward and finger-tighten the sprocket bolt. NOTE: Align the "EX"...
Page 200 NE ASSEMBLY AND ADJUSTMENT 7. Turn the crankshaft and tighten the cam sprocket bolts. Camshaft Sprocket: 24 Nm (2.4 kg, 17 Be sure to attain the specified torque value to avoid the possibility of these bolts coming loose and causing damage to the engine. 8.
Page 201 NE ASSEMBLY AND ADJUSTMENT 2. Install: Cam chain sprocket the "T-2" mark on the flywheel with the stationary pointer on the crank- case cover use mm wrench. 2) Install the sprocket with the punched mark "FRONT" facing outward and finger-tighten the sprocket bolts. 3) Rotate the intake and exhaust camshafts to align the timing mark (0 : big hole) on the camshaft with the embossed match...
Page 202 NOTE: sure all cam caps are covered with oil plugs mark on the cover should face toward the exhaust side. the head cover gasket and replace it if damaged. 3. Tighten: Bolts (cylinder head cover) *Spark plugs Cylinder Head Cover: 10 Nm (1.0 Spark Plug: 17.5 Nm (1.75...
Page 203 ENGINE ASSEMBLY AND ADJUSTMENT REMOUNTING ENGINE When remounting the engine, reverse the removal procedure. Note the following points. 1. Install: Down tube frame (right) Bolts (down tube) Bolts (engine) NOTE: Tighten the bolts (#1 #9) in that order. Engine Mounting: Bolts (Down Tube)@, 45 Nm (4.5 kg, 32...
Page 204 ENGINE ASSEMBLY AND ADJUSTMENT Tighten: nuts or bolts By the following specification torque. Clutch Release Cylinder: 12 Nm (1.2 Middle Gear Case Cover: 10 Nm (1.0 Change Pedal 10 Nm (1.0 Footrest (Left) : 40 Nm (4.0 Footrest (Right) : 23 Nm (2.3 Rear Brake Master Cylinder: 23 Nm (2.3...
Page 205 ENGINE ASSEMBLY AND ADJUSTMENT 8. Connect: hoses and lead (conduit) Refer "CHAPTER COOLING SYSTEM, RADIATOR AND CONDUIT" section. 9. Adjust: cable free play Refer t o "CHAPTER CARBURETION, THROTTLE CABLE CYLINDER" section. Add: Engine oil Refer to "CHAPTER 2. ENGINE OIL REPLACEMENT"...
Page 206 ENGINE ASSEMBLY AND ADJUSTMENT MEMO ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3-82...
Page 207: Cooling System
CHAPTER 4 COOLING SYSTEM ........... COOLANT ..........
Page 208 COOLANT COOLING SYSTEM COOLANT COOLANT FLOW Radiator Coolant drain valve Bypass pipe to the coolant drain valve Bypass pipe to the thermostatic valve Thermostatic valve Water pump To the reservoir tank Thermostat housing Conduit 4- 1...
Page 209 COOLANT COOLANT REPLACEMENT Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the fo I lowing procedure : Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise...
Page 210 CO O LANT 5. Rem ove: cover s ( cyl i nder ) 6. Rem ove: pl ugs D r ai n t he cool ant . NO TE: To f aci l i t at e r em oval of t he r ubber pl ug’ s, scr ew a spar k pl ug i nt o t he t hr eaded hol e and hand- pul l t he spar k pl ug f i r m l y.
Page 211 Reservoir Tank Capacity: 0.30 (0.26 0.32 US qt) harmful to the *Hard water or salt water engine. Y o u may use distilled water can't get soft water. not mix more than one t y pe of ethlen containing corrosion glycol antifreeze aluminum engine inhabitors.
Page 212: Water Pump
WATER PUMP W A T E R PUMP DISASSEMBLY NOTE: sure to dr ain t h e c oolant before disassembly of t h e c ooling system components. *Refer to Engine Disassembly for water pump disassembly 1. Remove: *Drive gear *Gear stopper *Impeller shaft Eliminate:...
Page 213: Assembly
WATER PUMP 3. Install: pump Use Water Pump Seal Installer Apply Sealant (Quick to crank- case cover before installing seal. PRESS APPLY SEALANT (QUICK 4. Remove: From impeller. Pry out with a small screwdriver. NOTE: Be careful not to scratch or bend the impeller shaft.
Page 214 WATER PUMP ASSE MB LY Mechanical seal seat Bearing Gear stopper pin Drivengear Drive gear Water pump cover O-ring Crankcase cover FRONT F R O M RADIATOR Impeller shaft Gear stopper pin gear sure not to scratch the water pump seal while installing.
Page 215: Thermostatic Valve
THERMOSTATIC VALVE THERMOSTATIC VALVE REMOVAL 1. Remove: Thermostat cover Thermostatic valve Thermostat housing INSPECTION AND ASSEMBLY 1. Inspect: .Thermostatic valve Valve does not open a t 80 84°C (176 (176 Replace. By the following inspection steps. Thermostatic valve inspection steps: thermostatic valve in a vessel or water.
Page 216: Coolant Drain Valve
COOLANT DRAIN VALVE Inspect: Replace. Install: .Thermostatic valve NOTE: Line t h e valve breather hole with t h e housing projection cover housing COOLANT DRAIN VALVE DISASSEMBLY Remove: .Retaining screw assembly INSPECTION 1. Inspect: O-ring Replace. Damage Replace. .Stopper ball Replace.
Page 217: Cylinder Head Water Jacket Joint
CYLINDER HEAD WATER JACKET RADIATOR AND CONDUIT CYLINDER HEAD WATER JACKET JOINT sure to drain the coolant before you disas- semble the water jacket joints otherwise the coolant will flow into the crankcase. not remove the water jacket joints unless absolutely essential;...
Page 218: Inspection
RADIATOR AND CONDUIT Remove: (radiator) Disconnect: hose hoses 4. Disconnect: motor coupler 5. Remove: Radiator assembly 6. Disconnect: hoses and leads (conduit) 7. Remove: (conduit) 8. Remove: motor assembly INSPECTION 1. Inspect: Obstruction Blow out with compressed air through rear of radiator. Flattened fins Repair.
Page 219: Assembly
RADIATOR AND CONDUIT Inspect: *Vacuum valve spring Fatigue Replace. *Vacuum valve seating condition Poor condition Replace. Measure: *Valve opening pressure By the following measurement steps. Valve opening pressure measurement steps: the radiator cap pressure using the (YU-24460). Radiator Cap Tester Valve opens a t pressure below specified valve or defective Replace.
Page 220 AND CONDUIT Inspect *Cooling system By the following inspection steps. Cooling system inspection steps: Connect Radiator Cap Tester *Apply pressure. *Measure pressure with gauge. Decrease of pressure (leaks) Repair at requ ired. 4-13...
Page 221 CHAPTER 5 CARBURETION ..........CARBURETOR ................... REMOVAL ..........DISASSEMBLY ..........INSPECTION ..........ASSEMBLY ........... INSTALLATION ..........ADJUSTMENT ......... THROTTLE CABLE CYLINDER 5-10 ..........ADJUSTMENT 5-10 ............ V-BOOST 5-13 ..........REMOVAL 5-13 ..........INSPECTION 5-13 ...........
Page 222 CARBURETOR CARBURETION CARBURETOR Throttle cable (Close side) shaft Throttle cable (Open side) Fuel overflow hose Fuel overflow hose Main j e t # 3 : Fuel feed hose Fuel feed hose Main air j e t air j e t Jeet needle Float needle valve Coasting enrichment...
Page 223: Carburetor
CARBURETOR SECTION VIEW screw Pilot air jet No. 1 Bypass hole Pilot outlet Main air jet Purge hole Jet needle Throttle valve Pilot air jet No. Pilot jet Piston valve , , - - - Main jet Diaphragm Purge jet No. 2 Main bleed pipe Purge jet No.
Page 224: Removal
REMOVAL 1. Remove: Carburetor Refer to engine removal section. NOTE: The following parts can be cleaned and inspected without d bI y valve plunger enrichment valve DISASSEMBLY The plastic piston valve is fragile and highly susceptible to damage. Be sure to handle with extreme care.
Page 225 CARBURETOR 5. Remove: brackets 6. Remove: lever shafts 7. Remove: *Synchronization screws *Synchronization rod NOTE: When separating the carburetors be sure not to lose the small spring that may fall out. This spring connects the throttle levers. 8. Remove: plunger plunger body Spring 9.
Page 226 CARBURETO R 10. Rem ove: • Spri ng • Vacuum pi st on • O - r i ng • Pi l ot ai r j et N o. 2 11. Rem ove: • C oast i ng enr i chm ent cover •...
Page 227: Inspection
CARBURETOR Remove: Rubber caps bleed pipe 16. Remove: air jet No. INSPECTION 1. Inspect: Carburetor body Contamination Clean. NOTE: Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. Inspect: Float Damage Replace. valve am i nation I ace.
Page 228: Assembly
CARBURETOR 4. Inspect: needle Replace. Inspect: Tears Replace. 6. Inspect: plunger Replace. 7. Inspect Damage Replace. ASSEMBLY To assemble t h e carburetors, reverse the disas- sembly procedures. N o t e t h e following points. reassembling, wash all parts in clean gasoline.
Page 229 CARBURETOR Install: block NOTE: Make sure the projection on the j e t block is meshed with the groove on the needle jet. Install: enricher piston NOTE: There is a tab on the rubber diaphragm and a matching recess in the carburetor body to accept the diaphragm tab.
Page 230: Adjustment
CARBURETOR ADJUSTMENT Measure: level Out of specification Adjust. the following measurement steps. Fuel Level: 1.0 mm (0.63 0.04 in) Below the Carburetor Piston Valve Center Fuel level measurement steps: t h e motorcycle on a level surface. a garage jack under the engine to ensure t h a t t h e carburetor is positioned vertically.
Page 231: Throttle Cable Cylinder
THROTTLE CABLE CYLINDER THROTTLE CABLE CYLINDER Throttle stop screw Cable cylinder Slider tape Cable adjustment Cable adjustment mark (Close side) mark (Open side) Cable adjuster Standard adjuster distance (Throttle grip side) .Turning direction Cable adjuster (Carburetor side) Free play (Throttle grip) Locknut (Carburetor side) ADJUSTMENT 1.
Page 232 THROTTLE CABLE CYLINDER Measure: Free play (throttel grip) Out of specification Adjust. Throttle Grip Free Play : (0.16 0.28 in) 4. Check: carburetor throttle valve operation By the following checking steps. No. 2 carburetor throttle valve operation checking steps: Loosen the locknut (carburetor side) throttle grip back and forth.
Page 233 THROTTLE CABLE CYLINDER Second step: a. Loosen the locknut (carburetor side). b. Turn the adjuster (carburetor side) counter- clockwise a little. c. Turn adjuster (throttle grip side) clock- wise so that the free play (throttle grip) is within 4 7 mm (0.16 0.28 in).
Page 234: V-Boost
V-BOOST Install: cleaner 7. Set engine idle speed. V-BOOST REMOVAL 1. Remove: assembly Refer to engine removal section. NOTE: The V-boost can be inspected without the disassembly. It is not necessary to disassemble the V-boost. INSPECTION 1. Inspect: Contamination Clean. Use a petroleum based solvent.
Page 235 V-BOOST Measure: Between the pulley and the adjuster Out of specification Adjust. m (0.012 0.004 in) Lockunt Adjust: By the following adjustment steps. Clearance adjustment steps: First step: NOTE: not loosen the locknut in this stage. the lock bolt on the main switch for the servo motor initial operation (valve closed position).
Page 236 V-BOOST V-boost Synchronization NOTE: Before synchronizing the V-boost, the control cable should be adjusted. a ’ 0.1 mm (0.016 0.004 in) Adjust: By the following adjustment steps. V-boost synchronization adjustment step: the locknut the adjuster clockwise or counter- clockwise until proper clearance is attained. the clearance.
Page 237: Air Cleaner And Crankcase Ventilation System
AIR CLEANER AND CRANKCASE VENTILATION SYSTEM AIR CLEANER AND CRANKCASE VENTILATION SYSTEM Refer to "CHAPTER 2" for t h e air cleaner maintenance. Air cleaner Carburetor 5-16...
Page 238 CHAPTER 6 CHASSIS ..........FRONT WHEEL .
Page 239 ..........6-43 .
Page 240 FRONT W H E E L CHASSIS FRONT W H E E L Collar seal clutch Bearing @Clutch retainer seal unit assembly...
Page 241 REMOVAL Securely support the motorcycle so won't fall over when the front wheel. Place the motorcycle on i t s centerstand. 2. Remove: @Speedometer c able Remove: Fork brace Front fender 4. Loosen: bolt (front axle) Front axle Elevate the front wheel by placing a suitable stand under the engine.
Page 242: Front Wheel
FRONT WHEEL 2. I nspect : F r o n t axle Bends Replace. Roll the axle on a f l a t surface. attempt to straighten a dent axle. 3. Inspect: Wheel Replace. 4. Measure: Wheel Over specified limit Repalce.
Page 243 FRONT WHEEL Eye protection is recommended when using striking tools. the new bearing by reversing the previous steps. NOTE: Use a socket that matches the outside diameter of the race of the bearing. Do not strike the center race or balls of the bearing.
Page 244 FRONT WHEEL Install: Front wheel NOTE: sure that the projecting portion (torque stopper) of the gear unit housing is ed correctly. .Compress the front forks several times t o con- firm proper fork operation before tightening the pinch bolt. 4. Tighten: Front axle (6.0 5.
Page 245 R E A R W HEEL R E A R W HEEL Cylinder bearing seat seal Bearing Clutch hub Spacer Damper Hub dust seal Spacer T I R E SIZE: 1.0 mm (0.04 in) RIM SIZE: M73.50 x 15 RADIAL: LATERAL: 2.0 mm (0.08 in) 120 Nm (12.0...
Page 246 R E A R W HEEL REMOVAL 1. Place the motorcycle on its centerstand. 2. Remove: *Cotter pin *Axle nut Washer 3. Remove: Rear caliper Tension bar NOTE: Do not depress the brake pedal when the wheel is off the motorcycle as the brake pads will be forced.
Page 247 INSTALLATION When installing the rear wheel, reverse the re- moval procedure. Note the following points. 1. Apply: Lithium base grease Lightly grease t o the final gear case splines. 2. Install: Rear wheel assembly NOTE: Be sure the splines on the wheel hub f i t into final gear case.
Page 248 FRONT AND REAR BRAKE FRONT AND REAR BRAKE Air bleed screw : Install the pad spring with i t s longer in the Retaining pin disc rotating direction. Dust seal Piston seal Piston F R O N T CALIPER 5 N m (0.5...
Page 249 FRONT AND REAR BRAKE Air bleed screw Install the pad spring with i t s longer tangs@ in the disc Retaining pin Dust seal rotating direction. Piston seal Piston Be sure to position the shim that i t s arrow mark@ points in the rotating direction of the disc plate Shim...
Page 250 FRONT AND REAR BRAKE CALIPER PAD REPLACEMENT It is not necessary t o disassemble the brake caliper and brake hose t o replace the brake pads. 1. Remove: 2. Remove: Retaining clips Retaining pins spring Remove: Pads NOTE: the pad spring if pad replacement is required.
Page 251 FRONT AND REAR BRAKE BRAKE ONLY: Be sure to position the shim so that i t s arrow mark points in the rotating direction of the disc plate rotation. CALIPE SASSE MB LY 1. Remove: Pads Refer to "CALIPER section. 2.
Page 252 FRONT AND REAR BRAKE MASTER CYLINDER DISASSEMBLY Master cylinder cap Rubber seal cylinder kit 4 Copper washer joint BRAKE FLUID TYPE: D O T # 3 Nm (0.9 m*kg, 6.5 ft-lb) Nm (2.5 m-kg, 18 ft-lb) 25 Nm (2.5 m-kg, 18ft.Ib) 6-1 3...
Page 253 FR O N T A N D R EA R B R A K E Reservoi r t ank BR AKE H O SE R O U TI N G : B and W hen i nst al l i ng t he rear brake hose, Copper washer al i gn t he br ake pi pe w i t h t he f r ont...
Page 254 FRONT AND REAR BRAKE Front Brake Master Cylinder Disassembly NOTE: Drain the brake fluid before removing master cylinder. Dust b o o t Piston Piston cups Return spring Washer Seat A MASTER CYLINDER KIT (Replace as a set) 1. Remove: Brake light switch leads Brake lever Lever spring...
Page 255 FRONT AND REAR BRAKE Rear Brake Master Cylinder Disassembly NOTE: Drain the brake fluid before removing master cyI i nder 1. Remove: cover (right) 2. Disconnect: Brake hose Spring Piston cup Piston Adjusting rod Circlip Dust boot MASTER C Y L I N D E R K I T (Replace as a set) Remove: Master cylinder Fluid reservoir tank...
Page 256 FR O N T A N D R EA R B R A K E Al l internal parts should be cleaned in new brake f l ui d onl y. D o not use sol vent s w i l l cause seal s to sw ell and distort.
Page 257 FRONT AND REAR BRAKE Caliper Reassembly When assembling the caliper, reverse the disas- sembly procedure. Note the following points. 1. Install: Brake calipers Brake hoses m-kg, 32 ft-lb) 25 Nm (2.5 m-kg, 18 ft-lb) 2. Bleed the air completely from the brake system.
Page 258 FRONT AND REAR BRAKE 3. Fill: Master cylinders 4. Bleed the air completely from the brake system. AIR BLEEDING Bleed the brake system it: The system has been disassembled. A brake hose has been loosened or removed. The brake fluid i s very low. brake operation is faulty.
Page 259 FRONT AND REAR BRAKE NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have pered. j. Add brake fluid t o the level line on the reservoir.
Page 260: Hydraulic Clutch
HYDRAULIC CLUTCH HYDRAULIC CLUTCH Copper washer Master cylinder kit (Replace as a set) 1 Nm (0.1 CLUTCH FLUID TYPE: DOT...
Page 261 HYDRAULIC CLUTCH CLUTCH RELEASE DISASSEMBLY 1. Remove: Footrest Change pedal Middle gear case cover NOTE: When removing the middle gear case cover, be sure oil does not leak out of the case. 2. Remove: hose Drain the fluid. release assembly Remove: Dust seal Piston assembly...
Page 262 HYDRAULIC CLUTCH 1 . Remove: switch leads lever hose Drain the fluid. Remove : Master cylinder Drain the excess fluid. Remove: boot Circlip Master cylinder k i t CLUTCH INSPECTION AND REPAIR Recommended Clutch Component Replacement Schedule: Piston seal, dust Every two years Every four years Clutch hoses...
Page 263 HYDRAULIC CLUTCH Inspect: Replace. seal Wear Replace. CLUTCH REASSE M B LY internal parts should be cleaned in new brake fluid only. Internal parts should be lubricated with brake fluid when installed. Clutch Release Reassembly When assembling the clutch release, reverse the disassembly procedure.
Page 264 HYDRAULIC CLUTCH 9 Nm (0.9 Clutch Hose: Install: Lever NOTE: Grease the pivot point Fill: Master cylinder 4. Bleed the air completely from the clutch system. AIR BLEEDING Bleed the clutch system The system has been disassembled. A clutch hose has been loosened or removed. The clutch fluid is very low.
Page 265 HYDRAULI C CLUTCH i .R epeat st eps ( e) t o ( h) unt i l al l of t he ai r bubbl es have been r em oved f r om t he I syst em . NO TE: I f bl eedi ng i s di f f i cul t , i t m ay be necessar y t o l et t he cl ut ch f l ui d syst em st abi l i ze f or a...
Page 266 FRONT FORK FRONT FORK Damper complete Air joint lock piece O-ring Inner fork tube @Guide bush Air valve Dust cover Fork cap Retaining clip O-ring seal Cap bolt spacer bush Spring seat @Outer fork tube Fork spring Drain screw Rebound spring 6-27...
Page 267 FRONT FORK REMOVAL Securely support the motorcycle so won't fall over when the front wheel and front forks are removed. 1. Remove: Front wheel Refer t o "FRONT WHEEL" seciton. Brake calipers Cable holders Remove: valve cap (left) Depress the valve until all of the air has been released.
Page 268 FRONTFORK 1. Remove: bolt Use the Front Fork Cap Socket 01 104). Spring seat Fork spring Inner fork tube 2. Remove: Dust cover Retaining clip Use a thin screwdriver, and be careful not t o scratch the inner fork tube. 3.
Page 269 FR O N T FO R K NO TE: • Excessi ve f or ce wi l l dam age t he oi l seal and/ or t he bushes, Dam aged oi l seal and bushi ng m ust be r epal ced. bot t om i ng t he i nner t ube i n t he out er t ube dur i ng t he above pr ocedur e, as t he oi l l ock pi ece wi l l be dam aged.
Page 270 FRONTFORK 3. Inspect: Damper rod Replace. Contamination Blow out all oil passages with compressed air. 4. Inspect: @O-ring(cap bolt) lock piece Damage Replace. Seals Replace. ASSEMBLY Before assembling, clean and inspect all parts and replace when necessary. NOTE: In front fork assembly, be sure to use following new parts.
Page 271 FRONT FORK 3. Tighten: Bolt (cylinder complete) Use the Damper Rod Holder and the T-Handle Bolt (Cylinder Complete) : 40 Nm (4.0 4. Install: *Slide bush outer tube. Use the Fork Seal Driver Weight 33963) and the Adapter (YM-33964). @inner tube Outer tube Install: spacer...
Page 272 FRONT FORK 8. Install: Fork spring With smaller pitch side up. *Spring seat bolt Temporarily tighten the cap bolt. INSTALLATION 1. Install: Front underbracket. Circlip Onto inner tube. Apply a light coat of lithium base grease to the O-rings in the air joint bracket. joint bracket Rubber damper Over inner fork tube.
Page 273 FRONT FORK 5. Adjust: Front fork air pressure Refer to "CHAPTER 2. FRONT FORK A DJUSTM E NT" section. 6. Install: valve cap Fork cap Brake calipers *Cable holders Refer to "FRONT A N D REAR BRAKE" section. Front wheel Refer to "FRONT WHEEL"...
Page 274 STEERING H E A D STEERING HE AD @Steering stem nut Ring nut (Lower) Lock washer Bearing cover nut (Upper) Bearing (Upper) @Washer Bearing (Lower) (2.0 (2.0 (4.0 1. TIGHTEN RING (5.0 LOOSEN IT COMPLETY: 3. RETIGHTEN IT: 3 Nrn (0.3 6-35...
Page 275 REMOVAL Securely support the motorcycle so there is no danger of it falling over. 1. Remove: Front wheel Front forks Remove: Headlight lens unit 3. Disconnect: leads (in the headlight body) 4. Remove: *Bolt (headlight body bracket) Emblem Remove: Flasher light bracket assembly 6.
Page 276 STEER I N G H EA D R em ove: • Br ake hose j oi nt R em ove: • N ut ( st eer i ng cr ow n) • St eer i ng cr own 9. R em ove: Lock w asher ( r i ng nut ) •...
Page 277 INSPECTION 1. Wash the bearing in a solvent. 2. Inspect: Bearings Bearing race Replace. NOTE: Always repalce bearing and race as a set. I NST A LLAT 1. Lubricate: Bearing and races Install: (lower) Onto steering stem. stem Hold the steering stem until is secured.
Page 278: Steering Head
STEERING HEAD @Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings Install the washer Install the ring nut (upper) NOTE: The tapered side of ring nut must face down- ward.
Page 279: Rear Shock Absorber
REAR SHOCK ABSORBER REAR SHOCK ABSORBER shock absorber assembly SPRING PRELOAD POSITION (STANDARD): 1 DAMPING POSITION (STANDARD): 1 20 Nm (2.0 Nm (2.0 6-40...
Page 280 REAR SHOCK ABSORBER REMOVAL 1. Remove: Bolt (shock absorber top) Special washer Nut (shock absorber bottom) *Plain washer Pull out the shock absorber top, and turn the shock absorber clockwise. 3. Remove: Rear shock absorber INSPECTION 1. Inspect: Shock absorber rod Replace the shock absorber assembly *Shock absorber...
Page 281 REAR SHOCK ABSORBER Install: Rear shock absorber NOTE: The rear shock absorber should be installed so that the damping match mark on the shock absorber faces outward Tighten: Bolt (shock absorber top) Nut (shock absorber bottom) Bolt (Shock Absorber Top): 20 Nm (2.0 Nut (Shock Absorber Bottom): 30 Nm...
Page 282 SWI NGARM Locknut Pivot shaft (right) Collar seal Taper roller bearing Pivot shaft (left) Lock washer Collar seal Taper roller bearing Rubber boot 20Nm (2.0 (0.6 100 Nm (10.0 100 Nm (10.0 6-43...
Page 283 SW I NGARM FREE PLAY INSPECTION 1. Remove: Rear wheel Rear shock absorbers Check: Swingarm (side play) Side play Replace taper roller bearings and collars. Move swingarm from side to side. There should be no noticeable side play. 3. Check: Swingarm (vertical movement) spots Replace...
Page 284 5. Remove: Rubber boot *Bolts (muffler) 6. Remove: Push down the muffler. 7. Remove: Final gear assembly INSPECTION 1. Wash the bearings in a solvent. Inspect: Bearings Replace. seals Damage Replace. 3. Inspect: Rubber boot Damage Replace. 6-45...
Page 285 INSTALLATION When installing the swingarm, reverse the re- moval steps. Note the following points. 1. Lubricate: Bearing seals Lithium Base Waterproof Wheel Bearing Grease 2. Install: Swingarm Pivot shafts Tighten: Pivot shafts By the following tightening steps. Pivot shaft tightening steps: the pivot shaft (left) to specifi- cation,...
Page 286 SHAFT DRIVE SHAFT DRIVE Dust cover Bearing Bearing Bearing housing Drive pinion gear Ring gear Stopper shim Ring gear stopper Bearing O-ring Bearing retainer seal O-ring Ring gear shim seal Bearing Coupling gear Ring gear Spring Thrust washer Bearing Drive shaft seal seal Washer...
Page 287 SHAFT DRIVE TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Possible Causes Symptoms 1. A pronounced hesitation or "jerky" movement during acceleration, deceleration, or sustained A. Bearing damage. speed. (This must not be confuse with engine surging or tansmission characteristics.) B.
Page 288 SHAFT DRIVE Inspection Notes lnrestigate any unusual noises The following "Noises" may indicate a mechanical defect: a. A "rolling rumble" noise during coasting, acceleration, or deceleration. The noise increases with rear wheel speed, but it does not increase with higher engine or trans- mission speeds.
Page 289 Inspect: leakage By the following inspection steps. Oil leakage inspection steps: Clean the entire motorcycle thoroughly, then dry it. a leak-localizing compound or dry powder spray t o the shaft drive. test the motorcycle for the distance necessary to locate the leak, Leakage Inspect component housing, gasket, and/or seal for damage.
Page 290 SHAFT DRIVE TroubleshootingChart When basic conditions and "b" above exist, check the following points: "a" Elevate and spin the front wheel. Feel Replace the wheel bearing. for wheel bearing damage. (Refer to "CHAPTER FRONT Rear wheel bearings and shaft drive Check the rear wheel.
Page 291 SHAFT DRIVE FINAL DRIVE GEAR Gear Lash Measurement 1.5 mm (0.06 1. Secure the gear case in a vise or other support. 2. Remove: (0.55 Drain plug Drain the oil. (3.94 in) 3. Install: A specified bolt the drain plug Finger tighten the bolt until it holds the ring gear.
Page 292 SH A FT D R I VE R em ove: • Bear i ng housi ng • Dust cover • Ri ng gear • Shi m ( s) • Thr ust w asher 3. Adj ust : • G ear l ash By t he f ol l ow i ng adj ust m ent st eps.
Page 293 SHAFT DRIVE Measure: Ring gear stopper clearance Use the Feeler Gauge O u t of specification Adjust. Ring Gear Stopper Clearance 0.30 0.60 mm (0.012 0.024 in) Ring gear stopper R i n g gear Install: Bearing housing with ring gear Ring Gear Stopper Clearance Adjustment 1.
Page 294 SHAFT DRIVE Final Drive Gear Disassembly 1. Remove: Nuts (bearing housing) Bolts (bearing housing) NOTE: Working in a crisscross pattern, loosen nut 1/4 turn each, Remove them after all loosened. Remove: Bearing housing Dust cover washer Remove: nut (coupling gear) Use a Final Drive Shaft Holder Coupling gear Remove:...
Page 295 Bearing Removal and Reassembly 1. Remove: *Guide collar seal Roller bearing Use a suitable press tool and an appro- priate support for the main housing. 2. I nspect: Roller bearing Damage Replace. NOTE: Reuse of roller bearing OK, but recom- mends installation of new bearing.
Page 296 SHAFT DRIVE Install: Guide collar (new) Roller bearing (outer race) Use a suitable press tool and a press to install the above components into the main housing. Final Gear Positioning Gear positioning is necessary when any of the following parts are replaced: Final gear case Ring gear bearing housing 1.
Page 297 SHAFT DRI VE W her e: a = a num er al ( usual l y a deci m al num ber ) on t he gear i s ei t her added t o or subt r act ed f r om “84”.
Page 298 SHAFT DRIVE c =numeral on gear case 45.52) d =numeral (usually a decimal number) on outside of ring gear bearing housing and added to 3. e =numeral (usually a decimal number) on inside of ring gear either added to or subtracted from 35.40.
Page 299 SHAFT DRIVE Hundredths Round In the example above, the calculated shim thickness i s 0.46 mm. The chart instructs however, t o round off the 6 t o 5. Thus you should use a shims. Install: *Shims (proper size as calculated) Final drive shaft assembly Bearing retainer (final drive shaft) Use a Final Drive Shaft Bearing Retainer...
Page 300 SHAFT DRIVE Thrust clearance measurement steps: Remove t h e ring gear assembly. Place four pieces of between originally f i t t e d thrust washer and r i n g gear. Install t h e r i n g gear assembly and tighten t h e bolts and nuts to specification.
Page 301 SHAFT DRIVE DRIVE SHAFT Removal 1. Remove: Rear wheel Final gear assembly Drive shaft Inspection 1. Inspect: Drive shaft splines Replace. Installation When installing the dirve shaft, reverse the removal procedure. Note the following points. 1. Lubricate: splines Molybdenum Disu If i de Grease Install: Drive shaft Before installing, first set the universal joint in...
Page 302 CHAPTER 7 ELECTR ......... CIRCUIT DIAGRAM ........ELECTRICAL COMPONENTS ........ELECTRIC STARTING SYSTEM ......... CIRCUIT DIAGRAM .
Page 303 ..........COOLING SYSTEM ........CIRCUIT DIAGRAM 7-45 ........UBLESHOOTING 7-47 ....ELECTRIC FAN AND THERMOSTATIC SWITCH ......THERMO-UNIT AND THERMOMETER 7-49 .......... FUEL PUMP SYSTEM ........
Page 304: Circuit Diagram
CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM...
Page 305 CIRCUIT DIAGRAM COLOR CODE Cancelling unit Ignition coil ..Spark plug Starter switch .Black "TURN" switch ..Ignition coil .Blue "TURN" indicator light ..Spark plug .Orange light...
Page 306: Electrical Components
ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (1) TCI unit Pressure sensor IGNITION COIL: Ignition coil PRIMARY 2.752 Neutral switch gauge Ignition coil Thermostatic switch Thermo-unit...
Page 307 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (2) Starter relay Diode Main fuse Main switch Battery Wire harness Rectifier with regulator Sidestand switch Rear brake switch Horn Relay unit Sidestand relay V-boost valve control unit Fuel pump relay BATTERY: CAPACITY: 16AH SPECIFIC GRAVITY: 1.280...
Page 308: Electric Starting System
ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM...
Page 309 ELECTRIC STARTING SYSTEM Aforementioned circuit diagram shows electrical starting circuit in wiring diagram. NOTE: 7-2. For the encircled numbers and color cords, see page Relay unit Starting circuit cut-off relay Starter switch Main fuse Battery Starter motor Starter Main switch Fuse (IGNITION) "...
Page 310: Troubleshooting
ELECTRI C STARTI NG SYSTEM TR O U B LESH O O TI N G Troubl eshoot i ng C hart ( 1) Rem ove t he seat . D i sconnect t he “L/ W ” l ead f rom t he st art er rel ay.
Page 311 ELECTRI C STARTI NG SYSTE Troubl eshoot i ng C hart ( 2) TH E STA R TER M O TO R D O ES N O T O PE- RATE. r el ay and st ar t er m ot or ; e m ai n sw i t c f r am e;...
Page 312: Starting Circuit Cut-Off System
ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM A starting circuit cut-off system is employed, and operates as follows: Starting Circuit Operation The starting circuit on this model consist of the starter motor, starter relay, and the relay unit (starting circuit cut-off relay). I f the engine stop switch and the main switch are both on, the starter motor can operate only if: The transmission is in neutral (the neutral...
Page 313: Starter Motor Test
ELECTRIC STARTING SYSTEM STARTER MOTOR TEST O-ring Brush holder assembly seal Brush MINIMUM BRUSH LENGTH: (0.22 COMMUTATOR WEAR LIMIT:...
Page 314 ELECTRIC STARTING SYSTEM Removal 1. Remove: motor Refer to "CHAPTER ENGINE DIS- ASSEMBLY" section. Inspection and Repair 1. Inspect: Commutator Dirty Clean with grit sandpaper. Measure: Commutator diameter Out of specification Replace starter motor. 3. Measure: undercut (between commutator segments) Out of specification Scrape mica to proper valve.
Page 315 ELECTRIC STARTING SYSTEM Inspect: Replace 6. Inspect: brushes Damage Replace. Measure: length Out of specification Replace. Minimum Brush Length: mm (0.22 in) springs Compare with new spring. Replace. Installation 1. Install: motor NOTE: Align the match marks on the brackets with the match marks on the housing.
Page 316: Battery Inspection
B A T T E R Y INSPECTION 1. Inspect: Refer to "CHAPTER B A T T E R Y IN- SPECTION" section. STARTER R E L A Y TEST 1. Inspect: realy Poor condition Replace. B y the following inspection steps. Starter relay inspection steps: the seat.
Page 317: Starting Circuit Cut-Off Relay Test
ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF RELAY TEST 1. Remove: cover (left) unit 2. Disconnect: unit connector 3. Measure: 22552 circuit out-off relay resistance Use the Pocket Tester Out of specification Replace. Starting Circuit Cut-off Relay Resist- 20°C 4. Check: circuit cut-off relay contacts Use 12V battery and the Pocket Tester...
Page 318 ELECTRI C STARTI NG SYSTEM 2. Check: r el ay cont act s U se 12V bat t er y and t he Pocket Test er ( YU - 03112) . O ut of speci f i cat i on R epl ace r el ay.
Page 319: Neutral Switch Test
ELECTRIC STARTING SYSTEM NEUTRAL SWITCH TEST 1. Disconnect: lead (Blue) 2. Check: switch contact Out of specification Replace switch. Blue Ground SIDESTAND SWITCH TEST 1. Remove: cover (left) 2. Disconnect: 02-pin connector (Blue/Yellow and Black) 3. Check: switch contacts Out of specification Replace switch.
Page 320: Chargingsystem Circuit Diagram
CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM...
Page 321 CHARGING SYSTEM Afcrementioned circuit diagram shows charging circuit in wiring diagram. NOTE: For the encircled numbers and color codes, see page 7-2. Magneto Rectifier with regulator Main fuse Battery Main switch 7-18...
Page 322 CHARG I NG SYSTEM TR O U B LESH O O TI N G Bat t er y vol t age: M or e t han 12V t o m easur e t he gener at or vol t age.
Page 323: Charging Voltage Test
CHARGING SYSTEM CHARGING V O L T A G E TEST 1. Remove: *Seat 2. Connect: Tester To battery terminals. 3. Start the engine and accelerate to about 2,000 or more. 4. Measure: Generator v oItage O u t of specification Check battery, stator coil, and Generator Voltage: 14.5...
Page 324 CHARGING SYSTEM 4. Measure: coil resistance O u t of specification Replace stator coils. 15% of 20°C (68°F) (White - White) White RECTIFIER TEST 1. Check: element Replace rectifier. White Regulator White Brown White Rectifier Black Pocket Tester Continuity : Discontinuity NOTE: The results should be reversed ac-...
Page 325 - M E M O ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7-22...
Page 326: Circuit Diagram
IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM 7-23...
Page 327 IGNITION SYSTEM Aforementioned circuit diagram shows ignition circuit in wiring diagram. NOTE: For the encircled numbers and color codes, see page Ignition coil Main switch Spark plug Fuse (IGNITION) / , - Ignition coil "ENGINE STOP" switch Spark plug Sidestand relay ignition coil Pressure sensor Spark plug...
Page 328 IGNITION SYSTEM T OUBLESHOOT The entire ignition system can be checked for misfire and weak spark by using the Electro Tester. 1. Warm up the engine so that all of the electri- cal componentsare a t operatingtemperature. Connect: Tester 3. Start the engine, and increase the spark gap until misfire occurs.
Page 329 IGNITION SYSTEM Troubleshooting Chart Check the entire ignition for connections. Correct. Faulty Measure the battery voltage and ,specific gravity. Recharge the battery. Battery voltage: More than 12V Specific gravity: 1,280 Check the fuse "IGNITION" "ON". Check for voltage 2V) on the and wiring circuit.
Page 330: Operation
IGNITION SYSTEM DE SC PTI ON This model is equipped with a battery operated, transistorized, breakerless ignition system. By using magnetic pickup coils, the need for contact breaker points is eliminated. This adds to the dependability of the system by eliminating frequent cleaning and adjustment of points and ignition timing.
Page 331: Ignition Spark Gap Test
IGNITION SYSTEM IGNITION SPARK GAP TEST 1. Remove: cover (left) component board Disconnect: coil leads plug leads 3. Connect: Tester NOTE: Be sure to use a fully charge 12V battery 4. Turn the spark plug gap adjuster and increase the gap to the maximum limit unless misfire occurs first.
Page 332: Pickup Coil Resistance Test
IGNITION SYSTEM PICKUP COIL RESISTANCE TEST 1. Remove: Disconnect: connecter (Black, Orange, and Gray) 3. Measure coil resistance Use a Pocket Tester Out of specification Replace. Pickup Coil Resistance: 10% at 20°C Black Orange Gray SPARK PLUG INSPECTION Refer to "CHAPTER SPARK PLUG IN- S PE CT section.
Page 333 IGNITION SYSTEM Removal 1. Remove: cover (left) component board 2. Disconnect: connector hose 3. Remove: sensor Inspection 1. Connect: Tester Measure: voltage Out of specification Replace. Output Voltage: About 2.0 Volt Output voltage Atmospheric pressure Pressure Installation 1. Install: sensor Reverse the removal procedure.
Page 334: Lighting System
LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 7-31...
Page 335 LIGHTING SYSTEM Aforementioned circuit diagram shows lighting circuit in wiring diagram. NOTE: 7-2. For the encircled numbers and color codes, see page "LIGHTS" (Dimmer) switch Headlight "HIGH BEAM" indicator light Meter lights light Fuse (HEAD) Starter switch Main fuse Battery Main switch 7-32...
Page 336 LIGHTING SYSTEM CHECKS TESTS AND The battery provides power for operation of the headlight, taillight, and meter lights. If none of the above fail to operate proceed further. Low battery voltage indicates either a faulty battery, low battery fluid level, or a defective charging system.
Page 337 LI G HTI NG SYSTEM H eadl i ght Troubl eshoot i ng R epl ace. Repl ace. Check m ai n swi t ch, r epl ace i f necessar y. C heck “ STAR T” sw i t ch, i f necessar y. n open or poor co Poor gr ound or poor connect i on of head-...
Page 338 LIGHTING SYSTEM Taillight Troubleshooting TAILLIGHT DOES NOT COME ON WHEN ENGINE IS RUNNING. Faulty Check taillight bulb. Replace. Faulty Check main fuse. Replace. Novoltaae Measure voltage on Blue lead from main Check main switch, replace if necessary. switch ("ON" position). No voltage Measure voltage a t taillight terminal, An open or poor connection between taillight...
Page 339 MEMO ......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7-36...
Page 340 SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 7-37...
Page 341: Signal System
SIGNAL SYSTEM Aforementioned circuit diagram shows signal circuit in wiring diagram. , --- NOTE: 7-2. For the encircled numbers and color codes, see page Horn Flasher relay "HORN" switch unit "OIL indicator light "TURN" switch gauge "TURN" indicator light "NEUTRAL" indicator light light Neutral switch Flasher light...
Page 342: Signal System Tests And Checks
SIGNAL SYSTEM SIGNAL SYSTEM TESTS AND CHECKS The battery provides power for operation of the horn, brakelight, indicator lights and flasher lights. If none of the above operates, always check battery voltage before proceeding further. Battery 1. Check: voltage Defective components Replace.
Page 343 SIGNAL SYSTEM " 01 L LEVEL" Warning Indicator Light 1. Check: light operation Defective components Replace. Defective bulb Defective oil level gauge Check for: 1 2 V on Brown lead to indicator light Flasher Light 1. Check: light operation Refer to " SELF-CANCELLING FLASHER SYSTEM section.
Page 344: Reed Switch Test
SIGNAL SYSTEM REED SWITCH TEST 1. Remove: *Headlight lens unit cover (left) 2. Disconnect: *Relay assembly coupler 3. Measure: Reed switch resistance Use the Pocket Tester Out of specification Replace. Lift the front wheel and rotate the wheel by hand. Then return back when wheel is stopped Black...
Page 345 SIGNAL SYSTEM Operation The handlebar switch has three positions: L (left), OFF, and R (right). The switch lever will return to the "OFF" position after being pushed to L or R, but the signal will function. lever in, the signal may be By pushing the cancelled manually.
Page 346: Switches Test
SIGNAL SYSTEM SWITCHES TEST Switches may be checked for continuity with a on the "Ohm x 1" Pocket Tester position. "LIGHTS" (Dimmer) switch "TURN" switch "HORN" switch "ENGINE STOP" switch "START" switch Main Switch Lead Color Switch Position "LIGHTS" (Dimmer) Switch Lead Color Switch Position "TURN"...
Page 347 SIGNAL SYSTEM Lead Color Switch Position R I B "START" Switch Switch Position Color Code / - - 7-44...
Page 348: Cooling System Circuit Diagram
COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 7-45...
Page 349 COOLING SYSTEM Aforementioned circuit diagram shows cooling circuit in wiring diagram. NOTE: 7-2. For the encircled numbers and color codes, see page Temperature meter Thermo-unit Fuse (SIGNAL) Thermostatic switch Electric fan Fuse Main fuse Battery Main switch 7-46...
Page 350 COOLING SYSTEM TROUBLESHOOTING The electric fan will not turn at coolant temperatures of 105 3°C (221.0 37.4" or more: Defective Correct. Check the connectors. Replace fan motor assembly. No voltage Fan operative Check wiring circuit, and correct defective Check battery voltage on Blue leads. Fan operative Replace the thermostatic switch.
Page 351: Electric Fan And Thermostatic Switch
CO O LI NG SYSTEM ELEC TR I C FA N A N D TH ER M O STA TI C SW I TC H O peration The el ect r i c f an w i l l be sw i t ched O N or O FF accor di ng t o t he cool ant t em per at ur e i n t he radi ator.
Page 352: Thermo-Unit And Thermometer
COOLING SYSTEM 2. Inspect: switch operation By the following inspection steps. Thermostatic switch inspectionsteps: thermostatic switch in water. Thermometer Thermostatic switch Pocket Tester continuity as indicated. Note temperatures while heating the water. Malfunction Replace switch. Pocket Tester Water Temperature Step 0 - 98°C Discontinuity (32-...
Page 353 COOLING SYSTEM Thermo-unit.Inspection 1. Remove: cover (right) n it Handle the thermo-unit with special care. Never subject to strong shock or allow to be drop- ped. Should be dropped, must be replaced. operation the following inspection steps. Thermo-un it inspectionsteps: I mmerse thermo-unit in water.
Page 354: Fuel Pump System
FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM 7-51...
Page 355 FUEL PUMP SYSTEM Aforementioned circuit diagram shows fuel pump circuit in wiring diagram. / -- NOTE: For the encircled numbers and color codes, see page 7-2. "FUEL" indicator light Fuel sender unit Main fuse Battery Main switch Fuse (IGNITION) "ENGINE STOP" switch "FUEL"...
Page 356: Fuel Pump Circuit Operation
FUEL PUMP SYSTEM FUEL PUMP CIRCUIT OPERATION Fuel pump relay Fuel pump The fuel pump circuit consists of the fuel pump Fuel reserve switch in " RES' position relay, fuel pump, and fuel reserve switch. "ON" Fuel reserve switch in position The fuel pump starts and stops as indicated in Ignitor unit...
Page 357: Troubleshooting
FUEL PUMP SYSTEM TROUBLESHOOTING TroubleshootingChart (1) Fuel pump fails to operate after engine is started. , More than 11V Start the engine and the fuel pump input Check fuel pump, replace if necessary. voltage (Blue/Black lead). Less than 11V Check ignitor unit output voltage condition Check fuel pump relay ground lead.
Page 358 FUEL PUMP SYSTEM Troubleshooting chart Fuel pump fails to operate for a interval when carburetor fuel level is low with the main/ engine stop switches turned t o "ON" and fuel reserve switch turned to "RES". More than Check fuel pump, replace if necessary. Stop the engine and turn on the main/ engine stop switches and measure the fuel More than...
Page 359 FUEL PUMP SYSTEM Troubleshooting Chart Fuel pump does not stop after 30 seconds when fuel indicater light on while engine is running. pump input voltage 30 seconds after fuel Check fuel pump connections correct if sender Green lead is grounded (Blue/ necessary.
Page 360: Fuel" (Reserve) Switch Test
FUEL PUMP SYSTEM "FUEL" (RESERVE) SWITCH TEST Switch may be checked for continuity with a Pocket Tester on the "Ohm x 1" position. Lead Color Switch Position FUEL PUMP RELAY TEST 1. Remove: cover (left) 2. Check: pump operation Refer to "FUEL PUMP TEST" section. 3.
Page 361: Fuel Sender Unit Test
FUEL PUMP SYSTEM Cut-out switch Diaphragm Plunger Solenoid coil Fuel chamber Valve Outlet Inspection 1. Connect: Check: pump operation Faulty operation Replace. 3. Inspect: pump Replace. FUEL SENDER UNIT TEST 1. Remove: cover 2. Measure: sender unit resistance Out of specification Replace.
Page 362 V- B O O ST SYSTEM V- B O O ST SYSTEM C I R C U I T D I A G R A M...
Page 363 Aforementioned circuit diagram shows V-boost circuit in wiring diagram. NOTE: For the encircled numbers and color codes, see page 7-2. Ignition coil Spark plug Main fuse Battery Main switch (IGNITION) Fuse "ENGINE STOP" switch V-boost valve control unit Servo motor Ignitor unit Pick-up coil 7-60...
Page 364: V-Boost System
V-BOOST SYSTEM V-BOOST SYSTEM Description The V-Boost consists of a servomotor, a control cable, special intake joints and butterfly valves. The front and rear cylinders are connected by the special intake joint. In the middle of the intake joint is the butterfly valve. The butterfly valve is opened and closed by the servomotor.
Page 365 V- B O O ST SYSTEM O perat i on Ther e i s a l ag i n t i m e bet w een t he st ar t i ng of t he ser vo m ot or and t he openi ng of t he but t er f l y val ves.
Page 366 Valve opens Valve closed Servo motor starts "ON" Main switch second Engine starting Increased engine speed Time Initial operation 8,000 rlmin ----- - 5,730 7-63...
Page 367: V-Boost System
V-BOOST SYSTEM TROUBLESHOOTING Troubleshooting Chart (1) When the main switch is turned on, the Refer to "Troubleshooting Chart butterfly valves operate one cycle. section. Recharge the battery. Check the battery voltage 16V). When the main switch is turned on after Check butterfly valves and control cable the control cable is disconnected, the for mechanical faults.
Page 368 V- B O O ST SYSTEM Troubl eshoot i ng C hart ( 2) W hen t he m ai n sw i t ch i s t urned on, t he but t erf l y val ves operat e one cycl e. uni t and t he V- b C heck the ignitor and the ignition coil.
Page 369: Servo Motor Test
SERVO MOTOR TEST 1. Disconnect: motor coupler 2. Connect: Battery 3. Check: motor operation Not operation Replace. 4. Measure: .Potentiometer resistance Use the Pocket Tester Out of specification Replace. (68°F) 20°C 7-66...
Page 370 CHAPTER 8 APPENDICES ..........SPECIFICATIONS ........GENERAL SPECIFICATIONS ......MAIWTENANCE FICATIONS ......GENERAL TORQUE SPECIFICATIONS 8-18 ........DEFINITION OF UNITS 8-18 ......... CONVERSION TABLES 8-19 ........LUBRICATION DIAGRAMS 8-20 ..........CABLE ROUTING 8-24 ........CONSUMER INFORMATION 8-32 ..........WIRING DIAGRAM 8-33...
Page 371: Chapter 8 . Appendices
SPECIFICATIONS APPENDICES SPECIFICATIONS GENERAL SPECIFICATIONS Engine Starting Number 1 F K-000101 Vehicle Identification Number Dimensions: I Length 2,300 mm (90.6 in) OveraI I Width 795 mm (31.3 in) Overall Height 1,160 mm (45.7 in) Seat Height 765 mm (30.1 in) Wheelbase 1,590 mm (62.6 in) Minimum Ground Clearance...
Page 372 FICATIONS Model Carburetor: BDS 34 x Spark Plug: G K , X24EP IPPON D ENSO anufacturer 0.9 mm (0.031 0.035 in) Clutch Type: Wet, multiple-disc Transmission: Primary ReductionSystem Spar gear Primary Reduction Ratio 87/49 (1.775) Secondary ReductionSystem Shaft drive Secondary Reduction Ratio 21/27 x (2.851) Transmission Type...
Page 373: Maiwtenance Fications
Model Shock Absorber: Front Shock Absorber spring, Oil damper Rear Shock Absorber Coil spring, Oil damper Wheel Travel: Front Wheel Travel 140 mm (5.5 in) Rear Wheel Travel 100 mm (3.9 in) Electrical Ignition System T.C. I. Generator System A.C. magneto generator Battery Type or Model Battery Capacity 12V 16AH...
Page 374 Model 0.03 mm (0.0012 in) Camshaft Runout Limit Cam Chain: Cam Chain of Links Automatic Cam Chain Adjustment Method Valve, Valve Seat, Valve Guide: 0.1 1 0.15 mm (0.004 0.006 in) Valve Clearance (Cold) : 0.26 0.30 mm (0.010 0.012 in) 30.6 mm (1.197 1.205 "...
Page 375 Model Valve Spring: Inner Spring: Free Length 39.65 mm (1.561 in) 39.65 mm (1.561 in) > Limit 37.45 mm 1.474 in) 37.45 mm (1.474 in) Set Length (ValveClosed) 31.8 mm (1.25 in) 31.8 mm (1.25 in) Compressed Pressure (Installed) 6.29 7.39 13.9 16.3 Ib)
Page 376 Model 76.25 mm (3.002 in) Oversize: 76.50 mm (3.012 in) Piston Ring: Ring: Barrel Dimensions 3.1 x 1.0 mm (0.122 x 0.040 in) 0.35 0.50 mm (0.0138 0.0197 in) (Installed) < 0.75 mm (0.0295 in) Limit Side Clearance (Installed) 0.03 0.07 mm (0.0012 0.0028 in) Limit...
Page 377 SPECIFICATIONS Model Shifter: Guide Bar Shifter Type 0.025 mm (0.001 in) Guide Bar Bending Limit Carburetor: 1FKOO 1JHOO I.D. Mark Main Jet Main Air Jet Jet Needle (N.J.) Y -0 Needle Jet Pilot Jet Pilot Air Jet (P.A.J. (P.A.J. Preset Pilot Screw Pilot Outlet Bypass...
Page 378 FICATIONS Model Lubrication Chart: Intake camshaft Cylinder head Crankcase Tightening Sequence: Lower Case With...
Page 379 SPECIFICATIONS Model Cooling System: 363.8 rnrn (14.3 in) Radiator Core Size: Width Height 240 mm (9.45 in) Thickness 16 rnrn (0.63 in) 73.6 103.0 Radiator Cap Opening Pressure (0.75 1.05 10.7 14.9 psi) 0.3 L (0.26 Imp qt, 0.32 US Reservoir Tank Capacity <...
Page 380 TIGHTENING TORQUE Tightening Torque Part to be Tightened Part Name Thread Size Q'ty Remarks Camshaft Cap Bolt M6 x 1.0 Spark Plug M12 x 1.25 17.5 1.75 12.5 Cylinder Head x 1.25 Cylinder Head Cover Bolt M6 x 1.0 Connecting Rod Bolt M8 x 0.75 AC Magneto...
Page 381 Tightening Torque Part t o be Tightened Part Name Thread Size Q'ty Remarks Crankcase Bolt M6 x 1.0 Crankcase M8 x 1.25 Bolt Crankcase Bolt 1.25 Dive Axle Bearing Retainer M8 x 1.25 Torx screw Stake Main Axle Bearing Retainer Screw M6 x 1.0 Crankcase Cover (Left)
Page 382 Chassis Model Steering System: Taper roller bearing Steering Bearing Type Front Suspension: 140 mm (5.51 in) Front Fork Travel 492.5 mm (19.4 in) Fork Spring Free Length < 487.5 mm (19.2 in) Limit> 136 mm (5.35 in) Collar Length Spring Rate: 3.92 22.4 4.90...
Page 383 Model Master Cylinder Inside Diameter 15.87 mm (0.63 in) Caliper Cylinder Inside Diameter 45.4 mm (1.79 in) Brake Fluid Type Rear Disc Brake: Single 7.5 mm (11.1 x 0.30 in) Disc Outside Diameter x Thickness 5.5 mm (0.22 in) Pad Thickness Inner <...
Page 384 SPECIFICATIONS TIGHTENING TORQUE: Tightening Torque Part to be Tightened Thread Size Remarks Front Wheel Axle Front Axle Pinch Bolt M8 x 1.25 Under Bracket Inner Tube M8 x 1.25 M8 x 1.25 Steering Crown Inner Tube Steering Crown Steering Shaft M22 x 1.0 11.0 M25 x 1.0...
Page 385 FICATIONS Electrical Model Voltage: Ignition System: Timing 3" 1,000 Advanced Timing (B.T.D.C.) 43" 9,000 Advancer Type Vacuum and electrical T.C. Pickup Coil Resistance 15% a t 20°C (68°F) (Orange Black), (Orange Gray) (Orange (Orange T.C.I. I TACHI Ignition Coil: CM1 1 -61 Primary Winding Resistance 20°C (68°F) Secondary Winding Resistance...
Page 386 Model Voltage ReguI /--- Short control INDEN G EN No Load Regulated Voltage 14- 15V Rectifier: I N D ENGEN Capacity Withstand Voltage 200v Battery: Capacity 16AH Specific Gravity 1.280 Electric Starter System: Constant mesh type Starter Motor: o u t put Bush: Overall Length 12.5 mm (0.49 in)
Page 387 SPECIFICATIONS Mode I Starting Circuit Cut-off Relay: T- 1 00-Y 1 Coil Winding Resistance 10% a t 20°C (68" Diode Yes. Fuel Pump Relay: 10% a t 20" C Coil Winding Resistance Electric Fan: PPONDENSO Thermostatic Switch: I PPON THE RMOSTAT Thermo-unit: ufacturer Circuit Breaker :...
Page 388: General Torque Specifications
GENERAL TORQUE UNITS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners General torque I.S.O. pitch threads. Torque with standard if i ca ions spec (Bolt) (Nut) specifications for special components or assem- blies are included in the applicable sections of 10 mm 6 mm this book.
Page 389: Conversion Tables
CONVERSION TABLES CONVERSION TABLES Metric t o inch system Inch t o metric system Known Multiplier Result Known Multiplier Result 7.233 0.13826 86.80 0.01 152 0.0723 13.831 0.8680 1.1521 0.4535 0.03527 28.352 2.352 0.4252 0.6214 1.609 0.6214 1.609 3.281 0.3048 1.094 0.9141 0.3937...
Page 390: Lubrication Diagrams
LUBRICATION DIAGRAMS LUBRICATION AG RAMS LUBRICATION DIAGRAM 8-20...
Page 391 LUBRICATION DIAGRAMS LUBRICATION DIAGRAM (2)
Page 392 LUBRICATION AG RAMS LUBRICATION DIAGRAM 8-22...
Page 393 LUBRICATION DIAGRAMS LUBRICATION DIAGRAM (4)
Page 394 Headlight body @Brake joint Hose guide Wireharness Front flasher light lead (Left) light lead Clutch hose @Front flasher light lead (Right) Speedometer cable Front brake hose Front brake hose / - - 8-24...
Page 395: Cable Routing
CABLE ROUTING Fuel pump control unit Sidestand relay Pass the handlebar switch lead Relay unit inside the clutch hose V-boost valve control unit Radiator fan lead Pass the meter lead outside the V-boost valve control unit lead Horn lead u tch hose. Clamp Pass the clutch hose outside the hose clamp...
Page 396 CABLE ROUTING Main fuse (For clutch hose) Ignition coil Clamp (For sidestand switch lead) Oil level switch lead Clamp Neutral switch lead Clamp (For clutch hose) Regulater lead Starter relay Sidestand switch lead Pass the band through the guide on frame lead on frame.
Page 397 CABLE ROUTING Handlebar switch lead cover fuse Diode lead pump Ignitor unit flasher light lead (Left) Fuse box Ignition coil lead coil lead V-boost valve control unit Conduit lead up coil lead @Meter lead Band @Starter relay lead Clamp the taillight lead and @Starter motor lead rear flasher light lead (Right) Battery negative...
Page 398 @Earth lead negative lead Pass the wireharness outside the reservoir main switch stay. 'switch lead (Left) Band Earth lead: coil @Main switch lead Pass the earth lead outside the conduit switch reservoir tank breather hose. Earth lead brake reservoir tank Guide (For battery breather hose, Rear brake switch lead @Battery box...
Page 399 CABLE ROUTING Fuel filter bracket Battery band Fuel filter Fuel pump Fuel pipe Clamp cover Fuel pipe Filler cap...
Page 400 CABLE ROUTING flow hose Reservoir tank Over valve clip Spring Holder clip Filler cover Fuel sender Pipe joint clip Battery breather hose Drain hose Band 8-30...
Page 401 CABLE ROUTING CANISTER PIPE ROUTING To carburetor To fuel tank Canister...
Page 402: Consumer Information
CONSUMER IN FORMATION CONSUMER IN NOTICE The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions. These figures indicate braking performance that can be met or exceeded by the vehicles to which they apply, without locking the wheels, under different conditions of loading and with partial failures of the braking system.
Page 403 ............. .
Page 404 Being a Yamaha owner, you obviously prefer a quality product. 1 Real 2. Authentic, not artificial Yamaha. PARTS GENUINE ACCESSORIES & Don't compromise the quality and performance of your Yamaha with off-brand alternatives. You'll be getting exactly what you're paying...
Page 405 PROTECT YOUR INVESTMENT Genuine YAMAHA Parts And Accessories LIT-11616-VM-13 YAMAHA MOTOR CORPORATION, U.S.A PRINTED IN U.S.A.

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Yamaha VMX12H Supplementary Service Manual

Table of Contents

Table of Contents

General Information . Chapter 1

Chapter 1 . General Information

Chapter 2

Engine Overhaul

Chapter 3

Chapter 4

Chapter 5

.

Chapter 7

Chapter 8 . Appendices

Quick Links

Chapters

Troubleshooting

Related Manuals for Yamaha VMX12H

Summary of Contents for Yamaha VMX12H