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3 2:46 PM Page 1

T110LE

SERVICE MANUAL

3P9-F8197-E0
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EAS00000

T110LE
SERVICE MANUAL
©2005 by Yamaha Motor Co., Ltd.
First edition, November, 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
3P9-F8197-E0_1 05.11.3 1:15 PM Page B

EAS00002

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

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

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

EAS00004

IMPORTANT MANUAL INFORMATION

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

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

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

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

the vehicle.

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

3P9-F8197-E0_1 05.11.3 1:15 PM Page C

HOW TO USE THIS MANUAL

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

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step - by - step format. The informa-
tion has been compiled to provide the mechanic with a easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of mark “▼” or “▲” with each pro-
cedure preceded by “8”.

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

EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
3P9-F8197-E0_1 05.11.3 1:15 PM Page D
3P9-F8197-E0_1 05.11.3 1:15 PM Page E

1 2 SYMBOLS
The following symbols are not relevant to every
GEN SPEC vehicle.
INFO Symbols 1 to 8 indicate the subject of each
chapter.
3 4
1 General information
CHK 2
ENG Specifications
ADJ 3 Periodic checks and adjustments
4 Engine
5 6 5 Carburetor
6 Chassis
7 Electrical system
CARB CHAS 8 Troubleshooting

7 8 Symbols 9 to y indicate the following.

TRBL 9 Serviceable with engine mounted

ELEC SHTG 0 Filling fluid
q Lubricant
9 0 w Special tool
e Tightening torque
r Wear limit, clearance
t Engine speed
y Electrical data
q w
Symbols u to s in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.

e r u Engine oil
i Gear oil
o Molybdenum-disulfide oil
p Wheel-bearing grease
a Lithium-soap-based grease
s Molybdenum-disulfide grease
t y
Symbols d to f in the exploded diagrams indi-
cate the following.

d Apply locking agent (LOCTITE®)

u i o
f Replace the part

p a s

d f

LT New
3P9-F8197-E0_1 05.11.3 1:15 PM Page F
3P9-F8197-E0_1 05.11.3 1:15 PM Page G

TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS
SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE
ENG
4
CARBURETOR
CARB
5
CHASSIS
CHAS
6
ELECTRICAL SYSTEM
ELEC
7
TROUBLESHOOTING TRBL
SHTG 8
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GEN
INFO
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION ................................................................................... 1-1
VEHICLE IDENTIFICATION NUMBER ............................................................. 1-1
ENGINE SERIAL NUMBER ............................................................................... 1-1

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

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

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

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

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GEN
INFO
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GEN
VEHICLE IDENTIFICATION INFO
EAS00014

1 GENERAL INFORMATION
VEHICLE IDENTIFICATION
EAS00017

VEHICLE IDENTIFICATION NUMBER

The number 1 is stamped into the frame as
shown.

ENGINE SERIAL NUMBER

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

1-1
3P9-F8197-E0_1 05.11.3 1:15 PM Page 2

GEN
IMPORTANT INFORMATION INFO
EAS00020

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

EAS00021

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

EAS00022

GASKETS, OIL SEALS AND O-RINGS

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

1-2
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GEN
IMPORTANT INFORMATION INFO
EAS00023

LOCK WASHERS/PLATES AND COT-

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

EAS00024

1 BEARINGS AND OIL SEALS

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

1 Oil seal
300-003

cC
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.

1
1 Bearing

300-002

EAS00025

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

1-3
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GEN
CHECKING THE CONNECTIONS INFO
EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
9lead
9coupler
9connector
2. Check:
9lead
9coupler
9connector
Moisture → Dry with compressed air.
Rust/stains → Connect and disconnect
several times.
3. Check:
9all connections
Loose connection → Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
1
4. Connect:
9lead
9coupler
9connector

NOTE:
Make sure all connections are tight.

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

NOTE:
8If there is no continuity, clean the terminals.
8When checking the wire harness, perform
steps (1) to (3).
8As a quick remedy, use a contact revitalizer
available at most part stores.

1-4
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GEN
SPECIAL TOOLS INFO
EAS00027

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

Tool No. Tool name/Usage Illustration

Meter gear bush tool

90890-01052

This tool is used to remove or install the

bushing.
Crankcase separating tool

90890-01135

This tool is necessary for separating the

crankcase.

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

90890-01184

This tool is used for to install the oil seal.

Fork seal driver attachment

90890-01186

This tool is used to install the oil seal.

Ring nut wrencht

90890-01268

This tool is used to loosen and tighten

the steering ring nut
Crankshaft instoller pot

90890-01274

This tool is necessary for installing the

crankshaft.

1-5
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GEN
SPECIAL TOOLS INFO

Tool No. Tool name/Usage Illustration

Crankcase installer bolt

90890-01275

This tool is necessary for installing the

crankshaft.

Adoptor (M12)

90890-01278

This tool is necessary for installing the

crankshaft.

Tappet adjusting tool

90890-01311

This tool is necessary for adjusting

valve clearance.
Fuel level gauge

90890-01312

This gauge is used to measure the fuel

level in the float chamber.

T-handle

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

Flywheel puller

90890-01362

This tool is used for removing the roter.

Steering nut wrencht

R20

90890-01403

This tool is used to loosen and tighten

the steering ring nut

Sheave holder

90890-01701

This tool is used for holding the

generator roter.

1-6
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GEN
SPECIAL TOOLS INFO

Tool No. Tool name/Usage Illustration

Thickness gauge

90890-03079

This tool is used to measure the valve

clearance.

Compression gauge

90890-03081

These tools are used to measure the

engine compression.

Pocket tester

90890-03112

This instrument is necessary for

checking the electrical system.

Engine tachometer

90890-03113

This tool is needed for detecting engine

rpm.

Valve spring compressor

90890-04019 M6xP1.0
Ø31

This tool is used when removing or

installing the valve and valve spring.
Spacer

90890-04081

This tool is necessary for insatlling the

crankshaft.

Universal clutch holder

90890-04086
This tool is needed to hold the clutch
when removing or installing the clutch
boss nut.

Valve lapper

90890-04101
This tool is used for removeing and
installing the lifter and for lapping the
valve.

1-7
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GEN
SPECIAL TOOLS INFO

Tool No. Tool name/Usage Illustration

Valve guide remover (4.5 mm)

90890-04116

This tool is needed to remove and

installing the valve guide.
Valve guide installer (4.5 mm)

90890-04117

This tool is needed to install the valve

guide.

Valve guide reamer (4.5 mm)

90890-04118

This tool is needed rebore the new

valve guide.
Ignition checker

90890-06754

This instrument is necessary for check-

ing the ignition system components.

Yamaha bond No. 1215

90890-85505

This sealant (bond) is used for crankcase

mating surface, etc.

1-8
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SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ............................................................................... 2-1

MAINTENANCE SPECIFICATIONS ...................................................................... 2-4

ENGINE ............................................................................................................ 2-4
TIGHTENING TORQUES ................................................................................. 2-10
CHASSIS ........................................................................................................... 2-12
TIGHTENING TORQUES ................................................................................. 2-14
ELECTRICAL .................................................................................................... 2-15

GENERAL TIGHTENING TORQUE SPECIFICATIONS ........................................ 2-17

LUBRICATION POINTS AND LUBRICANT TYPES ............................................. 2-18

ENGINE ............................................................................................................ 2-18
CHASSIS ........................................................................................................... 2-20

CABLE ROUTING .................................................................................................. 2-21

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SPEC
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GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model T110LE
Model code 3P91
Dimensions
Overall length 1,890 mm (74.4 in)
Overall width 665 mm (26.2 in)
Overall height 1,030 mm (40.6 in)
Seat height 770 mm (30.3 in)
Wheelbase 1,195 mm (47.0 in)
Minimum ground clearance 135 mm (5.31 in)
Minimum turning radius 1,900 mm (74.8 in)
Weight
Wet (with oil and full fuel tank) 99 kg (218 lb)
Engine
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 110.3 cm3 (6.73 cu. in)
Bore × stroke 51.0 × 54.0 mm (2.01 × 2.13 in)
Compression ratio 9.3 : 1
Compression pressure (STD) 1,300 kPa (13 kgf/cm2) at 500 r/min
Starting system Kick and electric starter
Lubrication system Wet sump
Engine idling speed 1,400 − 1,600 r/min
Oil type or grade
Engine oil SAE 20W40 API service SE, SF, SG type or
higher
Periodic oil change amount 0.8 L (0.85 US qt)(0.70 lmp.qt)
Total amount 1.0 L (1.06 US qt)(0.88 lmp.qt)
Air filter Dry type element
Fuel
Recommended fuel Regular gasoline
Fuel tank capacity 4.2 L (1.11 US gal)(0.92 lmp gal)

2-1
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GENERAL SPECIFICATIONS SPEC

Model T110LE
Carburetor
Type/quantity VM17SH/1
Manufacturer MIKUNI
Spark plug
Type C6HSA
Manufacturer NGK
Spark plug gap 0.6 − 0.7 mm (0.024 − 0.028 in)
Clutch type Wet, multiple-disc and centrifugal automatic
Transmission
Primary reduction system Spur gear
Primary reduction ratio 67/18 (3.722)
Secondary reduction system Chain drive
Secondary reduction ratio 35/15 (2.333)
Transmission type Constant mesh 4-speed
Operation Left foot operation
Gear ratio 1st 38/12 (3.166)
2nd 33/17 (1.941)
3rd 29/21 (1.380)
4th 23/21 (1.095)
Chassis
Frame type Steel tube underbone
Caster angle 26.20°
Trail 73 mm (2.87 in)
Tire
Type With tube
Size front 70/90-17 38P
rear 80/90-17 44P
Model (manufacturer) front LOCAL MADE
rear LOCAL MADE
Min. tire tread depth front 0.8 mm (0.03 in)
rear 0.8 mm (0.03 in)
Tire pressure (cold tire)
Up to 90 kg load front 200 kPa (29 psi)(2.00 kgf/cm2)(2.00 bar)
rear 225 kPa (33 psi)(2.25 kgf/cm2)(2.25 bar)
90 kg − maximum load* front 200 kPa (29 psi)(2.00 kgf/cm2)(2.00 bar)
rear 225 kPa (33 psi)(2.25 kgf/cm2)(2.25 bar)
* Load is the total weight of cargo, rider, passenger,and accessories.

2-2
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GENERAL SPECIFICATIONS SPEC

Model T110LE
Brake
Front brake type Drum brake
operation Right hand operation
Rear brake type Drum brake
operation Right foot operation
Suspension
Front suspension Telescopic fork
Rear suspension Swingarm
Shock absorber
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel
Front wheel travel 95 mm (3.74 in)
Rear wheel travel 77 mm (3.03 in)
Electrical
Ignition system DC. C.D.I.
Generator system A.C. magneto
Battery type/manufacturer YB5L-B/YUASA
GM5Z-3B/GS
Battery capacity 12 V 5 AH
Headlight type Incandescence
Bulbs (voltage/wattage × quantity)
Headlight 12 V, 32 W/32 W × 1
Tail/brake light 12 V, 5 W/21 W × 1
Front turn signal light 12 V, 10 W × 2
Rear turn signal light 12 V, 10 W × 2
Meter light 12 V, 1.7 W × 1
High beam indicator light 12 V, 1.7 W × 1
Neutral indicator light 12 V, 1.7 W × 1
Turn signal indicator light 12 V, 1.7 W × 1
Gear position indicator light 12 V, 1.7 W × 4
Auxiliary light 12 V, 5 W × 2

2-3
3P9-F8197-E0_2 05.11.18 9:25 AM Page 4

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head
Max. warpage “*” ---- 0.03 mm
(0.0012 in)

Cylinder
Bore 51.000 − 51.015 mm (2.0079 − 2.0085 in) 51.1 mm
(2.03 in)
Out of round limit ---- 0.03 mm
(0.0012 in)
Camshaft
Drive Method Chain drive (left)
Cam dimensions
Intake “A” A 25.775 − 25.875 mm (1.0148 − 1.0187 in) 25.745 mm
(1.0136 in)
“B” 21.045 − 21.145 mm (0.8285 − 0.8325 in) 21.015 mm
(0.8274 in)
Exhaust “A”
B 25.775 − 25.875 mm (1.0148 − 1.0187 in) 25.749 mm
(1.0137 in)
“B” 20.950 − 21.050 mm (0.8248 − 0.8287 in) 20.924 mm
(0.8238 in)

Camshaft runout limit ---- 0.03 mm

(0.0012 in)
Timing chain
Timing chain type/No. of links SILENT CHAIN/86 ----
Tensioning system Automatic ----
Rocker arm/rocker arm shaft
Rocker arm inside diameter 10.000 − 10.015 mm (0.3937 − 0.3943 in) 10.030 mm
(0.3949 in)
Rocker arm shaft outside diameter 9.981 − 9.991 mm (0.3930 − 0.3933 in) 9.950 mm
(0.3917 in)
Rocker-arm-to-rocker-arm-shaft 0.009 − 0.034 mm (0.0004 − 0.0013 in) 0.08 mm
clearance (0.0032 in)

2-4
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MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.05 − 0.09 mm (0.0020 − 0.0035 in) ----
EX 0.08 − 0.12 mm (0.0032 − 0.0045 in) ----
Valve dimensions

B C
D
A
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 22.9 − 23.1 mm (0.9016 − 0.9094 in) ----
EX 19.9 − 20.1 mm (0.7835 − 0.7913 in) ----
“B” face width IN 1.2 − 2.5 mm (0.0472 − 0.0984 in) ----
EX 1.6 − 2.9 mm (0.0630 − 0.1142 in) ----
“C” seat width IN 0.9 − 1.1 mm (0.0354 − 0.0433 in) 1.6 mm
(0.06 in)
EX 0.9 − 1.1 mm (0.0354 − 0.0433 in) 1.6 mm
(0.06 in)
“D” margin thickness IN 0.5 − 0.9 mm (0.0197 − 0.0354 in) ----
EX 0.8 − 1.2 mm (0.0315 − 0.0472 in) ----
Valve stem outside diameter IN 4.475 − 4.490 mm (0.1762 − 0.1768 in) 4.450 mm
(0.1752 in)
EX 4.460 − 4.475 mm (0.1756 − 0.1762 in) 4.435 mm
(0.1746 in)
Valve guide inside diameter IN 4.500 − 4.512 mm (0.1772 − 0.1776 in) 4.542 mm
(0.1788 in)
EX 4.500 − 4.512 mm (0.1772 − 0.1776 in) 4.542 mm
(0.1788 in)
Valve-stem-to-guide clearance IN 0.010 − 0.037 mm (0.0004 − 0.0015 in) 0.08 mm
(0.0032 in)
EX 0.025 − 0.052 mm (0.0010 − 0.0020 in) 0.10 mm
(0.0039 in)
Valve stem runout limit ---- 0.01 mm
(0.0004 in)
Valve seat width IN/EX 0.9 − 1.1 mm (0.0354 − 0.0433 in) 1.6 mm
(0.06 in)

2-5
3P9-F8197-E0_2 05.11.18 9:25 AM Page 6

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Valve spring
Free length IN/EX 33.75 mm (1.33 in) 32.05 mm
(1.26 in)
Installed length (valve closed) IN/EX 24.2 mm (0.95 in) ----
Compressed spring force IN/EX 138 − 148 N (31.02 − 33.27 lb, ----
14.07 − 15.09 kgf)
Tilt limit “*” IN/EX 2.5 °/1.4 mm 1.4 mm
(0.06 in)

Winding direction IN/EX Clockwise ----

Piston
Piston-to-cylinder clearance 0.020 − 0.025 mm (0.0008 − 0.0010 in) 0.15 mm
(0.0059 in)
Piston size “D” 50.977 − 50.992 mm (2.0070 − 2.0076 in) ----
Measuring point “H” 4.0 mm (0.158 in) ----
Offset H 0.5 mm (0.0197 in) ----
D
Offset direction Intake side ----
Piston pin bore inside diameter 13.002 − 13.013 mm (0.5119 − 0.5123 in) 13.043 mm
(0.5135 in)
Piston pin outside diameter 12.996 − 13.000 mm (0.5117 − 0.5118 in) 12.976 mm
(0.5109 in)
Piston rings
Top ring
Ring type B Barrel ----
Dimensions (B × T) T 1.0 × 2.0 mm (0.04 × 0.08 in) ----
End gap (installed) 0.10 − 0.25 mm (0.0039 − 0.0098 in) 0.40 mm
(0.0157 in)
Ring side clearance (installed) 0.03 − 0.07 mm (0.0012 − 0.0028 in) 0.12 mm
(0.0047 in)
2nd ring
Ring type Taper ----
B
Dimensions (B × T) 1.0 × 2.0 mm (0.04 × 0.08 in) ----
T
End gap (installed) 0.10 − 0.25 mm (0.0039 − 0.0098 in) 0.40 mm
(0.0157 in)
Ring side clearance 0.02 − 0.06 mm (0.0008 − 0.0024 in) 0.12 mm
B (0.0047 in)
Oil ring T
Dimensions (B × T) 2.0 × 2.2 mm (0.08 × 0.09 in) ----
End gap (installed of oil ring rails) 0.20 − 0.70 mm (0.0079 − 0.0276 in) ----

2-6
3P9-F8197-E0_2 05.11.18 9:25 AM Page 7

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Crankshaft
C C

E
D

A
Crank width “A” 42.95 − 43.00 mm (1.691 − 1.693 in) ----
Max. runout limit “C” ---- 0.03 mm
(0.0012 in)
Big end side clearance “D” 0.11 − 0.41 mm (0.0043 − 0.0161 in) ----
Big end radial clearance “E” 0.004 − 0.014 mm (0.0002 − 0.0006 in) ----
Clutch
Friction plates
Thickness 2.7 − 2.9 mm (0.106 − 0.114 in) 2.6 mm
(0.1024 in)
Plate quantity 5pcs ----
Clutch plates
Thickness 1.1 − 1.3 mm (0.043 − 0.051 in) ----
Plate quantity 4pcs ----
Max. warpage ---- 0.05 mm
(0.0019 in)
Clutch springs
Free length 30.3 mm (1.19 in) 28.3 mm
(1.11 in)
Spring quantity 4pcs ----
Clutch release method Inner push, cam push ----
Clutch shoe thickness 2.20 mm (0.0866 in) ----
Clutch shoe groove depth 1.20 mm (0.0472 in) 0.1 mm
(0.0039 in)
Clutch housing inside diameter 105 mm (4.13 in) 106 mm
(4.17 in)
Weight outside diameter 105 mm (4.13 in) 103.8 mm
(4.09 in)
Clutch - in revolution 1,800 − 2,200 r/min ----
Clutch - stall revolution 3,100 − 3,700 r/min ----
Push rod bending limit ---- 0.5 mm
(0.0197 in)
Transmission
Main axle runout limit ---- 0.03 mm
(0.0012 in)
Drive axle runout limit ---- 0.03 mm
(0.0012 in)

2-7
3P9-F8197-E0_2 05.11.18 9:25 AM Page 8

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Kickstarter
Kickstarter type Ratchet type ----
Kick clip friction force 5.8 − 14.7 N (1.3 − 3.3 lb)(0.59 − 1.50 kgf) ----
Carburetor
Type VM17SH ----
I.D. mark 5TP6 00 ----
Main jet (M.J) #105 ----
Main air jet (M.A.J) ø1.2 ----
Jet needle (J.N) 4CJT5-2 ----
Needle jet (N.J) E-8M ----
Pilot outlet (P.O) ø0.8 (pitch: 1.70) ----
Pilot jet (P.J) #17.5 ----
Pilot air screw turns out 1-3/8 ----
Valve seat size ø1.5 ----
Starter jet 1 #32.5 ----
Starter jet 2 ø0.6 ----
Throttle valve size #3.5 ----
Fuel level 3.0 mm (0.12 in) ----
Oil pump
Oil pump type Trochoid type ----
Inner-rotor-to-outer-rotor-tip clear- 0.15 mm (0.0059 in) 0.20 mm
ance (0.0079 in)
Outer-rotor-to-oil-pump housing 0.06 − 0.10 mm (0.0024 − 0.0039 in) 0.15 mm
clearance (0.0059 in)
Oil-pump-housing-to-inner-rotor-and- 0.06 − 0.10 mm (0.0024 − 0.0039 in) 0.15 mm
outer-rotor clearance (0.0059 in)

2-8
3P9-F8197-E0_2 05.11.18 9:25 AM Page 9

MAINTENANCE SPECIFICATIONS SPEC

Model T110LE
Lubrication chart
OIL RING PISTON CYLINDER HEAD CAMSHAFT

CONNECTING
ROD BIG END

CRANKSHAFT

CLUTCH TRANSMISSION
OIL PUMP

OIL STRAINER

OIL PAN

2-9
3P9-F8197-E0_2 05.11.18 9:25 AM Page 10

MAINTENANCE SPECIFICATIONS SPEC

TIGHTENING TORQUES
ENGINE
Tightening
Thread
Part to be tightened Part name Q’ty torque Remarks
size
Nm m·kg ft·lb
Cylinder head Nut M8 4 22 2.2 16
Cylinder head (timing chain side) Bolt M6 2 10 1.0 7.2
Spark plug — M10 1 12.5 1.25 9.0
Camshaft sprocket cover Screw M6 2 7 0.7 5.0
Tappet cover (intake and exhaust side) — M45 2 18 1.8 13
Stud bolt (cylinder head) Bolt M6 2 7 0.7 5.0
Generator rotor Nut M12 1 70 7.0 5.0
Timing chain guide (intake side) Bolt M6 2 10 1.0 7.2 LT

Valve adjusting screw locknut (intake Nut M5 2 7 0.7 5.0

and exhaust side)
Camshaft sprocket Bolt M8 1 20 2.0 15
Camshaft retainer Bolt M8 2 10 1.0 7.2
Timing chain tensioner cap bolt Bolt M6 1 8 0.8 5.8
Timing chain tensioner Bolt M6 2 10 1.0 7.2
Oil pump assembly Bolt M6 2 7 0.7 5.0
Engine oil drain bolt Bolt M12 1 20 2.0 15
Intake manifold (engine side) Bolt M6 2 10 1.0 7.2
Carburetor assembly Bolt M6 2 10 1.0 7.2
Exhaust pipe Nut M6 2 7 0.7 5.0
Muffler and muffler bracket Bolt M8 1 16 1.6 12
Muffler and passenger footrest Bolt M10 1 38 3.8 28
Air cut-off valve assembly Bolt M6 2 7 0.7 5.0
Air induction system pipe Bolt M6 2 10 1.0 7.2
Air filter (Air induction system) Screw M6 2 12 1.2 8.6
Air filter case Screw M6 4 2 0.2 1.4
Crankcase Bolt M6 9 10 1.0 7.2
Crankcase cover (left) Bolt M6 8 10 1.0 7.2
Drive sprocket cover Bolt M6 2 7 0.7 5.0
Crankcase cover (right) Bolt M6 9 10 1.0 7.2
Center plug — M32 1 7 0.7 5.0
Timing check plug — M14 1 7 0.7 5.0
Stud bolt (crankcase) Bolt M8 4 13 1.3 9.4
Kickstarter lever Bolt M6 1 10 1.0 7.2
Starter clutch Bolt M6 3 14 1.4 10.1 stake
Clutch shoe housing Nut M12 1 50 5.0 36
Clutch pressure plate Bolt M5 4 6 0.6 4.3
Clutch boss Nut M14 1 70 7.0 50
Clutch release adjusting locknut Nut M6 1 8 0.8 5.8
Shift pedal Bolt M6 1 10 1.0 7.2
Shift drum segment Bolt M6 1 12 1.2 8.6 LT

2-10
3P9-F8197-E0_2 05.11.18 9:25 AM Page 11

MAINTENANCE SPECIFICATIONS SPEC

Tightening
Thread
Part to be tightened Part name Q’ty torque Remarks
size
Nm m·kg ft·lb
Pickup coil Bolt M6 2 10 1.0 7.2 LT

Stator coil Bolt M6 3 10 1.0 7.2 LT

Neutral switch Bolt M5 2 4 0.4 2.9 LT

2-11
3P9-F8197-E0_2 05.11.18 9:25 AM Page 12

MAINTENANCE SPECIFICATIONS SPEC

CHASSIS

Item Standard Limit

Steering system
Steering bearing type Ball and race bearing ----
Lock-to-lock angle (left/right) 45° ----
Front suspension
Front fork travel 95 mm (3.74 in) ----
Fork spring free length 266.7 mm (10.50 in) 261.4 mm
(10.29 in)
Installed length 264.7 mm (10.42 in) ----
Spring rate (K1) 11 N/mm (62.81 lb/in)(1.12 kgf/mm) ----
(K2) 17.2 N/mm (98.21 lb/in)(1.75 kgf/mm) ----
Stroke (K1) 0 − 64 mm (0.00 − 2.52 in) ----
(K2) 64 − 95 mm (2.52 − 3.74 in) ----
Optional spring available No ----
Oil capacity 0.061 L (61 cm3) ----
Oil level 87.0 mm (3.43 in) ----
Recommended oil Fork oil 10W or equivalent ----
Inner tube outer diameter 26 mm ----
Inner tube bend limit ---- 0.2 mm
(0.008 in)
Rear suspension
Shock absorber stroke 70 mm (2.76 in) ----
Spring free length 231.4 mm (9.11 in) 226.8 mm
(8.93 in)
Installed length 216.4 mm (10.29 in) ----
Spring rate (K1) 17.41 N/mm (99.41 lb/in)(1.78 kgf/mm) ----
(K2) 30.78 N/mm (175.75 lb/in)(3.14 kgf/mm) ----
Stroke (K1) 0 − 34 mm (0 − 1.34 in) ----
(K2) 34 − 70 mm (1.34 − 2.76 in) ----
Optional spring available No ----
Front wheel
Type Spoke wheel ----
Rim size 17 × 1.40 ----
Rim material Steel ----
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 0.5 mm
(0.02 in)

2-12
3P9-F8197-E0_2 05.11.18 9:25 AM Page 13

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Rear wheel
Type Spoke wheel ----
Rim size 17 × 1.40 ----
Rim material Steel ----
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 0.5 mm
(0.02 in)
Drive chain
Type/manufacturer 428/FSCM ----
Link quantity 98 ----
Drive chain slack 25 − 35 mm (0.98 − 1.38 in) ----
Front brake
Drum brake type Leading, trailing ----
Brake drum inside diameter 110.0 mm (4.33 in) 111.0 mm
(4.37 in)
Lining thickness 4.0 mm (0.16 in) 2.0 mm
(0.08 in)
Shoe spring free length 1 52.0 mm (2.05 in) 61.2 mm
(2.41 in)
Shoe spring free length 2 48.0 mm (1.89 in) 56.5 mm
(2.22 in)
Front brake lever free play 8.0 − 12.0 mm (0.31 − 0.47 in) ----
Rear brake
Drum brake type Leading, trailing ----
Rear brake pedal free play (pedal 20 − 30 mm (0.79 − 1.18 in) ----
end)
Drum inside diameter 130 mm (5.12 in) 131 mm
(5.16 in)
Lining thickness 4.0 mm (0.16 in) 2.0 mm
(0.08 in)
Shoe spring free length 1 52.0 mm (2.05 in) 61.2 mm
(2.41 in)
Shoe spring free length 2 48.0 mm (1.89 in) 56.5 mm
(2.22 in)
Throttle cable free play 3 − 7 mm (0.12 − 0.28 in) ----

2-13
3P9-F8197-E0_2 05.11.18 9:25 AM Page 14

MAINTENANCE SPECIFICATIONS SPEC

TIGHTENING TORQUES
CHASSIS
Tightening torque
Part to be tightened Thread size Remarks
Nm m·kg ft·lb
Handlebar bracket and lower bracket M10 53 5.3 38
Handlebar and handlebar bracket M8 16 1.6 12
Brake lever holder M6 7 0.7 5.0
Rear view mirror (left and right) M10 32 3.2 23
Front wheel axle nut M10 39 3.9 28
Lower bracket and front fender M6 10 1.0 7.2
Front fork cap bolt M20 20 2.0 15
Lower bracket pinch bolt M10 38 3.8 27
Damper rod bolt M8 23 2.3 17 LT

Upper ring nut M25 75 7.5 54 See NOTE

Lower ring nut M25 30 3.0 22 See NOTE
Brake camshaft and brake camshaft lever M6 7 0.7 5.0
Driven sprocket and rear wheel drive hub M8 30 3.0 22
Rear wheel axle nut M12 60 6.0 43
Rear shock absorber and frame M10 32 3.2 23
Rear shock absorber and swingarm M10 32 3.2 23
Swingarm pivot nut M12 51 5.1 37
Engine mounting nut M8 34 3.4 25
Swingarm and drive chain case M6 7 0.7 5.0
Drive chain adjuster locknut M6 7 0.7 5.0
Swingarm and brake torque rod M8 16 1.6 12
Brake shoe plate and brake torque rod M8 19 1.9 14
Rider footrest and crankcase M8 23 2.3 17
Passenger footrest and frame M8 30 3.0 22
Sidestand and rider footrest (bolt) M8 26 2.6 19
Sidestand and rider footrest (nut) M8 16 1.6 12
Front cowling bracket and crankcase cover M6 7 0.7 5.0
(left and right)
Main switch and frame M6 10 1.0 7.2
Ignition coil and frame M6 7 0.7 5.0
Fuel tank and frame M8 16 1.6 12
Fuel cock and frame M6 9 0.9 6.5
Seat and seat bracket M6 7 0.7 5.0

NOTE:
1. First tighten the lower ring nut 30 Nm (3.0 m • kg, 22 ft • lb) by using a torque wrench, then loosen
the ring nut 1/4 turn.
2. Then, hold the lower ring nut and tighten the upper ring nut 75 Nm (7.5 m • kg, 54 ft • lb) by using a
torque wrench.

2-14
3P9-F8197-E0_2 05.11.18 9:25 AM Page 15

MAINTENANCE SPECIFICATIONS SPEC

ELECTRICAL

Item Standard Limit

System voltage 12 V ----
Ignition system
Ignition timing (B.T.D.C.) 10° at 1,500 r/min ----
Advanced type Digital ----
DC-C.D.I
Pickup coil resistance/color 248 − 372 Ω at 20 °(68 °F)/R–W ----
C.D.I. unit model/manufacturer 5TF/PT.MORIC ----
Ignition coil
Model/manufacturer 5TP/PT.MORIC ----
Minimum ignition spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.32 − 0.48 Ω at 20 °C(68 °F) ----
Secondary coil resistance 5.68 − 8.52 kΩ at 20 °C(68 °F) ----
Spark plug cap
Material Resin ----
Resistance 7.5 − 12.5 kΩ ----
Charging system
Type A.C. magneto ----
Model/manufacturer F5TP/PT.MORIC ----
Nominal output 14 V 100 W at 5,000 r/min ----
Lighting coil resistance/color 0.24 − 0.36 Ω at 20 °C(68 °F)/Y–B ----
Charging coil resistance/color 0.32 − 0.48 Ω at 20 °C(68 °F)/W–B ----
Rectifier/regulator
Regulator type Semiconductor short-circuit ----
Model/manufacturer SH656CA/PT.SHINDENGEN ----
No load regulated voltage (DC) 14.1 − 14.9 V ----
(AC) 12.6 − 13.6 V ----
Rectifier capacity (AC) 12 A ----
Withstand voltage 400 V ----
Battery
Specific gravity 1.280 ----

2-15
3P9-F8197-E0_2 05.11.18 9:25 AM Page 16

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Electric starting system
Type Constant mesh ----
Starter motor
Model/manufacturer 3S0/PT.MORIC ----
Operation voltage 12 V ----
Power output 0.35 kW ----
Armature coil resistance 0.018 − 0.022 Ω at 20 °C(68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm
(0.14 in)
Spring force 3.92 − 5.88 N (14.11 − 21.17 oz)
(400 − 600 gf) ----
Commutator diameter 17.6 mm (0.69 in) 16.6 mm
(0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in) ----
Starter relay
Model/manufacturer G4R-D/OMRON ----
Amperage rating 50 A ----
Coil resistance 54 − 66 Ω at 20 °C(68 °F) ----
Horn
Type Plane ----
Quantity 1 ----
Model/manufacturer UBH-F21/MITSUBA ----
Max. amperage 1.5 A ----
Performance 97 − 107 db/2 m ----
Coil resistance 4.30 − 4.80 Ω ----
Turn signal relay
Relay type Condenser ----
Model/manufacturer FR22-091/MITSUBA ----
Self-canceling device built-in No ----
Flasher frequency 75 − 95 cycles/min ----
Wattage 10 W × 2 + 3.4 W ----
Fuel gauge
Model/manufacturer 3S0/NIPPON SEIKI ----
Sender unit resistance- full 4 − 10 Ω ----
- empty 90 − 100 Ω ----
Circuit breaker
Circuit breaker type Fuse ----
Main 10.0 A ----
Reserve 10.0 A ----

2-16
3P9-F8197-E0_2 05.11.18 9:25 AM Page 17

GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC

EAS00029

GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications
require clean, dry threads. Components should
be at room temperature.
A: Width across flats
B: Thread diameter

General tightening
A B
torques
(nut) (bolt)
Nm m·kg
10 mm 6 mm 6 0.6
12 mm 8 mm 15 1.5
14 mm 10 mm 30 3.0
17 mm 12 mm 55 5.5
19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0

2-17
3P9-F8197-E0_2 05.11.18 9:25 AM Page 18

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Lubricant
Oil seal lips
Bearings
O-rings
Cylinder head tightening nut and stud bolt thread
Rocker arm inner surfaces
Rocker arm shaft
Camshaft
Valve stem (IN, EX)
Valve stem guide (IN, EX)
Piston pin
Piston outside and ring groove
Piston ring
Cylinder inner surface
Starter clutch gear inner surface
Starter idle gear inner surface
Kickstarter ratchet gear
Kickstarter gear
Kickstarter shaft
Primary driven gear inner surface
Clutch push rod
Clutch pressure plate
Friction plate
Clutch shoe housing inner surface
Cage
Clutch shoe housing boss
Oil pump assembly
Shift guide inner surface
Shift fork guide bar
Shift shaft thrust surface
Shift lever inner surface
Shift shaft stopper lever inner surface
Timing chain
Transmission wheel gears inner surface

2-18
3P9-F8197-E0_2 05.11.18 9:25 AM Page 19

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

Lubrication point Lubricant

Transmission side plate inner surface
Transmission pinion gears inner surface
Starter motor guard bolt Yamaha bond No.1215
Generator lead grommet Yamaha bond No.1215
Crankcase cover bolt Yamaha bond No.1215
Crankcase mating surface Yamaha bond No.1215

2-19
3P9-F8197-E0_2 05.11.18 9:25 AM Page 20

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

CHASSIS

Lubrication point Lubricant

Front wheel oil seal lips
Speedometer driven gear
Front brake camshaft
Speedometer drive gear
Rear wheel oil seal lips
Rear brake camshaft
Brake torque rod bolt
Front wheel axle
Rear wheel axle
Throttle grip tube guide inner surface
Brake cable (brake lever)
Brake lever pivot bolt
Steering head bearing inner race
Steering head bearing outer race
Steering head upper bearing
Steering head lower bearing
Sidestand pivot bolt
Swingarm pivot shaft
Centerstand pivot shaft

2-20
3P9-F8197-E0_2 05.11.18 9:25 AM Page 21

CABLE ROUTING SPEC

CABLE ROUTING
1 Band ∫ Push in the coupler between the handlebar and
2 Choke cable speedometer assembly, after connected.
3 Headlight assembly ç Hock the wire harness onto the strap.
4 Wire harness ∂ Push in the coupler between the handlebar and
5 Throttle cable speedometer assembly, after connected.
6 Speedometer cable ´ To headlight assembly.
7 Brake cable ƒ To turn signal light.
© To front brake switch.
å Pass through the right handlebar switch lead ˙ To auxiliary light.
behind the handlebar.

A ∫
1
å
å

5 ∂ 1 2

7
ç
4

©
3

´
˙ ´
ƒ
´

6 ∂

2-21
3P9-F8197-E0_2 05.11.18 9:25 AM Page 22

CABLE ROUTING SPEC

1 Wire harness å Pass through the wire harness onto the cable
2 Cable guide guide.
3 Choke cable ∫ Align the clamp with the white tape on the wire
4 Throttle cable harness.
5 Speedometer cable
6 Brake cable ç The wire harness should not be forced out from
handle cover.

6
1

5
43

1
5
A
6 2
34 ç
B A
1 ∫
B
3

å 4

6 5

2-22
3P9-F8197-E0_2 05.11.18 9:25 AM Page 23

CABLE ROUTING SPEC

1 Wire harness w Starter motor lead
2 Air vent hose e Choke cable
3 Air induction system vacuum hose r Throttle cable
4 Clamp t Main switch lead
5 A.C. magneto lead y Battery breather hose
6 Neutral switch lead u Fuel cock vacuum hose
7 Turn signal relay i Air filter drain hose
8 Negative lead o Carburetor overflow hose
9 Air induction system hose (air cut-off valve
assembly to air filter)
0 Fuel hose
q Fuel cock

r
1
e

r t
e

t y
1
1 r

å
A
B
1
C 8 ∂
B 2
A
C 3
4
5 67
∫ç

9
0
˙
© q
u
w
i D

ƒ ´

2-23
3P9-F8197-E0_2 05.11.18 9:25 AM Page 24

CABLE ROUTING SPEC

å Pass the wire harness, choke cable, and throttle cable through the guide.
∫ Pass the fuel hose and fuel cock vacuum hose through the guide.
ç Pass the starter cable, neutral switch lead, and A.C. magneto lead through the guide.
∂ Install the negative terminal in this angle.
´ Pass the over flow hose through the guide.
ƒ Insert the drain hose into the guide.
© Do not obstruct the clip for route the fuel cock vacuum hose.
˙ Install the fuel hose clamp facing down.

r
1
e

r t
e

t y
1
1 r

å
A
B
1
C 8 ∂
B 2
A
C 3
4
5 67
∫ç

9
0
˙
© q
u
w
i D

ƒ ´

2-24
3P9-F8197-E0_2 05.11.18 9:25 AM Page 25

CABLE ROUTING SPEC

1 Rectifier/regulator w Main switch
2 Ignition coil e Starter motor cover
3 Air vent hose r Starter motor
4 Cover t Starter motor lead
5 Main switch lead y Footrest
6 Horn
7 Spark plug lead å Insert the end of the air vent hose into the hole in
8 Turn signal relay the frame.
9 Neutral switch lead
0 A.C. magneto lead
q Protector

1 8

q e

w r
9 5

0
y t

5 6

B
4

å
B

3
1
2

2-25
3P9-F8197-E0_2 05.11.18 9:25 AM Page 26

CABLE ROUTING SPEC

1 Fuel sender w Battery positive lead
2 Battery breather hose e Wire harness
3 Starter motor lead
4 Rear brake light switch å Insert the battery breather hose into the hose
5 Rear brake light switch lead guide.
6 Battery negative lead
7 Fuse
8 Starter relay
9 Battery
0 C.D.I. unit
q Box

q
7890

w
6 e
1

A
B

A
B

2 3
4
2
å
3 5

2-26
3P9-F8197-E0_2 05.11.18 9:25 AM Page 27

CABLE ROUTING SPEC

1 Wire harness å Clamp the fuel sender lead wire harness.
2 Rectifier/regulator ∫ Align the white tape of the wire harness with the
3 Battery guide on the fuel tank.
4 C.D.I. unit ç To the battery.
5 Fuel sender ∂ To the starter motor.
6 Tail/brake light lead ´ To the wire harness.
7 Tail/brake light ƒ Pass the battery positive lead.
8 Negative lead © To the fuse.
9 Starter relay ˙ To the starter motor.
0 Turn signal relay ˆ To the C.D.I. unit.
q Neutral switch lead ∆ To the starter relay.
w A.C. magneto lead
e Fuel sender lead wire harness

1
w
q
0 2

3
ƒ
A
B
9
4
8
A B
å ©
ç ∆
e
∂ ˙
5 ˆ
´
∫

2-27
3P9-F8197-E0_3 05.11.18 9:24 AM Page A

CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS

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

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

COVERS ................................................................................................................. 3-3

REMOVING THE FRONT COWLINGS ............................................................ 3-3
INSTALLING THE FRONT COWLINGS ........................................................... 3-3
REMOVING THE REAR COWLINGS ............................................................... 3-4
INSTALLING THE REAR COWLINGS .............................................................. 3-4
REMOVING THE HEADLIGHT ASSEMBLY ..................................................... 3-5
INSTALLING THE HEADLIGHT ASSEMBLY .................................................... 3-5

ENGINE .................................................................................................................. 3-6

ADJUSTING THE VALVE CLEARANCE .......................................................... 3-6
ADJUSTING THE ENGINE IDLING SPEED .................................................... 3-9
ADJUSTING THE THROTTLE CABLE FREE PLAY ........................................ 3-10
CHECKING THE SPARK PLUG ....................................................................... 3-11
MEASURING THE COMPRESSION PRESSURE ........................................... 3-13
CHECKING THE ENGINE OIL LEVEL ............................................................. 3-15
CHANGING THE ENGINE OIL ......................................................................... 3-16
CHECKING THE EXHAUST SYSTEM ............................................................. 3-17
CLEANING THE AIR FILTER ELEMENT .......................................................... 3-17
ADJUSTING THE CLUTCH RELEASE SYSTEM ............................................ 3-18
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD ................ 3-19
CHECKING THE FUEL AND VACUUM HOSES .............................................. 3-19
CHECKING THE CRANKCASE BREATHER HOSE ........................................ 3-20

CHASSIS ................................................................................................................ 3-21

ADJUSTING THE FRONT BRAKE .................................................................... 3-21
ADJUSTING THE REAR BRAKE ...................................................................... 3-21
CHECKING THE FRONT AND REAR BRAKE SHOES .................................... 3-22
ADJUSTING THE REAR BRAKE LIGHT SWITCH ........................................... 3-23
ADJUSTING THE DRIVE CHAIN SLACK ........................................................ 3-24
LUBRICATING THE DRIVE CHAIN .................................................................. 3-25
CHECKING AND ADJUSTING THE STEERING HEAD ................................... 3-26
CHECKING THE FRONT FORK ....................................................................... 3-28
CHECKING THE TIRES .................................................................................... 3-29
CHECKING AND TIGHTENING THE SPOKES ................................................ 3-31
CHECKING AND LUBRICATING THE CABLES .............................................. 3-32
LUBRICATING THE LEVER AND PEDALS....................................................... 3-32
3P9-F8197-E0_3 05.11.18 9:24 AM Page B

CHK
ADJ
LUBRICATING THE SIDESTAND...................................................................... 3-32
LUBRICATING THE CENTERSTAND .............................................................. 3-32

ELECTRICAL SYSTEM ......................................................................................... 3-33

CHECKING AND CHARGING THE BATTERY ................................................. 3-33
CHECKING THE FUSE .................................................................................... 3-37
REPLACING THE HEADLIGHT BULBS ........................................................... 3-38
ADJUSTING THE HEADLIGHT BEAM ............................................................. 3-39
3P9-F8197-E0_3 05.11.18 9:24 AM Page 1

INTRODUCTION/ CHK
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ADJ
EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

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

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

INITIAL EVERY
No. ITEM CHECK OR MAINTENANCE JOB
500 km 2,000 km 4,000 km 8,000 km
• Check valve clearance.
1 * Valve(s)
• Adjust if necessary. √ √
• Check condition.
2 * Spark plug
• Clean or replace if necessary. √ √ √ √
• Clean.
3 Air filter
• Replace if necessary. √ √
• Check engine idling speed and starter operation.
4 * Carburetor
• Adjust if necessary. √ √ √ √
• Check fuel hose and vacuum hose for cracks or
5 Fuel line damage. √ √
• Replace if necessary.
6 * Engine oil • Replace. (Warm engine before draining.) √ √ Every 2,000 km
7 * Engine oil filter • Check, clean and replace if necessary. √ √ √ √
• Check operation and adjust brake lever free play.
8 * Front brake
• Replace brake shoes if necessary. √ √
• Check operation and adjust brake pedal free
9 * Rear brake play. √ √
• Replace brake shoes if necessary.
• Check swingarm assembly for looseness.
• Correct if necessary.
10 * Swingarm pivot √
• Lubricate with lithium soap base grease every
16,000 km.
• Check balance, runout, spoke tightness and for
11 * Wheels damage. √ √
• Replace if necessary.
• Check bearing assembly for looseness or dam-
12 * Wheels bearings age. √ √ √
• Replace if damaged.
• Check bearing assembly for looseness.
• Correct if necessary.
13 * Steering bearing √ √
• Lubricate medium weight wheel bearing grease
every 8,000 km.
• Check operation and for oil leakage.
14 * Front forks √ √
• Repair if necessary.
Rear shock • Check operation and for oil leakage.
15 * √ √
absorber • Repair if necessary.
• Check chain slack and alignment.
16 * Drive chain • Adjust if necessary. Every 500 km
• Clean and lubricate.
• Check all chassis fitting and fasteners.
17 * Fittings/Fasteners
• Correct if necessary. √ √ √ √

3-1
3P9-F8197-E0_3 05.11.18 9:24 AM Page 2

CHK
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ADJ
INITIAL EVERY
No. ITEM CHECK OR MAINTENANCE JOB
500 km 2,000 km 4,000 km 8,000 km
Centerstand and • Check operation.
18 * √ √
sidestand • Repair if necessary.
• Check specific gravity.
19 * Battery • Check that the breather hose is working properly. √ √
• Correct if necessary.

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

NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

3-2
3P9-F8197-E0_3 05.11.18 9:24 AM Page 3

CHK
COVERS ADJ
EASF0004

2 COVERS
1 REMOVING THE FRONT COWLINGS
1. Remove:
9main switch cover 1
9center panel 2
NOTE:
Remove the main switch cover by turning it in
the direction of the arrow shown.

2. Remove:
9front cowlings (left and right) 1

1
1

1
1

3. Remove:
9front panel 1
1

INSTALLING THE FRONT COWLINGS

For installation, reverse the removal procedure.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 4

CHK
COVERS ADJ
REMOVING THE REAR COWLINGS
1. Remove:
9front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS”.
9side panel 1

2. Remove:
9rear panel 1
1 NOTE:
Remove the rear panel by sliding it in the direc-
tion of the arrow shown.

3. Remove:
2
1 9cover 1
9rear cowlings (left and right) 2

INSTALLING THE REAR COWLINGS

1
2 1. Install:
9rear cowlings (left and right) 1
9cover 2
NOTE:
Before tightening the rear cowling screws, make
sure that all projections are securely fitted.

2. Install:
9rear panel 1
NOTE:
Make sure that all projections are securely fit-
1 ted.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 5

CHK
COVERS ADJ
3. Install:
9side panel 1
NOTE:
Before tightening side panel screw, make sure
that projections is securely fitted.
1
9front cowlings (left and right)
Refer to “INSTALLING THE FRONTCOWL-
INGS”.

REMOVING THE HEADLIGHT ASSEMBLY

1. Remove:
9headlight assembly 1

2. Disconnect:
9turn signal light coupler 1
3 9headlight connectors 2
2 9auxiliary light coupler 3
1

INSTALLING THE HEADLIGHT ASSEMBLY

1. Connect:
9auxiliary light coupler
1 9headlight connectors
9turn signal light coupler
2. Install:
9headlight assembly 1
NOTE:
Before tightening the headlight assembly
screws, make sure that all projections are
securely fitted.

3-5
3P9-F8197-E0_3 05.11.18 9:24 AM Page 6

CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00049

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

1. Remove:
9center panel
9front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS”.

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

3. Remove:
9timing check plug 1
(with O-ring)
9center plug 2
(with O-ring)

3-6
3P9-F8197-E0_3 05.11.18 9:24 AM Page 7

CHK
ADJUSTING THE VALVE CLEARANCE ADJ
4. Measure:
9valve clearance
a Out of specification → Adjust.

b Valve clearance (cold)

Intake valve
0.05–0.09 mm (0.0020–0.0035 in)
Exhaust valve
0.08–0.12 mm (0.0032–0.0045 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark a on the
camshaft sprocket with the stationary point-
er b on the cylinder head.
c. Align the TDC mark c on the generator
rotor with the stationary pointer d on the
crankcase cover.
d. Measure the valve clearance with a thick-
ness gauge 1.
Out of specification → Adjust.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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

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

Tappet adjusting tool 4

90890-01311

3-7
3P9-F8197-E0_3 05.11.18 9:24 AM Page 8

CHK
ADJUSTING THE VALVE CLEARANCE ADJ
9Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica-
tion.

Locknut
7 Nm (0.7 m·kg, 5.0 ft·lb)

d. Measure the valve clearance again.

e. If the valve clearance is still out of specifica-
tion,repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
9camshaft sprocket cover
9O-ring
9timing check plug
(with O-ring) 7 Nm (0.7 m•kg, 5.0 ft•lb)
9center plug
(with O-ring) 7 Nm (0.7 m•kg, 5.0 ft•lb)

7. Install:
9tappet cover (intake side) 1
18Nm (1.8 m•kg, 13 ft•lb)

9O-ring 2
8. Install:
9tappet cover (exhaust side)
9O-ring
9. Install:
9front cowlings (left and right)
9center panel
Refer to “INSTALLING THE FRONT COWL-
INGS”.

3-8
3P9-F8197-E0_3 05.11.18 9:24 AM Page 9

CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
EAS00054

ADJUSTING THE ENGINE IDLING SPEED

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

1. Remove:
9front cowling (right)
Refer to “REMOVING THE FRONT COWL-
INGS”.
2. Start the engine and let it warm up for sev-
eral minutes.
3. Connect:
9engine tachometer
(onto the spark plug lead)
Engine tachometer
90890-03113

4. Check:
9engine idling speed
Out of specification → Adjust.
Engine idling speed
1,400 – 1,600 r/min

5. Adjust:
1 9engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2 a. Turn the pilot air screw 1 in or out until it is
a b lightly seated.
b. Turn the pilot air screw out the specified
number of turns.

Pilot air screw setting

1–3/8 turns out

c. Turn the throttle stop screw 2 in direction

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

Engine idling speed is

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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3P9-F8197-E0_3 05.11.18 9:24 AM Page 10

ADJUSTING THE ENGINE IDLING SPEED/ CHK

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

Throttle cable free play (at the

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

7. Install:
9front cowling (right)
Refer to “INSTALLING THE FRONT COWL-
INGS”.

EAS00058

ADJUSTING THE THROTTLE CABLE

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

1. Check:
9throttle cable free play a
Out of specification → Adjust.

Throttle cable free play (at the

a
flange of the throttle grip)
3–7 mm (0.12–0.28 in)
2. Remove:
9front cowling (left)
Refer to “REMOVING THE FRONT COWL-
INGS”.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 11

ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHK

CHECKING THE SPARK PLUG ADJ
3. Adjust:
1
9throttle cable free play
2
a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b a. Pull back the adjusting nut cover.
b. Loosen the locknut 1
c. Turn the adjusting nut 2 in direction a or
b until the specified throttle cable free play
is obtained.

Throttle cable free play

Direction a
is increased.
Throttle cable free play
Direction b
is decreased.

d. Tighten the locknut.

e. Slide the adjusting nut cover to its original
position.

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00060

CHECKING THE SPARK PLUG

1. Remove:
9front cowling (right)
Refer to “REMOVING THE FRONT COWL-
INGS”.
2. Disconnect:
9spark plug cap
3. Remove:
9spark plug

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

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 12

CHK
CHECKING THE SPARK PLUG ADJ
4. Check:
9spark plug type
Incorrect → Change.

Spark plug type (manufacturer)

C6HSA (NGK)

5. Check:
9electrode 1
1 Damage/wear → Replace the spark plug.
9insulator 2
a Abnormal color → Replace the spark plug.
2 Normal color is medium-to-light tan.
6. Clean:
9spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
9spark plug gap a
(with a wire thickness gauge)
Out of specification → Regap.

Spark plug gap

0.6–0.7 mm (0.024–0.028 in)
8. Install:
9spark plug 12.5 Nm (1.25 m•kg, 9.0 ft•lb)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.

9. Connect:
9spark plug cap
10. Install:
9front cowling (right)
Refer to “INSTALLING THE FRONT COWL-
INGS”.

3-12
3P9-F8197-E0_3 05.11.18 9:24 AM Page 13

CHK
MEASURING THE COMPRESSION PRESSURE ADJ
EAS00067

MEASURING THE COMPRESSION

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

1. Measure:
9valve clearance
Out of specification → Adjust
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Disconnect:
9spark plug cap
4. Remove:
9spark plug

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

5. Install:
9compression gauge 1
1
Compression gauge
90890-03081
6. Measure:
9compression pressure
Out of specification → Refer to steps (c)
and (d).

Compression pressure
(at sea level)
Minimum
1,130 kPa (11.3 kg/cm2, 161 psi)
Standard
1,300 kPa (13.0 kg/cm2, 185 psi)
Maximum
1,460 kPa (14.6 kg/cm2, 208 psi)

3-13
3P9-F8197-E0_3 05.11.18 9:24 AM Page 14

CHK
MEASURING THE COMPRESSION PRESSURE ADJ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the compression
gauge stabilizes.

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

c. If the compression pressure is above the

maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure again.
Refer to the following table.

Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Piston ring(s) wear
Higher than with-
or damage →
out oil
Repair.
Piston, valves, cyl-
Same as without inder head gasket
oil or piston possibly
defective → Repair.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
9spark plug 12.5 Nm (1.25 m•kg, 9.0 ft•lb)
8. Connect:
9spark plug cap
9. Install:
9front cowling (right)
Refer to “INSTALLING THE FRONT COWL-
INGS”.

3-14
3P9-F8197-E0_3 05.11.18 9:24 AM Page 15

CHK
CHECKING THE ENGINE OIL LEVEL ADJ
EAS00070

CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle on a level surface.
NOTE:
Make sure the vehicle is upright.

2. Start the engine, warm it up for several min-

utes, and then turn it off.

3. Remove:
9oil level plug 1
4. Check:
9engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
Recommended oil
SAE 20W40 type SE, SF, SG or
higher grade motor oil

cC
Do not allow foreign materials to enter the
crankcase.

NOTE:
9Insert the oil level plug back into the oil filler
hole (without screwing it in), and then remove
it again to check the oil level.
9Before checking the engine oil level, wait a few
minutes until the oil has settled.

5. Start the engine, warm it up for several min-

utes, and then turn it off.
6. Check the engine oil level again.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 16

CHK
CHANGING THE ENGINE OIL ADJ
EAS00075

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place a container under the engine oil drain
bolt.

3. Remove:
1 9oil level plug 1
9engine oil drain plug 2
(with gasket)
4. Drain:
9engine oil
(completely from the crankcase)
5. Check:
9engine oil drain bolt gasket
Damage → Replace.
6. Install:
9engine oil drain bolt
(with gasket) 20 Nm (2.0 m•kg, 15 ft•lb)
7. Fill:
9crankcase
(with the specified amount of the recom-
mended engine oil)

Quantity
Total amount
1.0 L (1.06 US qt, 0.88 lmp.qt)
Periodic oil change amount
0.8 L (0.85 US qt, 0.70 lmp.qt)

8. Install:
9oil level plug
9. Start the engine, warm it up for several min-
utes, and then turn it off.
10. Check:
9engine
(for engine oil leaks)
11. Check:
9engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 17

CHECKING THE EXHAUST SYSTEM/ CHK

CLEANING THE AIR FILTER ELEMENT ADJ
CHECKING THE EXHAUST SYSTEM
1. Check:
9exhaust pipe nuts 1
Loose/damage → Tighten/replace.
7 Nm (0.7 m•kg, 5.0 ft•lb)
9exhaust pipe gasket
Exhaust gas leaks → Tighten/replace.
1

EAS00086

CLEANING THE AIR FILTER ELEMENT

1. Remove:
9center panel
9front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS”.

2. Remove:
2 9air filter case cover 1
9air filter element 2

3. Clean:
9air filter element
Apply compressed air to the outer surface
of the air filter element.
4. Check:
9air filter element
Damage → Replace.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 18

CLEANING THE AIR FILTER ELEMENT/ CHK

ADJUSTING THE CLUTCH RELEASE SYSTEM ADJ
5. Install:
9air filter element
9air filter case cover

cC
Never operate the engine without the air fil-
ter element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect the carbure-
tor tuning, leading to poor engine perfor-
mance and possible overheating.

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

6. Install:
9front cowlings (left and right)
9center panel
Refer to “INSTALLING THE FRONT COWL-
INGS”.

EAS00086

ADJUSTING THE CLUTCH RELEASE

SYSTEM
1. Adjust:
9clutch release system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting screw 2 in completely,
then turn the adjusting screw out the speci-
fied number of turns.
Adjusting screw:
1/8 turns out

c. Tighten the locknut.

8 Nm (0.8 m•kg, 5.8 ft•lb)
NOTE:
Hold the adjusting screw and tighten the lock-
nut.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-18
3P9-F8197-E0_3 05.11.18 9:24 AM Page 19

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/ CHK

CHECKING THE FUEL AND VACUUM HOSES ADJ
EAS00094

CHECKING THE CARBURETOR JOINT

AND INTAKE MANIFOLD
1. Remove:
9front cowling (right)
Refer to “REMOVING THE FRONT COWL-
INGS”.

2. Check:
9carburetor joint 1
9intake manifold 2
2 Cracks/damage → Replace.
Refer to “CARBURETOR” in chapter 5.
1 3. Install:
9front cowling (right)
Refer to “INSTALLING THE FRONT COWL-
INGS”.

EAS00096

CHECKING THE FUEL AND VACUUM

HOSES
The following procedure applies to all of the fuel
and vacuum hoses.
1. Remove:
9front cowling (left)
Refer to “REMOVING THE FRONT COWL-
INGS”.

2. Check:
9fuel cock vacuum hose 1
2 9fuel hose 2
Cracks/damage → Replace.
Loose connection → Connect properly.
3. Install:
1 9front cowling (left)
Refer to “INSTALLING THE FRONT COWL-
INGS”.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 20

CHK
CHECKING THE CRANKCASE BREATHER HOSE ADJ
EAS00098

CHECKING THE CRANKCASE

BREATHER HOSE
1. Remove:
9front cowling (right)
Refer to “REMOVING THE FRONT COWL-
INGS”.
9side panel
Refer to “REMOVING THE REAR COWL-
INGS”.

2. Check:
9crankcase breather hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.

cC
1
Make sure the crankcase breather hose is
routed correctly.

3. Install:
9side panel
Refer to “INSTALLING THE REAR COWL-
INGS”.
9front cowling (right)
Refer to “INSTALLING THE FRONT COWL-
INGS”.

3-20
3P9-F8197-E0_3 05.11.18 9:24 AM Page 21

ADJUSTING THE FRONT BRAKE/ CHK

ADJUSTING THE REAR BRAKE ADJ
EAS00109

CHASSIS
EAS00113

ADJUSTING THE FRONT BRAKE

1. Check:
9brake lever free play a
Out of specification → Adjust.

Brake lever free play (at the end

of the brake lever)
10–20 mm (0.39–0.79 in)

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

Brake lever free play is

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

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00113

ADJUSTING THE REAR BRAKE

1. Check:
9brake pedal free play a
Out of specification → Adjust.

Brake pedal free play (at the end

of the brake pedal)
20–30 mm (0.79–1.18 in)

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 22

ADJUSTING THE REAR BRAKE/ CHK

CHECKING THE FRONT AND REAR BRAKE SHOES ADJ
2. Adjust:
9brake pedal free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster 1 in direction a or b
a until the specified brake pedal free play is
obtained.
b Brake pedal free play is
1 Direction a
increased.
Brake pedal free play is
Direction b
decreased.

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
9rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.

EAS00127

CHECKING THE FRONT AND REAR

BRAKE SHOES
The following procedure applies to both the front
and rear brake shoes.
1. Operate the brake.
2. Check:
9wear indicator 1
Reaches the wear limit line 2 → Replace
the front or rear brake shoes as a set.
Refer to “FRONT WHEEL AND DRUM
BRAKE” in chapter 6 and “REAR WHEEL
AND BRAKE” in chapter 6.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 23

CHK
ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ
EAS00128

ADJUSTING THE REAR BRAKE LIGHT

SWITCH
NOTE:
The rear brake light switch is operated by move-
ment of the brake pedal. The rear brake light
switch is properly adjusted when the brake light
comes on just before the braking effect starts.

1. Remove:
9side panel
Refer to “REMOVING THE REAR COWL-
INGS”.
2. Check:
9rear brake light operation timing
Incorrect → Adjust.

3. Adjust:
2
9rear brake light operation timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body 1 of the rear brake
a b light switch so that it does not rotate and
1 turn the adjusting nut 2 in direction a or b
until the rear brake light comes on at the
proper time.

Brake light comes on

Direction a
sooner.
Brake light comes on
Direction b
later.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
9side panel
Refer to “INSTALLING THE REAR COWL-
INGS”.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 24

CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
EAS00140

ADJUSTING THE DRIVE CHAIN SLACK

NOTE:
The drive chain slack must be checked at the
tightest point on the chain.

cC
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.

1. Stand the vehicle on a level surface.

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

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

2. Spin the rear wheel several times and find

the tightest position of the drive chain.
3. Check:
9drive chain slack a
Out of specification → Adjust.

Drive chain slack

25–35 mm (0.98–1.38 in)

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 25

ADJUSTING THE DRIVE CHAIN SLACK/ CHK

LUBRICATING THE DRIVE CHAIN ADJ
4. Adjust:
9drive chain slack
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a a. Loosen the wheel axle nut 1.
b. Loosen both locknuts 2.
c. Turn both adjusting nuts 3 in direction a
or b until the specified drive chain slack is
b obtained.
2 3
Direction a Drive chain is tightened.
Direction b Drive chain is loosened.

NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.

d. Tighten both locknuts to specification.

Locknut
7 Nm (0.7 m·kg, 5.0 ft·lb)

e. Tighten the wheel axle nut to specification.

Wheel axle nut

60 Nm (6.0 m·kg, 43 ft·lb)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00143

LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained prop-
erly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
Use only kerosene to clean the drive chain.
Wipe the drive chain dry and thoroughly lubri-
cate it with engine oil or chain lubricant that is
suitable for non-O-ring chains.
Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains

3-25
3P9-F8197-E0_3 05.11.18 9:24 AM Page 26

CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
EASF0010

CHECKING AND ADJUSTING THE

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

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

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

2. Check:
9steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.

3. Remove:
9center panel
9front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS”.

4. Adjust:
9steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull back the rubber cover 1.
b. Loosen the upper ring nut 2
c. Loosen the lower ring nut 3 and then tight-
en it to specification with a steering nut
wrench 4.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.

Steering nut wrench

90890-01403

Lower ring nut

4 30 Nm (3.0 m·kg, 22 ft·lb)
3
d. Loosen the lower ring nut 3 counterclock-
wise 1/4 of a turn.

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CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
e. Hold the lower ring nut with a ring nut
wrench 5 and tighten the upper ring nut 2
with a steering nut wrench.

w
Do not overtighten the lower ring nut.

Ring nut wrench

90890-01268

Upper ring nut

75 Nm (7.5 m·kg, 54 ft·lb)

f. Check the steering head for looseness or

binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” in chapter 6.
g. Slide the rubber cover to its original posi-
tion.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Install:
9front cowlings (left and right)
9center panel
Refer to “INSTALLING THE FRONT COWL-
INGS”.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 28

CHK
CHECKING THE FRONT FORK ADJ
EAS00149

CHECKING THE FRONT FORK

1. Stand the vehicle on a level surface.

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

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

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 29

CHK
CHECKING THE TIRES ADJ
EASF0015

CHECKING THE TIRES

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

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

Basic weight
(with oil and
99 kg (218 lb)
a full fuel
tank)
Maximum
185 kg (407 lb)
load*
Cold tire
Front Rear
pressure
200 kPa 225 kPa
Up to 90 kg (2.00 kgf/cm , (2.25 kgf/cm2,
2

load 29 psi, 33 psi,

2.00 bar) 2.25 bar)
200 kPa 225 kPa
90 kg –
(2.00 kgf/cm , (2.25 kgf/cm2,
2

maximum
29 psi, 33 psi,
load
2.00 bar) 2.25 bar)

* Total weight of rider, passenger, cargo and

accessories

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

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 30

CHK
CHECKING THE TIRES ADJ
2. Check:
9tire surfaces
Damage/wear → Replace the tire.
Minimum tire tread depth
0.8 mm (0.03 in)

1 Tire tread depth

2 Sidewall
3 Wear indicator

w
9Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
9When using tube tires, be sure to install the
correct tube.
9Always replace a new tube tire and a new
tube as a set.
9To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
9Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality
replacement.

Tube wheel Tube tire only

Tube or tubeless
Tubeless wheel
tire
9After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufactur-
er and of the same design. No guarantee
concerning handling characteristics can be
given if a tire combination other than one
approved by Yamaha is used on this vehi-
cle.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 31

CHECKING THE TIRES/ CHK

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

NOTE:
For tires with a direction of rotation mark 1:
9Install the tire with the mark pointing in the
direction of wheel rotation.
9Align the mark 2 with the valve installation
point.

EAS00169

CHECKING AND TIGHTENING THE

SPOKES
The following procedure applies to all of the
spokes.
1. Check:
9spoke 1
Bends/damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.

2. Tighten:
9spoke
(with a spoke wrench 2)
3 Nm (0.3 m•kg, 2.2 ft•lb)
NOTE:
Be sure to tighten the spokes before and after
break-in.

3-31
3P9-F8197-E0_3 05.11.18 9:24 AM Page 32

CHECKING AND LUBRICATING THE CABLES/

LUBRICATING THE LEVER AND PEDALS/ CHK
LUBRICATING THE SIDESTAND/LUBRICATING THE CENTERSTAND ADJ
EAS00170

CHECKING AND LUBRICATING THE

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

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

1. Check:
9outer cable
Damage → Replace.
2. Check:
9cable operation
Rough movement → Lubricate.

Recommended lubricant
Engine oil or a suitable cable
lubricant

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

EAS00171

LUBRICATING THE LEVER AND PEDALS

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

Recommended lubricant
Lithium-soap-based grease
EAS00172

LUBRICATING THE SIDESTAND

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

Recommended lubricant
Lithium-soap-based grease
EAS00173

LUBRICATING THE CENTERSTAND

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

Recommended lubricant
Lithium-soap-based grease

3-32
3P9-F8197-E0_3 05.11.18 9:24 AM Page 33

CHK
CHECKING AND CHARGING THE BATTERY ADJ
EAS00176

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

1. Open the seat, and then open the battery

1 cover 1.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 34

CHK
CHECKING AND CHARGING THE BATTERY ADJ
2. Disconnect:
2 9battery leads
(from the battery terminals)
1
U

LO
PP

W
ER

ER
LE

LE
VE

VE
L

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

3. Remove:
9battery
4. Check:
9electrolyte level
b The electrolyte level should be between the
a minimum level mark a and the maximum
level mark b.
Below the minimum level mark → Add dis-
tilled water to the proper level.

cC
Add only distilled water. Tap water contains
minerals which are harmful to the battery.

5. Check:
9specific gravity
Less than 1.280 → Recharge the battery.
Specific gravity
1.280 at 20 ˚C

6. Charge:
9battery

Battery charging amperage and time

0.5 amps/10 hrs

w
Do not quick charge a battery.

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3P9-F8197-E0_3 05.11.18 9:24 AM Page 35

CHK
CHECKING AND CHARGING THE BATTERY ADJ
cC
9Loosen the battery sealing caps.
9Make sure the battery breather hose and
battery vent are free of obstructions.
9To ensure maximum performance, always
charge a new battery before using it.
9Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
9If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
9When charging a battery, be sure to remove
it from the vehicle. (If charging has to be
done with the battery mounted on the vehi-
cle, disconnect the negative lead from the
battery terminal.)
9To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
9Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
9Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring
may cause sparks.
9If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!

NOTE:
Replace the battery whenever:
9battery voltage does not rise to specification or
bubbles fail to rise during charging,
9sulfation of one or more battery cells occurs
(as indicated by the battery plates turning
white or material accumulating in the bottom of
the battery cell),
9specific gravity readings after a long, slow
charge indicate that the charge of one battery
cell is lower than the rest,

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CHK
CHECKING AND CHARGING THE BATTERY ADJ
9warpage or buckling of the battery plates or
insulators is evident.

7. Check:
9battery breather hose and battery vent
Obstruction → Clean.
Damage → Replace.
8. Install:
9battery

9. Connect:
9battery breather hose 1

cC
9When checking the battery, make sure the
battery breather hose is properly installed
and routed correctly. If the battery breather
hose is positioned so as to allow elec-
trolyte or hydrogen gas from the battery to
contact the frame, the vehicle and its fin-
ish may be damaged.
9Make sure the battery breather hose is
properly routed away from the drive chain
and from below the swingarm.

10. Check:
1
9battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
11.Connect:
1 9battery leads
(to the battery terminals)
2
U

LO
PP

W
ER

ER
LE

LE
VE

VE
L

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

12. Lubricate:
9battery terminals

Recommended lubricant
Dielectric grease

3-36
3P9-F8197-E0_3 05.11.18 9:24 AM Page 37

CHK
CHECKING THE FUSE ADJ
EASF0017

CHECKING THE FUSE

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

1. Open the seat, and then open the battery

cover.
2. Remove:
9fuse holder 1

1
3. Check:
9fuse

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.

Pocket tester
90890-03112

b. If the pocket tester indicates “∞”, replace

the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Replace:
9blown fuse

w
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.

5. Install:
9fuse holder

3-37
3P9-F8197-E0_3 05.11.18 9:24 AM Page 38

CHK
REPLACING THE HEADLIGHT BULBS ADJ
EAS00183

REPLACING THE HEADLIGHT BULBS

The following procedure applies to the headlight
bulb.
1. Remove:
9headlight assembly
Refer to “REMOVING THE HEADLIGHT
ASSEMBLY”.

2. Remove:
1
9headlight bulb holder 1

1 3. Remove:
9headlight bulb 1

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

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

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

5. Install:
9headlight bulb holder
6. Install:
9headlight assembly
Refer to “INSTALLING THE HEADLIGHT
ASSEMBLY”.

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CHK
ADJUSTING THE HEADLIGHT BEAM ADJ
EAS00186

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
1
9headlight beam (vertically)
a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the bolt 1.
b b. Slide the bottom of the headlight unit for-
ward a or backward b.

Slide forward Headlight beam is

a raised.
Slide backward Headlight beam is
b lowered.
c. Tighten the bolt 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3-39
3P9-F8197-E0_4_1 05.11.18 13:11 Page 1

ENG
CHAPTER 4
ENGINE
REMOVING THE ENGINE ..................................................................................... 4-1
ENGINE OIL ...................................................................................................... 4-1
CARBURETOR ................................................................................................. 4-1
MUFFLER .......................................................................................................... 4-1
FOOTREST AND ENGINE GUARD .................................................................. 4-2
BRAKE PEDAL .................................................................................................. 4-2
SHIFT PEDAL.................................................................................................... 4-3
FRONT COWLING BRACKET .......................................................................... 4-3
WIRE, CABLE AND HOSE ................................................................................ 4-3
ENGINE ASSEMBLY ......................................................................................... 4-4

INSTALLING THE ENGINE ................................................................................... 4-5

ENGINE ASSEMBLY ......................................................................................... 4-5
WIRE, CABLE AND HOSE ................................................................................ 4-5
FRONT COWLING ............................................................................................ 4-5
SHIFT PEDAL.................................................................................................... 4-5
BRAKE PEDAL .................................................................................................. 4-6
FOOTREST AND STARTER MOTOR GUARD ................................................. 4-6
MUFFLER .......................................................................................................... 4-6
ENGINE OIL ...................................................................................................... 4-6
CARBURETOR.................................................................................................. 4-7

CYLINDER HEAD .................................................................................................. 4-8

REMOVING THE CYLINDER HEAD ................................................................. 4-9
CHECKING THE CYLINDER HEAD.................................................................. 4-11
CHECKING TIMING CHAIN GUIDE.................................................................. 4-12
CHECKING THE TIMING CHAIN TENSIONER ................................................ 4-13
INSTALLING THE CYLINDER HEAD................................................................ 4-13

CAMSHAFT ............................................................................................................ 4-17

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

VALVES AND VALVE SPRINGS ............................................................................ 4-22

REMOVING THE VALVES................................................................................. 4-23
CHECKING THE VALVES AND VALVE GUIDES .............................................. 4-24
CHECKING THE VALVE SEATS ....................................................................... 4-26
CHECKING THE VALVE SPRINGS................................................................... 4-28
INSTALLING THE VALVES................................................................................ 4-29
3P9-F8197-E0_4_1 05.11.18 13:11 Page 2

ENG
CYLINDER AND PISTON ...................................................................................... 4-31
REMOVING THE CYLINDER AND PISTON .................................................... 4-32
CHECKING THE CYLINDER AND PISTON ..................................................... 4-33
CHECKING THE PISTON RINGS .................................................................... 4-34
CHECKING THE PISTON PIN .......................................................................... 4-35
INSTALLING THE PISTON AND CYLINDER ................................................... 4-36

GENERATOR AND STARTER CLUTCH ............................................................... 4-38

REMOVING THE GENERATOR ....................................................................... 4-39
REMOVING THE STARTER CLUTCH ............................................................. 4-40
CHECKING THE STARTER CLUTCH .............................................................. 4-41
INSTALLING THE STARTER CLUTCH ............................................................ 4-42
INSTALLING THE GENERATOR ...................................................................... 4-42

KICKSTARTER ...................................................................................................... 4-44

REMOVING THE KICKSTARTER .................................................................... 4-45
CHECKING THE KICKSTARTER ..................................................................... 4-46
INSTALLING THE KICKSTARTER ................................................................... 4-47

CLUTCH ................................................................................................................. 4-48

REMOVING THE CLUTCH ............................................................................... 4-49
CHECKING THE FRICTION PLATES .............................................................. 4-51
CHECKING THE CLUTCH PLATES ................................................................. 4-51
CHECKING THE CLUTCH SPRINGS .............................................................. 4-52
CHECKING THE CLUTCH HOUSING ............................................................. 4-52
CHECKING THE CLUTCH BOSS .................................................................... 4-52
CHECKING THE CLUTCH PRESSURE PLATE .............................................. 4-53
CHECKING THE CLUTCH PUSH ROD #2 ...................................................... 4-53
CHECKING THE PRIMARY DRIVEN GEAR ................................................... 4-53
CHECKING THE CLUTCH SHOE HOUSING .................................................. 4-54
CHECKING THE CLUTCH SHOE .................................................................... 4-54
CHECKING THE CAGE .................................................................................... 4-54
CHECKING THE CLUTCH RELEASE SHIFT ARM .......................................... 4-55
INSTALLING THE CLUTCH .............................................................................. 4-55

OIL PUMP .............................................................................................................. 4-57

REMOVING THE OIL PUMP ............................................................................ 4-58
DISASSEMBLING THE OIL PUMP .................................................................. 4-58
CHECKING THE OIL PUMP ............................................................................. 4-59
CHECKING THE OIL STRAINER ..................................................................... 4-60
CHECKING THE OIL FILTER ........................................................................... 4-60
ASSEMBLING THE OIL PUMP ........................................................................ 4-60
INSTALLING THE OIL PUMP ........................................................................... 4-61
3P9-F8197-E0_4_1 05.11.18 13:11 Page 3

ENG
SHIFT SHAFT ........................................................................................................ 4-62
REMOVING THE SHIFT SHAFT ...................................................................... 4-63
CHECKING THE SHIFT SHAFT ....................................................................... 4-65
CHECKING THE STOPPER LEVER ................................................................ 4-65
CHECKING THE SHIFT GUIDE ....................................................................... 4-65
CHECKING THE OIL SEAL .............................................................................. 4-65
INSTALLING THE SHIFT SHAFT ..................................................................... 4-66

CRANKCASE AND CRANKSHAFT ...................................................................... 4-67

DISASSEMBLING THE CRANKCASE ............................................................. 4-68
CHECKING THE CRANKSHAFT AND CONNECTING ROD ........................... 4-69
CHECKING THE CRANKCASE ....................................................................... 4-71
CHECKING THE BEARINGS ........................................................................... 4-71
CHECKING THE TIMING CHAIN GUIDE ......................................................... 4-71
CHECKING THE TIMING CHAIN ..................................................................... 4-71
INSTALLING THE CRANKSHAFT .................................................................... 4-72
ASSEMBLING THE CRANKCASE ................................................................... 4-72

TRANSMISSION .................................................................................................... 4-74

REMOVING THE TRANSMISSION .................................................................. 4-75
DISASSEMBLING THE TRANSMISSION ........................................................ 4-75
CHECKING THE SHIFT FORKS ...................................................................... 4-76
CHECKING THE SHIFT DRUM ASSEMBLY .................................................... 4-77
CHECKING THE TRANSMISSION ................................................................... 4-77
ASSEMBLING THE TRANSMISSION .............................................................. 4-78
INSTALLING THE TRANSMISSION.................................................................. 4-78
3P9-F8197-E0_4_1 05.11.18 13:11 Page 4

ENG
3P9-F8197-E0_4_1 05.11.18 13:11 Page 1

REMOVING THE ENGINE ENG

EASF0018

ENGINE
REMOVING THE ENGINE
NOTE:
It is not necessary to remove the engine in order
to remove the following components.
• Cylinder head
• Cylinder
• Piston
• Clutch
• Kickstarter
• Shift shaft
• Oil pump
• Generator
• Starter clutch

1. Remove:
• front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
• side panel
• rear cowlings (left and right)
Refer to “REMOVING THE REAR COWL-
INGS” in chapter 3.
• drive sprocket
Refer to “DRIVE CHAIN AND SPROCK-
ETS” in chapter 6.

ENGINE OIL
1. Drain:
• engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.

CARBURETOR
1. Drain:
• carburetor assembly
Refer to “CARBURETOR” in chapter 5.

MUFFLER
2
1. Remove:
• lower muffler bolt 1
• washer
• muffler nut
• upper muffler bolt 2
• washers
1

4-1
3P9-F8197-E0_4_1 05.11.18 13:11 Page 2

REMOVING THE ENGINE ENG

2. Remove:
• exhaust pipe nuts 1
• muffler 2

2 1

FOOTREST AND ENGINE GUARD

1. Remove:
• footrest bolts 1
• footrest

1
1

2. Remove:
• starter motor guard bolts 1
1 • starter motor guard 2

3. Remove:
• air induction system pipe bolts 1
• air induction system pipe 2

BRAKE PEDAL
1. Remove:
• rear brake light switch spring
• brake pedal spring
• circlip
• brake pedal 1

4-2
3P9-F8197-E0_4_1 05.11.18 13:11 Page 3

REMOVING THE ENGINE ENG

SHIFT PEDAL
1. Remove:
9shift pedal bolt 1
9shift pedal 2

1 2

FRONT COWLING BRACKET

1. Remove:
1 9front cowling bracket bolts 1
9front cowling bracket 2

WIRE, CABLE AND HOSE

2 1. Remove:
9negative battery lead 1
1 9positive battery lead 2
PP
ER
LE

LE
VE

VE
L

L
9battery breather hose
U
ER
W
LO

2. Remove:
2
9spark plug cap 1
9air induction system hose (air cut-off valve
assembly to cylinder head) 2

3. Remove:
9air induction system vacuum hose 1
1
9fuel cock vacuum hose 2

4-3
3P9-F8197-E0_4_1 05.11.18 13:11 Page 4

REMOVING THE ENGINE ENG

4. Remove:
9crankcase breather hose 1
1

5. Disconnect:
9stator coil coupler 1
3
2 9pickup coil coupler 2
1 9neutral switch coupler 3

6. Disconnect:
9starter motor lead coupler 1
1

ENGINE ASSEMBLY
2 1 1. Remove:
9rear upper mounting nut
9washer
9front mounting nut
9washer
9rear lower mounting nut
9washer
3 9rear upper mounting bolt 1
9front mounting bolt 2
9rear lower mounting bolt 3
9engine assembly

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

4-4
3P9-F8197-E0_4_1 05.11.18 13:11 Page 5

INSTALLING THE ENGINE ENG

EASF0019

INSTALLING THE ENGINE

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

1. Install:
9engine assembly
9rear lower mounting bolt
9front mounting bolt
9rear upper mounting bolt
9washer
9rear lower mounting nut
34 Nm (3.4 m·kg, 25 ft•lb)
9washer
9front mounting nut
34 Nm (3.4 m·kg, 25 ft•lb)
9washer
9rear upper mounting nut
34 Nm (3.4 m·kg, 25 ft•lb)

WIRE, CABLE AND HOSE

1. Connect:
9starter motor lead coupler
9neutral switch coupler
9pickup coil coupler
9stator coil coupler
9negative battery lead
2. Install:
9crankcase breather hose
9fuel cock vacuum hose
9air induction system vacuum hose
9air induction system hose
(air cut-off valve assembly to cylinder head)
9spark plug cap

FRONT COWLING
1. Install:
9front cowling bracket
9front cowling bracket bolts
7 Nm (0.7 m·kg, 5.0 ft•lb)
SHIFT PEDAL
1. Install:
9shift pedal 1
9shift pedal bolt
10 Nm (1.0 m·kg, 7.2 ft•lb)

4-5
3P9-F8197-E0_4_1 05.11.18 13:11 Page 6

INSTALLING THE ENGINE ENG

BRAKE PEDAL
1. Install:
9brake pedal
9circlip
9brake pedal spring
9rear brake light switch spring

FOOTREST AND STARTER MOTOR

1 GUARD
1. Install:
9starter motor guard
9starter motor guard bolts
23 Nm (2.3 m·kg, 17 ft•lb)
NOTE:
Apply sealant to the thread of starter motor
guard bolt 1.

Yamaha bond No. 1215

90890-85505

2. Install:
9footrest
9footrest bolts
23 Nm (2.3 m·kg, 17 ft•lb)

MUFFLER
1. Install:
9muffler
9exhaust pipe nuts
7 Nm (0.7 m•kg, 5.0 ft•lb)
9washers
9upper muffler bolt
38 Nm (3.8 m·kg, 28 ft•lb)
9washer
9lower muffler bolt
9muffler nut 16 Nm (1.6 m·kg, 12 ft•lb)

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

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3P9-F8197-E0_4_1 05.11.18 13:11 Page 7

INSTALLING THE ENGINE ENG

CARBURETOR
1. Install:
9carburetor assembly
Refer to “CARBURETOR” in chapter 5.

2. Adjust:
9throttle cable free play
9rear brake light operation timing
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” and “ADJUSTING
THE REAR BRAKE LIGHT SWITCH” in
chapter 3.

Throttle cable free play

(at the flange of the throttle grip)
3 – 7 mm (0.12 – 0.28 in)

4-7
3P9-F8197-E0_4_1 05.11.18 13:11 Page 8

CYLINDER HEAD ENG

EASF0023

CYLINDER HEAD
1 Intake manifold 8 Camshaft sprocket cover
2 Tappet cover (intake side) 9 Dowel pin
3 Cylinder head 0 Gasket
4 Spark plug q Timing chain tensioner
5 Tappet cover (exhaust side)
6 Timing chain guide (exhaust side)
7 Camshaft sprocket

4-8
3P9-F8197-E0_4_1 05.11.18 13:11 Page 9

CYLINDER HEAD ENG

EAS00222

REMOVING THE CYLINDER HEAD

1. Remove
9front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
9carburetor assembly
Refer to “CARBURETOR” in chapter 5.
1 9exhaust pipe
Refer to “REMOVING THE ENGINE”.
2. Remove:
9air induction system pipe bolts
9air induction system pipe 1
9air induction system pipe gasket

3. Remove:
9intake manifold bolts
1
9intake manifold 1
(with O-ring)

4. Remove:
2 9spark plug cap 1
9spark plug 2

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

4-9
3P9-F8197-E0_4_1 05.11.18 13:11 Page 10

CYLINDER HEAD ENG

6. Align:
• “I” mark a on the generator rotor
(with the stationary pointer b on the crank-
case)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark c on the
camshaft sprocket with the stationary point-
er d on the cylinder head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

c
d

7. Loosen:
9camshaft sprocket bolt 1
NOTE:
2 While holding the generator rotor with a wrench
2, loosen the camshaft sprocket bolt.

8. Remove:
9timing chain tensioner bolts
1 9timing chain tensioner 1
9gasket

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

4-10
3P9-F8197-E0_4_1 05.11.18 13:11 Page 11

CYLINDER HEAD ENG

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

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

EAS00227

CHECKING THE CYLINDER HEAD

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

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

4-11
3P9-F8197-E0_4_1 05.11.18 13:11 Page 12

CYLINDER HEAD ENG

3. Measure:
9cylinder head warpage
Out of specification → Resurface the cylin-
der head.
Maximum cylinder head warpage
0.03 mm (0.0012 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

CHECKING TIMING CHAIN GUIDE

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

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3P9-F8197-E0_4_1 05.11.18 13:11 Page 13

CYLINDER HEAD ENG

EAS00210

CHECKING THE TIMING CHAIN

1 TENSIONER
1. Check:
9timing chain tensioner
Cracks/damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
9cap bolt
9one-way cam
9timing chain tensioner rod
Damage/wear → Replace the defective
part(s).

EAS00232

2 INSTALLING THE CYLINDER HEAD

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

2. Install:
9cylinder head
9cylinder head nuts
9cylinder head bolts
NOTE:
Pass the timing chain through the timing chain
cavity.

4-13
3P9-F8197-E0_4_1 05.11.18 13:11 Page 14

CYLINDER HEAD ENG

3. Tighten:
9cylinder head nuts
22 Nm (2.2 m·kg, 16 ft•lb)
1 5
3 9cylinder head bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
4 NOTE:
6
2 9Lubricate the cylinder head nuts and bolts with
engine oil.
9Tighten the cylinder head nuts and bolts in the
proper tightening sequence as shown and
torque them in two stages.
1
c
4. Install:
d e 9camshaft sprocket 1
9timing chain 2
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. Align the “I” mark a on the generator rotor
with the stationary pointer b on the crank-
case.
c. Align the “I” mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
d. Install the timing chain onto the camshaft
sprocket, and then install the camshaft
sprocket onto the camshaft.
NOTE:
9When installing the camshaft sprocket, be sure
to keep the timing chain as tight as possible on
the exhaust side.
9Align the projection e on the camshaft sprock-
et with the slot in the camshaft.

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

e. While holding the camshaft, temporarily

tighten the camshaft sprocket bolt.
f. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-14
3P9-F8197-E0_4_1 05.11.18 13:11 Page 15

CYLINDER HEAD ENG

5. Install:
9timing chain tensioner
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
NOTE:
Make sure that the tensioner rod has been fully
set clockwise.

1 b. Install the gasket and the timing chain ten-

sioner 2 onto the cylinder.
2
w
Always use a new gasket.

Timing chain tensioner bolt

10 Nm (1.0 m·kg, 7.2 ft•lb)

c. Turn the timing chain tensioner rod counter-

clockwise with a thin screwdriver 1, make
sure it releases, and then install the cap.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Tighten:
9camshaft sprocket bolt
20 Nm (2.0 m•kg, 15 ft•lb)

cC
Be sure to tighten the camshaft sprocket
bolt to the specified torque to avoid the pos-
sibility of the bolt coming loose and damag-
ing the engine.

7. Turn:
9crankshaft
(several turns clockwise)

4-15
3P9-F8197-E0_4_1 05.11.18 13:11 Page 16

CYLINDER HEAD ENG

8. Check:
9“I” mark a
Align the “I” mark on the generator rotor
with the stationary pointer b on the crank-
case.
9“I” mark c
Align the “I” mark on the camshaft sprocket
with the stationary pointer d on the cylinder
head.
Out of alignment → Correct.
Refer to the installation steps above.

c
d

9. Measure:
9valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.

10. Install:
9camshaft sprocket cover screws
9camshaft sprocket cover
7 Nm (0.7 m•kg, 5.0 ft•lb)
11. Install:
9tappet cover (exhaust side)
9tappet cover (intake side)
18 Nm (1.8 m•kg, 13 ft•lb)
12. Install:
9spark plug 12.5 Nm (1.25 m•kg, 9.0 ft•lb)

13. Install:
9intake manifold bolts
9intake manifold
10 Nm (1.0 m•kg, 7.2 ft•lb)
14. Connect:
9air induction system pipe bolts
23 Nm (2.3 m•kg, 17 ft•lb)
9air induction system pipe
10 Nm (1.0 m•kg, 7.2 ft•lb)

4-16
3P9-F8197-E0_4_1 05.11.18 13:11 Page 17

CAMSHAFT ENG
EASf0020

CAMSHAFT
1 Locknut
2 Adjusting screw
3 Rocker arm
4 Rocker arm shaft
5 Camshaft
6 Camshaft retainer

4-17
3P9-F8197-E0_4_1 05.11.18 13:11 Page 18

CAMSHAFT ENG
EASF0022

REMOVING THE ROCKER ARMS AND

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

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

3. Remove:
9camshaft 1
NOTE:
Screw an 8 mm bolt 2 into the threaded end of
the camshaft and then pull out the camshaft.

4. Remove:
9rocker arm shafts
9rocker arms
NOTE:
Remove the rocker arm shafts with the slide
hammer bolt 1 and weight 2.

Slide hammer bolt

90890-01085
Weight
90890-01084

4-18
3P9-F8197-E0_4_1 05.11.18 13:11 Page 19

CAMSHAFT ENG
EAS00205

CHECKING THE CAMSHAFT

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

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

Camshaft lobe dimension limit

Intake
a 25.745 mm (1.0136 in)
b 21.015 mm (0.8274 in)
Exhaust
a 25.749 mm (1.0137 in)
b 20.924 mm (0.8238 in)

3. Check:
9camshaft oil passage
Obstructions → Blow out with compressed
air.

EAS00206

CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
The following procedure applies to all of the
rocker arms and rocker arm shafts.
1. Check:
9rocker arm
Damage/wear → Replace.

4-19
3P9-F8197-E0_4_1 05.11.18 13:11 Page 20

CAMSHAFT ENG
2. Check:
9rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrica-
tion system.

3. Measure:
9rocker arm inside diameter
Out of specification → Replace.

Rocker arm inside diameter

10.000 – 10.015 mm
(0.3937 – 0.3943 in)
<Limit>: 10.030 mm (0.3949 in)

4. Measure:
9rocker arm shaft outside diameter
Out of specification → Replace.

Rocker arm shaft outside diameter

9.981 – 9.991 mm
(0.3930 – 0.3933 in)
<Limit>: 9.950 mm (0.3917 in)
5. Calculate:
9rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.

Above 0.08 mm → Replace the rocker arm and

rocker arm shaft as a set.

Rocker-arm-to-rocker-arm-shaft
clearance
0.009 – 0.034 mm
(0.0004 – 0.0013 in)
<Limit>: 0.080 mm (0.0032 in)

4-20
3P9-F8197-E0_4_1 05.11.18 13:11 Page 21

CAMSHAFT ENG
EAS00207

CHECKING THE CAMSHAFT

a
SPROCKET
1. Check:
9camshaft sprocket
Worn more than 1/4 tooth a → Replace the
camshaft sprocket and the timing chain as a
set.
a 1/4 tooth
b Correct
1 Timing chain
2 Camshaft sprocket
EAS00212

CHECKING THE TAPPET COVERS AND

CAMSHAFT SPROCKET COVER
1. Check:
9tappet cover
9camshaft sprocket cover
Damage/wear → Replace the defective
part(s).

EAS00219

INSTALLING THE CAMSHAFT AND

ROCKER ARMS
1. Lubricate:
9camshaft journals

Recommended lubricant
Engine oil
2. Lubricate:
9rocker arm inside surface
9camshaft oil passage

Recommended lubricant
Molybdenum disulfide grease
3. Install:
9camshaft retainer 1
9camshaft retainer bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
9Apply locking agent (LOCTITE®) to the
threads of camshaft retainer bolt.
9Install the camshaft retainer with the bent ends
facing inward.

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 22

VALVES AND VALVE SPRINGS ENG

EASF0024

VALVES AND VALVE SPRINGS

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

4-22
3P9-F8197-E0_4_1 05.11.18 13:12 Page 23

VALVES AND VALVE SPRINGS ENG

EASF0025

REMOVING THE VALVES

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

The following procedure applies to all of the

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

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 24

VALVES AND VALVE SPRINGS ENG

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

Valve spring compressor

90890-04019

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

EAS00239

CHECKING THE VALVES AND VALVE

GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
9valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification → Replace the valve
guide.
Valve-stem-to-valve-guide clear-
ance
Intake
0.010 – 0.037 mm
(0.0004 – 0.0015 in)
<Limit>: 0.08 mm (0.0032 in)
Exhaust
0.025 – 0.052 mm
(0.0010 – 0.0020 in)
<Limit>: 0.10 mm (0.0039 in)

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 25

VALVES AND VALVE SPRINGS ENG

2. Replace:
9valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100°C in an oven.

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

Valve guide remover (4.5 mm)

90890-04116
Valve guide installer (4.5 mm)
90890-04117
Valve guide reamer (4.5 mm)
90890-04118

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
9carbon deposits
(from the valve face and valve seat)
4. Check:
9valve face
Pitting/wear → Grind the valve face.
9valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace the
valve.
5.Measure:
9valve margin thickness a
Out of specification → Replace the valve.
Valve margin thickness
Intake: 0.5 – 0.9 mm
(0.0197 – 0.0354 in)
Exhaust: 0.8 – 1.2 mm
(0.0315 – 0.0472 in)

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 26

VALVES AND VALVE SPRINGS ENG

6. Measure:
9valve stem runout
Out of specification → Replace the valve.
NOTE:
9When installing a new valve, always replace
the valve guide.
9If the valve is removed or replaced, always
replace the valve stem seal.

Valve stem runout limit

0.01 mm (0.0004 in)

EAS00240

CHECKING THE VALVE SEATS

The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
9carbon deposits
(from the valve face and valve seat)
2. Check:
9valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
9valve seat width a
Out of specification → Replace the cylinder
head.
Valve seat width
Intake: 0.9 – 1.1 mm
(0.0354 – 0.0433 in)
Exhaust: 0.9 – 1.1 mm
(0.0354 – 0.0433 in)
<Limit>: 1.6 mm (0.06 in)

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

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 27

VALVES AND VALVE SPRINGS ENG

NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound a to the
valve face.
cC
M Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.

b. Apply engine oil onto the valve stem.

c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.

e. Apply a fine lapping compound to the valve

face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.

4-27
3P9-F8197-E0_4_1 05.11.18 13:12 Page 28

VALVES AND VALVE SPRINGS ENG

j. Measure the valve seat width c again. If
the valve seat width is out of specification,
reface and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00241

CHECKING THE VALVE SPRINGS

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

Valve spring free length

Intake and exhaust valve
springs
33.75 mm (1.33 in)
<Limit>: 32.05 mm (1.2618 in)

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

Compressed valve spring force

(installed)
Intake and exhaust valve
springs
138 – 148 N
(14.07 – 15.09 kgf)
at 24.2 mm (0.95 in)
3. Measure:
9valve spring tilt a
Out of specification → Replace the valve
spring.

Spring tilt limit

Intake and exhaust valve
springs
1.4 mm (0.06 in)

4-28
3P9-F8197-E0_4_1 05.11.18 13:12 Page 29

VALVES AND VALVE SPRINGS ENG

EAS00245

INSTALLING THE VALVES

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

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

M Recommended lubricant
Engine oil

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

b Smaller pitch

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 30

VALVES AND VALVE SPRINGS ENG

4. Install:
9valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2.

Valve spring compressor

90890-04019

5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-
face hammer.
cC
Hitting the valve tip with excessive force
could damage the valve.

4-30
3P9-F8197-E0_4_1 05.11.18 13:12 Page 31

CYLINDER AND PISTON ENG

EASF0027

CYLINDER AND PISTON

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

4-31
3P9-F8197-E0_4_1 05.11.18 13:12 Page 32

CYLINDER AND PISTON ENG

EASF0028

REMOVING THE CYLINDER AND

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

1. Remove:
9cylinder 1

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

3. Remove:
9piston pin clip 1
9piston pin 2
9piston 3
cC
Do not use a hammer to drive the piston pin
out.

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

4. Remove:
9top ring
92nd ring
9oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the
ring over the piston crown.

4-32
3P9-F8197-E0_4_1 05.11.18 13:12 Page 33

CYLINDER AND PISTON ENG

EAS00255

CHECKING THE CYLINDER AND

PISTON
1. Check:
9piston wall
9cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.

2. Measure:
9piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.

51.000 – 51.015 mm
Cylinder bore “C”
(2.0079 – 2.0085 in)
Limit 51.1 mm (2.03 in)
Taper limit “T” 0.05 mm (0.002 in)
Out-of-round “R” 0.05 mm (0.002 in)

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

b. If out of specification, rebore or replace the

cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter “P” with a
micrometer.
a 4 mm from the bottom edge of the piston
Piston size “P”
50.977 – 50.992 mm
Standard
(2.0070 – 2.0076 in)
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 34

CYLINDER AND PISTON ENG

Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”

Piston-to-cylinder clearance
0.020 – 0.025 mm
(0.0008 – 0.0010 in)
<Limit>: 0.15 mm (0.0059 in)

f. If out of specification, rebore or replace the

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

EAS00263

CHECKING THE PISTON RINGS

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

Piston ring side clearance

Top ring
0.03 – 0.07 mm
(0.0012 – 0.0028 in)
<Limit>: 0.12 mm (0.0047 in)
2nd ring
0.02 – 0.06 mm
(0.0008 – 0.0024 in)
<Limit>: 0.12 mm (0.0047 in)

2. Install:
9piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.

a 40 mm

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 35

CYLINDER AND PISTON ENG

3. Measure:
9piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The end gap of the oil ring expander cannot be
measured. If the end gaps of the oil ring rails
are excessive, replace all three piston rings.

Piston ring end gap

Top ring
0.10 – 0.25 mm
(0.0039 – 0.0098 in)
<Limit>: 0.4 mm (0.0157 in)
2nd ring
0.10 – 0.25 mm
(0.0039 – 0.0098 in)
<Limit>: 0.4 mm (0.0157 in)
Oil ring rails
0.20 – 0.70 mm
(0.0079 – 0.0276 in)
EAS00265

CHECKING THE PISTON PIN

1. Check:
9piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication
system.

2. Measure:
9piston pin outside diameter a
Out of specification → Replace the piston
pin.

Piston pin outside diameter

12.996 – 13.000 mm
(0.5117 – 0.5118 in)
<Limit>: 12.976 mm (0.5109 in)

3. Measure:
9piston pin bore diameter (of the piston) b
Out of specification → Replace the piston.

Piston pin bore diameter (of the

piston)
13.002 – 13.013 mm
(0.5119 – 0.5123 in)
<Limit>: 13.043 mm (0.5135 in)

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 36

CYLINDER AND PISTON ENG

4. Calculate:
9piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston
pin and piston as a set.

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

Piston-pin-to-piston-pin-bore
clearance
1 0.002 – 0.017 mm
(0.0001 – 0.0007 in)
<Limit>: 0.067 mm (0.0026 in)
2

5
3
4

EAS00267
1 INSTALLING THE PISTON AND
2 CYLINDER
1. Install:
5 9top ring 1
3 92nd ring 2
9oil ring expander 3
4 9lower oil ring rail 4
9upper oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.

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

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3P9-F8197-E0_4_1 05.11.18 13:12 Page 37

CYLINDER AND PISTON ENG

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

Recommended lubricant
Engine oil

5. Offset:
9piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
å forward

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

4-37
3P9-F8197-E0_4_1 05.11.18 13:12 Page 38

GENERATOR AND STARTER CLUTCH ENG

EASF0034

GENERATOR AND STARTER CLUTCH

1 Starter clutch gear 8 Starter clutch idle gear shaft t Crankcase cover (left)
2 Starter clutch roller 9 Starter clutch idle gear
3 Starter clutch spring cap 0 Stator coil lead holder
4 Starter clutch spring q Pickup coil
5 Starter clutch w Stator coil
6 Woodruff key e Gasket
7 Generator rotor r Dowel pin

4-38
3P9-F8197-E0_4_1 05.11.18 13:12 Page 39

GENERATOR AND STARTER CLUTCH ENG

EAS00346

REMOVING THE GENERATOR

1. Drain:
9engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
2. Remove:
9front cowling (left)
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
9shift pedal
9drive sprocket cover
Refer to “REMOVING THE DRIVE CHAIN
AND SPROCKETS” in chapter 6.

3. Disconnect:
9stator coil coupler 1
9pickup coil coupler 2

4. Remove:
9crankcase cover (left) 1
9gasket
9dowel pins

5. Remove:
9generator rotor nut 1
9washer
NOTE:
9While holding the generator rotor 2 with the
sheave holder 3, loosen the generator rotor
nut.
9Do not allow the sheave holder to touch the
projection on the generator rotor.

Sheave holder
90890-01701

4-39
3P9-F8197-E0_4_1 05.11.18 13:12 Page 40

GENERATOR AND STARTER CLUTCH ENG

6. Remove:
9generator rotor 1
(with the flywheel puller 2)
9woodruff key
Flywheel puller
90890-01362

EAS00344

REMOVING THE STARTER CLUTCH

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

2. Remove:
9starter clutch rollers 1
9starter clutch spring caps
9starter clutch springs

3. Remove:
9starter clutch bolt
9starter clutch 1
NOTE:
9While holding the generator rotor 2 with the
sheave holder, remove the starter clutch bolt.
9Do not allow the sheave holder to touch the
projection on the generator rotor.

Sheave holder
90890-01701

4-40
3P9-F8197-E0_4_1 05.11.18 13:12 Page 41

GENERATOR AND STARTER CLUTCH ENG

EAS00351

CHECKING THE STARTER CLUTCH

1. Check:
9starter clutch rollers 1
Damage/wear → Replace.

2. Check:
9starter clutch idle gear 1
9starter clutch gear 2
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
9starter clutch gear contacting surfaces a
Damage/pitting/wear → Replace the starter
clutch gear.

4. Check:
9starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear 1 onto the
starter clutch and hold the starter clutch.
b. When turning the starter clutch gear clock-
wise å, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be
replaced.
c. When turning the starter clutch gear coun-
terclockwise ∫, it should turn freely, other-
wise the starter clutch is faulty and must be
replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-41
3P9-F8197-E0_4_1 05.11.18 13:12 Page 42

GENERATOR AND STARTER CLUTCH ENG

EAS00355

INSTALLING THE STARTER CLUTCH

1. Install:
9starter clutch 1
14 Nm (1.4 m•kg, 10.1 ft•lb)
NOTE:
9While holding the generator rotor 2 with the
sheave holder, tighten the starter clutch bolt.
9Do not allow the sheave holder to touch the
projection on the generator rotor.
9Lock the threads on the starter clutch bolts by
staking them with a center punch.

Sheave holder
90890-01701

EAS00353

INSTALLING THE GENERATOR

1. Install:
9woodruff key
9generator rotor
9generator rotor nut
NOTE:
9Clean the tapered portion of the crankshaft
and the generator rotor hub.
9When installing the generator rotor, make sure
the woodruff key is properly sealed in the key-
way of the crankshaft.

2. Tighten:
9generator rotor nut 1
70 Nm (7.0 m•kg, 50 ft•lb)
NOTE:
9While holding the generator rotor 2 with the
sheave holder 3, tighten the generator rotor
nut.
9Do not allow the sheave holder to touch the
projection on the generator rotor.

Sheave holder
90890-01701

4-42
3P9-F8197-E0_4_1 05.11.18 13:12 Page 43

GENERATOR AND STARTER CLUTCH ENG

3. Apply:
9sealant
(on to the generator lead grommet)
Yamaha bond No. 1215
90890-85505

4. Install:
9gasket
9crankcase cover
10 Nm (1.0 m•kg, 7.2 ft•lb)

4-43
3P9-F8197-E0_4_1 05.11.18 13:12 Page 44

KICKSTARTER ENG
EASF0035

KICKSTARTER
1 Kickstarter lever 8 Kickstarter ratchet gear clip
2 Crankcase cover (right) 9 Kickstarter ratchet gear
3 Gasket 0 Kickstarter gear
4 Dowel pin q Kickstarter shaft
5 Kickstarter spring guide 1
6 Kickstarter spring
7 Kickstarter spring guide 2

10 Nm (1.0 m•kg, 7.2 ft•lb )

5
6
7
8
9

0
q

4-44
3P9-F8197-E0_4_1 05.11.18 13:12 Page 45

KICKSTARTER ENG
REMOVING THE KICKSTARTER
1. Drain:
9engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
2. Remove:
9front cowling (right)
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
9muffler
9footrest
9brake pedal
Refer to “REMOVING THE ENGINE”.

3. Remove:
9kickstarter lever bolt 1
9kickstarter lever 2

4. Remove:
1 9crankcase cover bolts
9crankcase cover (right) 1
9gasket
9dowel pins

5. Remove:
9kickstarter shaft assembly 1

4-45
3P9-F8197-E0_4_1 05.11.18 13:12 Page 46

KICKSTARTER ENG
6. Remove:
9kickstarter spring guide 1 1
1 9kickstarter spring 2
2 9kickstarter spring guide 2 3
3 9circlip 4
5 9kickstarter ratchet gear clip 5
6
9kickstarter ratchet gear 6
9circlip 7
4 9shim 8
9wave washer 9
9kickstarter gear 0
0 9kickstarter shaft q
q
7
8
9

EAS00339

CHECKING THE KICKSTARTER

1. Check:
9kickstarter ratchet gear 1
9kickstarter gear 2
Damage/wear → Replace.

2. Check:
9kickstarter spring
Damage/wear → Replace.

3. Measure:
9kickstarter ratchet gear clip force
(with a spring gauge)
Out of specification → Replace the kick-
starter ratchet gear clip.

Kickstarter ratchet gear clip force

0.67 – 15.5 kg

4-46
3P9-F8197-E0_4_1 05.11.18 13:12 Page 47

KICKSTARTER ENG
EAS00340
a 2 1 INSTALLING THE KICKSTARTER
1. Install:
9kickstarter shaft assembly 1
9kickstarter ratchet gear clip 2
9kickstarter spring 3
NOTE:
Turn the kickstarter spring clockwise and install
3
its end into the hole a in the crankcase.

2. Install:
1 9crankcase cover (right) 1
9crankcase cover bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)

2 NOTE:
Apply sealant to the threads of the crankcase
cover bolts 2.

Yamaha bond No. 1215

90890-85505

3. Install:
9kickstarter lever 1
9kickstarter lever bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)

4-47
3P9-F8197-E0_4_1 05.11.18 13:12 Page 48

CLUTCH ENG
EASF0029

CLUTCH
1 Clutch boss nut 9 Clutch plate #2 u Clutch release adjusting
2 Clutch boss 0 Clutch push rod #1 screw
3 Clutch housing q Clutch shoe housing nut
4 Clutch push rod #2 w Clutch shoe housing
5 Clutch pressure plate bolt e Cage
6 Clutch pressure plate r Clutch shoe housing boss
7 Friction plate t Clutch shoe
8 Clutch plate #1 y Clutch release shift arm

4-48
3P9-F8197-E0_4_1 05.11.18 13:12 Page 49

CLUTCH ENG
EAS00277

REMOVING THE CLUTCH

1. Drain:
9engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
2. Remove:
9front cowling (right)
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
9muffler
9footrest
9brake pedal
Refer to “REMOVING THE ENGINE”.
9kickstarter lever
Refer to “KICKSTARTER”.
9crankcase cover (left)
Refer to “GENERATOR AND STARTER
CLUTCH”.
3. Remove:
9clutch release shift arm 1

4. Remove:
9clutch pressure plate bolts 1
9clutch springs
9clutch pressure plate 2
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.

5. Remove:
9thrust bearing 1
9clutch push rod #1 2
9friction plates 3
9clutch plates #1 4
9clutch plate #2 5
(with springs)

4-49
3P9-F8197-E0_4_1 05.11.18 13:12 Page 50

CLUTCH ENG
6. Straighten the lock washer tab.
7. Loosen:
9clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the uni-
versal clutch holder 3, loosen the clutch boss
nut.

Universal clutch holder

90890-04086

8. Remove:
9clutch boss nut 1
9lock washer 2
9clutch boss 3
9washer 4
9clutch housing 5
9collar 6
9spacer 7
9clutch push rod #2 8

9. Remove:
9clutch shoe housing nut 1
9washer
NOTE:
9Loosen the clutch shoe housing nut while hold-
ing the generator rotor 2 with the sheave
holder 3.
9Do not allow the sheave holder to touch the
1
projection on the generator rotor.

Sheave holder
90890-01701

4-50
3P9-F8197-E0_4_1 05.11.18 13:12 Page 51

CLUTCH ENG
10. Remove:
9collar 1
9clutch shoe housing 2
9washer 3
9rollers 4
9cage springs 5
9cage 6
9clutch shoe housing boss 7
9clutch shoe 8

EAS00280

CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric-
tion plates.
1. Check:
9friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
9friction plate thickness
Out of specification → Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.

Friction plate thickness

2.7 – 2.9 mm (0.106 – 0.114 in)
<Limit>: 2.6 mm (0.1024 in)

EAS00281

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the
clutch plates.
1. Check:
9clutch plate
Damage → Replace the clutch plates as a
set.

2. Measure:
9clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification → Replace the clutch
plates as a set.

Clutch plate warpage limit

0.05 mm (0.0019 in)

4-51
3P9-F8197-E0_4_1 05.11.18 13:12 Page 52

CLUTCH ENG
EAS00282

CHECKING THE CLUTCH SPRINGS

The following procedure applies to all of the
clutch springs.
1. Check:
9clutch spring
Damage → Replace the clutch springs as a
set.
2. Measure:
9clutch spring free length a
Out of specification → Replace the clutch
springs as a set.

Clutch spring free length

30.3 mm (1.19 in)
<Limit>: 28.3 mm (1.11 in)

EAS00284

CHECKING THE CLUTCH HOUSING

1. Check:
9clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause
erratic clutch operation.

2. Check:
9bearing
Damage/wear → Replace the bearing and
clutch housing.

EAS00285

CHECKING THE CLUTCH BOSS

1. Check:
9clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause
erratic clutch operation.

4-52
3P9-F8197-E0_4_1 05.11.18 13:12 Page 53

CLUTCH ENG
EAS00286

CHECKING THE CLUTCH PRESSURE

PLATE
1. Check:
9clutch pressure plate
Cracks/damage → Replace.

EAS00288

CHECKING THE CLUTCH PUSH ROD

#2
1. Check:
9clutch push rod #2
Cracks/damage/wear → Replace the clutch
push rod #2.
2. Measure:
9clutch push rod #2 bending limit
Out of specification → Replace the clutch
push rod #2.

Clutch push rods bending limit

0.5 mm (0.0197 in)

EAS00292

CHECKING THE PRIMARY DRIVEN

GEAR
1. Check:
9primary drive gear
(on the clutch shoe housing)
9primary driven gear
(on the clutch housing)
Damage/wear → Replace the clutch shoe
housing and clutch housing as a set.
Excessive noise during operation →
Replace the clutch shoe housing and clutch
housing as a set.

4-53
3P9-F8197-E0_4_1 05.11.18 13:12 Page 54

CLUTCH ENG
CHECKING THE CLUTCH SHOE
HOUSING
1. Check:
9clutch shoe housing
Damage/wear → Replace.

2. Measure:
9clutch shoe housing inside diameter a
Out of specification → Replace.

Clutch shoe housing inside diame-

ter
105 mm (4.13 in)
<Limit>: 106 mm (4.17 in)

CHECKING THE CLUTCH SHOE

1. Check:
9clutch shoe
Scratches → Smooth using coarse sandpa-
per.
Damage/wear → Replace.

2. Measure:
9clutch shoe groove depth a
Groove is worn away → Replace.

Clutch shoe groove depth

1.20 mm (0.0472 in)
<Limit>: 0.1 mm (0.0039 in)

2 CHECKING THE CAGE

1. Check:
1 9cage 1
Damage/wear/cracks → Replace.
9rollers 2
Wear/bend → Replace.
9cage springs 3
2 Wear → Replace.
1

4-54
3P9-F8197-E0_4_1 05.11.18 13:12 Page 55

CLUTCH ENG
CHECKING THE CLUTCH RELEASE
SHIFT ARM
1
1. Check:
9clutch release shift arm 1
2 Damage/wear → Replace.
9clutch release adjusting screw 2
Damage/wear → Replace.

EAS00293

INSTALLING THE CLUTCH

1. Install:
9washer
9cage 1
9cage springs 2
9rollers 3
9clutch shoe housing boss 4

2. Tighten:
9clutch shoe housing nut 1
50 Nm (5.0 m•kg, 36 ft•lb)
NOTE:
1 9While holding the generator rotor 2 with the
sheave holder 3, tighten the clutch shoe
housing nut.
9Do not allow the sheave holder to touch the
projection on the generator rotor.

Sheave holder
90890-01701

3. Install:
9clutch push rod #2 1
9spacer 2
9collar 3
9clutch housing 4
9washer 5
9clutch boss 6
9lock washer 7
9clutch boss nut 8

4-55
3P9-F8197-E0_4_1 05.11.18 13:12 Page 56

CLUTCH ENG
4. Tighten:
9clutch boss nut 1
70 Nm (7.0 m•kg, 50 ft•lb)
NOTE:
While holding the clutch boss 2 with the univer-
sal clutch holder 3, tighten the clutch boss nut.

Universal clutch holder

90890-04086

5. Bend the lock washer tab along a flat side

of the nut.
6. Lubricate:
9friction plates
9clutch plates #1
9clutch plate #2
(with the recommended lubricant)

Recommended lubricant
Engine oil
7. Install:
9friction plates
9clutch plate #2
(with springs)
9clutch plates #1
NOTE:
First, install a friction plate and then alternate
between a clutch plate and a friction plate.

8. Install:
9clutch springs
9clutch pressure plate 1
9clutch pressure plate bolts 2
6 Nm (0.6 m•kg, 4.3 ft•lb)
NOTE:
Tighten the clutch pressure plate bolts in
stages and in a crisscross pattern.

9. Adjust:
9clutch release system
Refer to “ADJUSTING THE CLUTCH
RELEASE SYSTEM” in chapter 3.

4-56
3P9-F8197-E0_4_1 05.11.18 13:12 Page 57

OIL PUMP ENG

EASF0032

OIL PUMP
1 Oil pump driven gear 8 Engine oil drain bolt
2 Oil pump assembly
3 Gasket
4 Oil filter
5 Oil pump drive gear
6 Oil strainer
7 Gasket

4-57
3P9-F8197-E0_4_1 05.11.18 13:12 Page 58

OIL PUMP ENG

REMOVING THE OIL PUMP
1. Drain:
9engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
2. Remove:
9clutch shoe
Refer to “CLUTCH”.

3. Remove:
9oil filter 1

4. Remove:
9oil pump drive gear 1
9oil pump driven gear 2

5. Remove:
9oil pump assembly 1
9gasket 2
9oil strainer 3

DISASSEMBLING THE OIL PUMP

1. Remove:
9screw
9oil pump housing cover 1
9oil pump shaft 2
9pin 3
9inner rotor 4
9outer rotor 5
9oil pump housing 6

4-58
3P9-F8197-E0_4_1 05.11.18 13:12 Page 59

OIL PUMP ENG

EAS00364

CHECKING THE OIL PUMP

1. Check:
9oil pump drive gear 1
9oil pump driven gear 2
9oil pump housing 3
9oil pump housing cover 4
Cracks/damage/wear → Replace the defec-
tive part(s).

2. Measure:
9inner-rotor-to-outer-rotor-tip clearance a
9outer-rotor-to-oil-pump-housing clearance
b
9oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance c
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing

Inner-rotor-to-outer-rotor-tip
clearance
0.15 mm (0.0059 in)
<Limit>: 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.06 – 0.10 mm
(0.0024 – 0.0039 in)
<Limit>: 0.15 mm (0.0059 in)
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
0.06 – 0.10 mm
(0.0024 – 0.0039 in)
<Limit>: 0.15 mm (0.0059 in)

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

4-59
3P9-F8197-E0_4_1 05.11.18 13:12 Page 60

OIL PUMP ENG

EAS00328

CHECKING THE OIL STRAINER

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

CHECKING THE OIL FILTER

1. Check:
9oil filter
Damage → Replace.
Contaminants → Clean with solvent.

EAS00375

ASSEMBLING THE OIL PUMP

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

Recommended lubricant
Engine oil

2. Install:
9oil pump shaft
(to the oil pump housing)
9pin 1
9inner rotor 2
9outer rotor
9oil pump housing cover
9screw
NOTE:
When installing the inner rotor, align the pin in
the oil pump shaft with the groove a in the
inner rotor.

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

4-60
3P9-F8197-E0_4_1 05.11.18 13:12 Page 61

OIL PUMP ENG

EAS00376

INSTALLING THE OIL PUMP

a 1. Install:
9gasket
9oil pump assembly 1
7 Nm (0.7 m•kg, 5.0 ft•lb)
NOTE:
Install the gasket with section a in the position
1 as shown in the illustration.

cC
After tightening the bolts, make sure the oil
pump turns smoothly.

2. Install:
9oil filter 1
NOTE:
Align the mark a on the oil filter with the oil
hole b in the crankshaft journal.

4-61
3P9-F8197-E0_4_1 05.11.18 13:12 Page 62

SHIFT SHAFT ENG

EASF0037

SHIFT SHAFT
1 Shift lever assembly 8 Shift guide spring t Stopper lever spring
2 Shift drum segment 9 Shift fork guide bar y Stopper lever assembly
3 Washer 0 Shift pedal
4 Thrust bearing q Shift shaft
5 Guide w Shift lever
6 Pawl holder e Shift shaft spring stopper
7 Shift guide r Shift shaft spring

4-62
3P9-F8197-E0_4_1 05.11.18 13:12 Page 63

SHIFT SHAFT ENG

REMOVING THE SHIFT SHAFT
1. Drain:
9engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
2. Remove:
9clutch
Refer to “CLUTCH”.
9oil pump driven gear
Refer to “OIL PUMP”.

3. Remove:
9shift fork guide bar 1
9washer 2
9shift guide spring

4. Remove:
9shift guide 1
9pawl holder 2
9guide 3
9dowel pin

5. Remove:
9washers 1
9thrust bearing 2

4-63
3P9-F8197-E0_4_1 05.11.18 13:12 Page 64

SHIFT SHAFT ENG

6. Remove:
9shift shaft assembly 1
9shift shaft spring stopper 2
9shift lever assembly 3

7. Remove:
9circlip 1
9washer 2
9shift shaft spring 3
9shift lever 4
9shift shaft 5

8. Remove:
9stopper lever assembly 1
9stopper lever spring 2

9. Remove:
9circlip 1
9washer 2
9stopper lever holder 3
9stopper lever 4

10. Remove:
9shift drum segment 1
9dowel pins

4-64
3P9-F8197-E0_4_1 05.11.18 13:12 Page 65

SHIFT SHAFT ENG

EAS00328

CHECKING THE SHIFT SHAFT

1. Check:
9shift shaft 1
9shift lever 2
Bends/damage/wear → Replace.
9springs
Damage/wear → Replace.

EAS00330

CHECKING THE STOPPER LEVER

1. Check:
9stopper lever 1
Bends/damage → Replace.
Roller turns roughly → Replace.
9stopper lever spring
Damage/wear → Replace.

CHECKING THE SHIFT GUIDE

1. Check:
9shift guide 1
9pawl holder 2
9guide 3
Bends/damage → Replace.
9shift guide spring
Damage/wear → Replace.

CHECKING THE OIL SEAL

1. Check:
9oil seal
Damage/wear → Replace.

4-65
3P9-F8197-E0_4_1 05.11.18 13:12 Page 66

SHIFT SHAFT ENG

EAS00331

INSTALLING THE SHIFT SHAFT

1. Install:
9shift drum segment 1
12 Nm (1.2 m•kg, 8.6 ft•lb)
NOTE:
Apply locking agent (LOCTITE®) to the threads
of shift drum segment screw.

2. Install:
9stopper lever 1
9stopper lever spring 2
NOTE:
9Hook the ends 3 of the stopper lever spring
onto the stopper lever and the crankcase boss.
9Mesh the stopper lever with the shift drum seg-
ment assembly.

3. Install:
9shift lever assembly 1
9shift shaft spring stopper 2
9shift shaft assembly 3
NOTE:
9Align the punched mark a in the shift lever
assembly with the punched mark b in the shift
shaft assembly.
9Hook the end of the shift shaft spring onto the
shift shaft spring stopper 2.

4-66
3P9-F8197-E0_4_1 05.11.18 13:13 Page 67

CRANKCASE AND CRANKSHAFT ENG

EASF0037

CRANKCASE AND CRANKSHAFT

1 Right crankcase 8 Timing chain
2 Dowel pin 9 Timing chain guide (intake side)
3 Left crankcase
4 Starter motor lead holder
5 Gear position pointer
6 Neutral switch
7 Crankshaft assembly

4-67
3P9-F8197-E0_4_1 05.11.18 13:13 Page 68

CRANKCASE AND CRANKSHAFT ENG

EAS00385

DISASSEMBLING THE CRANKCASE

1. Remove:
9engine
Refer to “REMOVING THE ENGINE”.

2. Remove:
9starter motor lead
9starter motor
Refer to “STARTER MOTOR” in chapter 7.
3. Remove:
9cylinder head
Refer to “CYLINDER HEAD”.
9cylinder
9piston
Refer to “CYLINDER AND PISTON”.
9clutch
Refer to “CLUTCH”.
9shift shaft
Refer to “SHIFT SHAFT”.
9oil pump drive gear
Refer to “OIL PUMP”.
9generator
9starter clutch
Refer to “GENERATOR AND STARTER
CLUTCH”.
4. Remove:
2 9timing chain guide (intake side) bolts 1
9timing chain guide (intake side) 2
1 9timing chain 3

5. Remove:
9crankcase bolts

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

4-68
3P9-F8197-E0_4_1 05.11.18 13:13 Page 69

CRANKCASE AND CRANKSHAFT ENG

6. Remove:
9right crankcase
9dowel pins
cC
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.

7. Remove:
9crankshaft spacer
9crankshaft assembly
NOTE:
Use the crankcase separating tool.

Crankcase separating tool

90890-01135

w
Never use the hammer to tapping and
removing the crankshaft directory.

EAS00394

CHECKING THE CRANKSHAFT AND

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

Maximum crankshaft runout

0.03 mm (0.0012 in)

4-69
3P9-F8197-E0_4_1 05.11.18 13:13 Page 70

CRANKCASE AND CRANKSHAFT ENG

2. Measure:
9big end side clearance
Out of specification → Replace the crank-
shaft.

Big end side clearance

0.11 – 0.41 mm
(0.0043 – 0.0161 in)

3. Measure:
9crankshaft width
Out of specification → Replace the crank-
shaft.

Crankshaft width
42.95 – 43.00 mm
(1.691 – 1.693 in)

4. Check:
9crankshaft sprocket 1
Damage/wear → Replace the crankshaft.
9bearing 2
Cracks/damage/wear → Replace the crank-
shaft.

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

4-70
3P9-F8197-E0_4_1 05.11.18 13:13 Page 71

CRANKCASE AND CRANKSHAFT ENG

EAS00399

CHECKING THE CRANKCASE

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

EAS00401

CHECKING THE BEARINGS

1. Check:
9bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.

CHECKING THE TIMING CHAIN GUIDE

1. Check:
9timing chain guide (intake side)
Damage/wear → Replace.

CHECKING THE TIMING CHAIN

1. Check:
9timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.

4-71
3P9-F8197-E0_4_1 05.11.18 13:13 Page 72

CRANKCASE AND CRANKSHAFT ENG

EAS00408
1 2
INSTALLING THE CRANKSHAFT
3
1. Install:
5 9crankshaft assembly 1
4
9crankshaft spacer
NOTE:
Use the crankshaft installing tool (spacer 2,
installer pot 3, installer bolt 4, adaptor 5) to
install the crankcase (left).

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

w
9Hold the connecting rod at top dead center
with one hand while turning the nut of the
installing tool with the other.
9Operate the installing tool until the crank-
shaft bottoms against the bearing .

Crank pot spacer 2 :

90890-04081
Crank shaft installer pot 3 :
90890-01274
Crank shaft installer bolt 4 :
90890-01275
Adaptor 5:
90890-01278
EAS00416

ASSEMBLING THE CRANKCASE

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

1 NOTE:
Do not allow any sealant to come into contact
with the oil gallery 1.

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

4-72
3P9-F8197-E0_4_1 05.11.18 13:13 Page 73

CRANKCASE AND CRANKSHAFT ENG

4. Install:
9starter motor lead holders
9crankcase bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
1
Apply sealant to the threads of crankcase bolt
1.

Yamaha bond No. 1215

90890-85505

5. Apply:
9engine oil
(onto the crankshaft bearings and oil deliv-
ery holes)
6. Check:
9crankshaft and transmission operation
Rough movement → Repair.
7. Install:
9timing chain
9timing chain guide (intake side)
9timing chain guide (intake side) bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
Apply locking agent (LOCTITE®) to the threads
of timing chain guide (intake side) bolts.

4-73
3P9-F8197-E0_4_1 05.11.18 13:13 Page 74

TRANSMISSION ENG
EASF0041

TRANSMISSION
1 Collar 9 Main axle/1st pinion gear
2 1st wheel gear 0 4th pinion gear
3 4th wheel gear q 3rd pinion gear
4 3rd wheel gear w 2nd pinion gear
5 Side plate e Shift fork guide bar
6 Side plate spring r Shift fork “R”
7 Drive axle/2nd wheel gear t Shift fork “L”
8 Drive sprocket y Shift drum

4-74
3P9-F8197-E0_4_1 05.11.18 13:13 Page 75

TRANSMISSION ENG
EASF0042

REMOVING THE TRANSMISSION

1 NOTE:
2 Prior to removing the transmission, separate the
crankcase.
4

3 1. Remove:
9shift fork guide bar 1
9circlip
9shift fork “R” 2
9shift fork “L” 3
9shift drum 4
NOTE:
Note the position of each part. Pay particular
attention to location and direction of shift forks.

2. Remove:
2 1 9main axle assembly 1
9drive axle assembly 2

DISASSEMBLING THE TRANSMISSION

1. Remove:
9washer 1
92nd pinion gear 2
93rd pinion gear 3
9circlip 4
94th pinion gear 5
9main axle/1st pinion gear 6

4-75
3P9-F8197-E0_4_1 05.11.18 13:13 Page 76

TRANSMISSION ENG
2. Remove:
9circlips 1
9washers 2
9collars 3
91st wheel gear 4
94th wheel gear 5
93rd wheel gear 6
9side plate 7
9side plate spring 8
9drive axle/2nd wheel gear 9

EAS00421

CHECKING THE SHIFT FORKS

The following procedure applies to both of the
shift forks.
1. Check:
9shift fork cam follower 1
9shift fork pawl 2
Bends/damage/scoring/wear → Replace
the shift fork.

2. Check:
9shift fork guide bar
Roll the shift fork guide bar on a flat sur-
face.
Bends → Replace.

w
Do not attempt to straighten a bent shift fork
guide bar.

3. Check:
9shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.

4-76
3P9-F8197-E0_4_1 05.11.18 13:13 Page 77

TRANSMISSION ENG
EAS00422

CHECKING THE SHIFT DRUM

ASSEMBLY
1. Check:
9shift drum grooves 1
Damage/scratches/wear → Replace the
shift drum assembly.
9shift drum bearing
Damage/pitting → Replace the shift drum
assembly.
EAS00424

CHECKING THE TRANSMISSION

1. Measure:
9main axle runout
(with a centring device and dial gauge 1)
Out of specification → Replace the main
axle.

Main axle runout limit

0.03 mm (0.0012 in)

2. Measure:
9drive axle runout
(with a centring device and dial gauge 1)
Out of specification → Replace the drive
axle.

Drive axle runout limit

0.03 mm (0.0012 in)

3. Check:
9transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
9transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).

4-77
3P9-F8197-E0_4_1 05.11.18 13:13 Page 78

TRANSMISSION ENG
4. Check:
9transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
2
1 NOTE:
19.3~19.5 mm When reassembling the drive axle, press the
2nd wheel gear 1 onto the drive axle 2 as
shown.

5. Check:
9transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
9circlips
Bends/damage/looseness → Replace.

1
ASSEMBLING THE TRANSMISSION
1. Install:
9side plate spring 1
2 9side plate 2
NOTE:
Install the side plate spring and side plate as
shown.

EAS00426

INSTALLING THE TRANSMISSION

1. Install:
9shift fork guide bar 1
a 1 9shift fork “R”
9shift fork “L”
2 9shift drum 2
NOTE:
9Install the side plate with its end a between
the shift fork guide bar and shift drum.
9The embossed marks a on the shift forks
should face towards the right side of the
engine and be in the following sequence:
“R”, “L”.

4-78
3P9-F8197-E0_4_1 05.11.18 13:13 Page 79

TRANSMISSION ENG
2. Check:
9transmission
9shift drum
9shift forks
Rough movement → Repair.
NOTE:
9Oil each gear, shaft, and bearing thoroughly.
9Before assembling the crankcase, be sure that
the transmission is in neutral and that the
gears turn freely.

4-79
3P9-F8197-E0_4_1 05.11.18 13:13 Page 80

ENG

4-80
3S3-F8197-E0_5 05.11.2 16:58 Page A

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

AIR INDUCTION SYSTEM..................................................................................... 5-10

AIR INJECTION ................................................................................................. 5-10
AIR CUT-OFF VALVE ......................................................................................... 5-10
REMOVING THE AIR INDUCTION SYSTEM.................................................... 5-12
CHECKING THE AIR INDUCTION SYSTEM .................................................... 5-12
INSTALLING THE AIR INDUCTION SYSTEM................................................... 5-12
3S3-F8197-E0_5 05.11.2 16:58 Page B

CARB
3S3-F8197-E0_5 05.11.2 16:58 Page 1

CARBURETOR CARB
EASF0043

CARBURETOR
CARBURETOR
1 Starter plunger assem- 6 Jet needle set e Needle jet o Float pivot pin
bly 7 Throttle valve r Main jet p Float chamber
2 Coasting enricher 8 Throttle stop screw set t Pilot jet a Fuel drain screw
spring 9 Pilot air screw set y Needle valve s Carburetor overflow
3 Coasting enricher 0 Air vent hose u Float hose
4 Carburetor top cover q Fuel hose i Float chamber rubber
5 Throttle valve spring w Carburetor joint gasket

5-1
3S3-F8197-E0_5 05.11.2 16:58 Page 2

CARBURETOR CARB
REMOVING THE CARBURETOR
w
Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.

1. Remove:
9front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
2. Loosen:
9fuel drain screw 1
3. Drain:
9fuel (from float chamber)
1

4. Remove:
9carburetor top cover 1

5. Remove:
9starter plunger assembly 1
1 (from carburetor body)
9gasket

6. Disconnect:
3 9fuel hose 1
9carburetor overflow hose 2
9air vent hose 3

2
1

5-2
3S3-F8197-E0_5 05.11.2 16:58 Page 3

CARBURETOR CARB
7. Loosen:
4 9carburetor joint clamp screw 1
8. Remove:
2
9bolts 2
9carburetor assembly 3
9carburetor joint 4

1 3

9. Remove:
9starter plunger assembly 1
(from starter cable)
1

10. Remove:
9throttle valve assembly 1
9throttle valve spring 2

11. Remove:
9throttle valve 1
1 2 9jet needle set 2
NOTE:
Push the jet needle holder 3 with a Phillips
screwdriver, and then turn it to remove the jet
3 needle holder.

DISASSEMBLING THE CARBURETOR

NOTE:
The following parts can be cleaned and inspect-
ed without disassembly.
9Coasting enricher
9Starter plunger
9Throttle stop screw
9Pilot air screw

5-3
3S3-F8197-E0_5 05.11.2 16:58 Page 4

CARBURETOR CARB
1. Remove:
9coasting enricher cover
2 9coasting enricher spring 1
1 9coasting enricher 2

2. Remove:
9pilot air screw set 1

3. Remove:
9throttle stop screw set 1

4. Remove:
1 9float chamber 1
9float chamber rubber gasket

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

2
1

5-4
3S3-F8197-E0_5 05.11.2 16:58 Page 5

CARBURETOR CARB
6. Remove:
9float pivot pin 1
9float 2
3 9needle valve 3
2
1

EAS00485

CHECKING THE CARBURETOR

1. Check:
9carburetor body
9float chamber
9jet housing
Cracks/damage → Replace.

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

5. Check:
9float
Damage → Replace.

5-5
3S3-F8197-E0_5 05.11.2 16:58 Page 6

CARBURETOR CARB
6. Check:
9needle valve
Damage/wear → Replace.

7. Check:
9coasting enricher 1
1
9coasting enricher spring 2
2 Cracks/damage → Replace.

8. Check:
1 2 3 4 5 6 9jet needle 1
9needle jet 2
9main jet 3
9pilot jet 4
9pilot air screw 5
9throttle stop screw 6
Bends/damage/wear → Replace.
Obstruction → Clean.
Blow out the jets with compressed air.
9. Check:
9throttle valve
Damage/scratches/wear → Replace.

10. Check:
9starter plunger
9starter plunger spring
Bends/cracks/damage → Replace the
starter plunger assembly.

5-6
3S3-F8197-E0_5 05.11.2 16:58 Page 7

CARBURETOR CARB
11. Check:
9hose joints
Cracks/damage → Replace.
12. Check:
9air vent hose
9fuel hoses
Cracks/damage/wear → Replace.
Obstructions → Clean.
Blow out the hoses with compressed air.

EAS00487

ASSEMBLING THE CARBURETOR

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

EAS00492

INSTALLING THE CARBURETOR

1. Install:
9jet needle set
NOTE:
Push the jet needle holder 1 with a Phillips
1 screwdriver, and then turn it to secure it in place.

2. Install:
9throttle valve assembly
a
NOTE:
Align the slit a of the throttle valve with the tab
b b of the carburetor body.

3. Install:
9carburetor joint
9carburetor joint clamp screw
9carburetor assembly
9bolts 10 Nm (1.0 m·kg, 7.2 ft·lb)
4. Adjust:
9engine idling speed

Engine idling speed

1,400–1,600 r/min
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” in chapter 3.

5-7
3S3-F8197-E0_5 05.11.2 16:58 Page 8

CARBURETOR CARB
5. Adjust:
9throttle cable free play

Throttle cable free play (at the

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

Refer to “ADJUSTING THE THROTTLE

CABLE FREE PLAY” in chapter 3.

EAS00498

MEASURING AND ADJUSTING THE

FUEL LEVEL
1. Measure:
9fuel level a
Out of specification → Adjust.
1
Fuel level (below the float chamber
mating surface)
2.5–3.5 mm (0.0984–0.1378 in)
a
4 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Stand the vehicle on a level surface.
2 b. Place the vehicle on a suitable stand to
ensure that the vehicle is standing straight
up.
c. Install the fuel level gauge 1 onto the fuel
drain pipe 2.

Fuel level gauge

90890-01312
d. Loosen the fuel drain screw 3.
e. Hold the fuel level gauge vertically next to
the float chamber 4.
f. Measure the fuel level a.
3 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5-8
3S3-F8197-E0_5 05.11.2 16:58 Page 9

CARBURETOR CARB
2. Adjust:
9fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carburetor.
1 b. Check the needle valve.
c. If worn, replace the needle valve.
d. If fine, adjust the float level by the needle
valve is slightly bending the float tang 1.
e. Install the carburetor.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00506

CHECKING THE FUEL COCK OPERA-

TION
1. Remove:
9rear cowling (left)
1 Refer to “REMOVING THE REAR COWL-
INGS” in chapter 3.
2. Place a container under the end of the fuel
hose 1.

3. Check:
1 9fuel cock operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suck on the end of the vacuum hose 1.

Fuel flows. Fuel cock is OK.

Replace the fuel
Fuel does not flow.
cock.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
9rear cowling (left)
Refer to “INSTALLING THE REAR COWL-
INGS” in chapter 3.

5-9
3S3-F8197-E0_5 05.11.2 16:58 Page 10

AIR INDUCTION SYSTEM CARB

EAS00507

AIR INDUCTION SYSTEM

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

EAS00508

AIR CUT-OFF VALVE

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

5-10
3S3-F8197-E0_5 05.11.2 16:58 Page 11

AIR INDUCTION SYSTEM CARB

1 Air cut-off valve assembly
2 Air induction system hose (air cut-off valve assembly to cylinder head)
3 Air induction system vacuum hose
4 Air induction system hose (air cut-off valve assembly to air filter)
5 Air filter

5-11
3S3-F8197-E0_5 05.11.2 16:58 Page 12

AIR INDUCTION SYSTEM CARB

REMOVING THE AIR INDUCTION SYS-
TEM
1. Remove:
9front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
1
9rear cowling (left)
Refer to “REMOVING THE REAR COWL-
INGS” in chapter 3.
9air filter 1

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

EAS00510

CHECKING THE AIR INDUCTION SYS-

TEM
1. Check:
9hoses
Loose connections → Connect properly.
Cracks/damage → Replace.
9pipe
Cracks/damage → Replace.

2. Check:
9air filter
9air cut-off valve
Cracks/damage → Replace.

INSTALLING THE AIR INDUCTION SYS-

TEM
For installation, reverse the removal procedure.

5-12
3P9-F8197-E0_6 11/8/05 3:13 PM Page A

CHAS
CHAPTER 6
CHASSIS
FRONT WHEEL AND DRUM BRAKE ................................................................... 6-1
REMOVING THE FRONT WHEEL .................................................................... 6-2
DISASSEMBLING THE BRAKE SHOE PLATE................................................. 6-2
CHECKING THE FRONT WHEEL..................................................................... 6-3
CHECKING THE SPEEDOMETER GEAR UNIT .............................................. 6-5
CHECKING THE BRAKE................................................................................... 6-6
ASSEMBLING THE BRAKE SHOE PLATE....................................................... 6-7
ASSEMBLING THE FRONT WHEEL ................................................................ 6-7
INSTALLING THE FRONT WHEEL ................................................................... 6-7

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

REMOVING THE REAR WHEEL ...................................................................... 6-10
DISASSEMBLING THE BRAKE SHOE PLATE................................................. 6-12
CHECKING THE REAR WHEEL ....................................................................... 6-13
CHECKING THE REAR WHEEL DRIVE HUB................................................... 6-13
CHECKING THE BRAKE................................................................................... 6-14
ASSEMBLING THE BRAKE SHOE PLATE....................................................... 6-14
INSTALLING THE REAR WHEEL ..................................................................... 6-15

FRONT FORK ........................................................................................................ 6-16

REMOVING THE FRONT FORK LEGS ............................................................ 6-17
DISASSEMBLING THE FRONT FORK LEGS .................................................. 6-18
CHECKING THE FRONT FORK LEGS............................................................. 6-19
ASSEMBLING THE FRONT FORK LEGS ........................................................ 6-20
INSTALLING THE FRONT FORK LEGS ........................................................... 6-22

HANDLEBAR ........................................................................................................ 6-24

REMOVING THE HANDLEBAR ........................................................................ 6-25
CHECKING THE HANDLEBAR......................................................................... 6-27
INSTALLING THE HANDLEBAR ...................................................................... 6-27

STEERING HEAD .................................................................................................. 6-30

REMOVING THE LOWER BRACKET ............................................................... 6-31
CHECKING THE STEERING HEAD ................................................................. 6-32
INSTALLING THE STEERING HEAD................................................................ 6-33

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM................................ 6-34

REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES
AND SWINGARM .............................................................................................. 6-35
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES........................... 6-37
CHECKING THE SWINGARM .......................................................................... 6-37
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES
AND SWINGARM .............................................................................................. 6-38
3P9-F8197-E0_6 11/8/05 3:13 PM Page B

CHAS

DRIVE CHAIN AND SPROCKETS ........................................................................ 6-39

REMOVING THE DRIVE CHAIN AND SPROCKETS ....................................... 6-40
CHECKING THE DRIVE CHAIN........................................................................ 6-41
INSTALLING THE DRIVE CHAIN AND SPROCKETS ...................................... 6-42
3P9-F8197-E0_6 11/8/05 3:13 PM Page 1

FRONT WHEEL AND DRUM BRAKE CHAS

EASF0044

EASF0045
CHASSIS
FRONT WHEEL AND DRUM BRAKE
1 Front wheel axle 8 Speedometer drive gear
2 Collar 9 Brake shoe
3 Oil seal 0 Brake camshaft
4 Bearing q Brake shoe plate
5 Spacer w Speedometer driven gear
6 Oil seal e Brake shoe wear indicator
7 Speedometer clutch r Brake camshaft lever

6-1
3P9-F8197-E0_6 11/8/05 3:13 PM Page 2

FRONT WHEEL AND DRUM BRAKE CHAS

EAS00519

REMOVING THE FRONT WHEEL

1. Stand the vehicle on a level surface.

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

2. Remove:
9brake cable adjusting nut
9brake cable
9boot
9compression spring
9pin
9speedometer cable
9axle nut
9washer

3. Elevate:
9front wheel
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.

4. Remove:
9front wheel axle
9collar
9front wheel
9brake shoe plate assembly

EAS00524

DISASSEMBLING THE BRAKE SHOE

PLATE
1. Remove:
9bushing 1
(with the special tool 2)
9speedometer driven gear 3
Meter gear bush tool
90890-01052

6-2
3P9-F8197-E0_6 11/8/05 3:13 PM Page 3

FRONT WHEEL AND DRUM BRAKE CHAS

2. Remove:
9brake shoes 1
9speedometer clutch 2
9speedometer drive gear 3
9washer 4

3. Remove:
9brake camshaft lever 1
9brake shoe wear indicator 2
9brake camshaft 3
NOTE:
When removing the brake camshaft lever, mark
the position on the brake camshaft lever where it
is aligned with the punch mark in the brake
camshaft.

EAS00526

CHECKING THE FRONT WHEEL

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

w
Do not attempt to straighten a bent wheel
axle.

2. Check:
9tire
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” in chap-
ter 3.
3. Check:
9spokes
Bends/damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
Refer to “CHECKING AND TIGHTENING
THE SPOKES” in chapter 3.

6-3
3P9-F8197-E0_6 11/8/05 3:13 PM Page 4

FRONT WHEEL AND DRUM BRAKE CHAS

4. Measure:
9front wheel radial runout a
9front wheel lateral runout b
Over the specified limits → Replace.
Front wheel radial runout limit
1.0 mm (0.04 in)
Front wheel lateral runout limit
0.5 mm (0.02 in)

5. Check:
9spacers
Damage/wear → Replace.

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

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

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

6-4
3P9-F8197-E0_6 11/8/05 3:13 PM Page 5

FRONT WHEEL AND DRUM BRAKE CHAS

c. Remove the wheel bearings 3 with a gen-
eral bearing puller.

d. Install the new wheel bearings and oil seals

in the reverse order of disassembly.
cC
Do not contact the wheel bearing inner race
4 or balls 5. Contact should be made only
with the outer race 6.

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00535

CHECKING THE SPEEDOMETER GEAR

UNIT
1. Check:
9speedometer clutch
Bends/damage/wear → Replace.

2. Check:
9speedometer drive gear 1
9speedometer driven gear 2
2 Damage/wear → Replace.
1

6-5
3P9-F8197-E0_6 11/8/05 3:13 PM Page 6

FRONT WHEEL AND DRUM BRAKE CHAS

EAS00536

CHECKING THE BRAKE

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

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

Brake shoe lining thickness limit

(minimum)
Front: 2.0 mm (0.08 in)
Rear: 2.0 mm (0.08 in)

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

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

3. Measure:
9brake drum inside diameter a
Out of specification → Replace the wheel.
a
Brake drum inside diameter limit
(maximum)
Front: 111 mm (4.37 in)
Rear: 131 mm (5.16 in)

4. Check:
9brake drum inner surface
Oil deposits → Clean.
Remove the oil with a rag soaked in lacquer
thinner or solvent.
Scratches → Repair.
Lightly and evenly polish the scratches with
an emery cloth.
5. Check:
9brake camshaft
Damage/wear → Replace.

6-6
3P9-F8197-E0_6 11/8/05 3:13 PM Page 7

FRONT WHEEL AND DRUM BRAKE CHAS

EAS00537

ASSEMBLING THE BRAKE SHOE

PLATE
1. Install:
9brake camshaft 1
9brake shoe wear indicator 2
9brake camshaft 3

7 Nm (0.7 m·kg, 5.0 ft·lb)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the brake camshaft so its punch mark
a is positioned as shown.
b. Align the projection on the brake shoe wear
indicator with the notch in the brake
camshaft.
c. Align the punch mark in the brake camshaft
with the mark on the brake camshaft lever.
a d. Check that the brake shoes are properly
positioned.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
9speedometer driven gear 1
9bushing
(with the special tool 2)

Meter gear bush tool

90890-01052

EAS00538

ASSEMBLING THE FRONT WHEEL

1. Install:
9brake shoe plate assembly
Align the tab on the speedometer clutch with
the slot in the wheel hub.
2. Install:
9collar

EAS00540

INSTALLING THE FRONT WHEEL

1. Lubricate:
9wheel axle
9wheel bearings
9oil seal lips
9speedometer drive gear
9speedometer driven gear

Recommended lubricant
Lithium-soap-based grease

6-7
3P9-F8197-E0_6 11/8/05 3:13 PM Page 8

FRONT WHEEL AND DRUM BRAKE CHAS

2. Install:
9front wheel
NOTE:
Make sure the slot in the brake shoe plate fits
over the stopper on the outer tube.

3. Tighten:
9wheel axle nut 39 Nm (3.9 m·kg, 28 ft·lb)

w
Make sure the brake cable is routed properly.

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

6-8
3P9-F8197-E0_6 11/8/05 3:13 PM Page 9

REAR WHEEL AND BRAKE CHAS

EASF0049

REAR WHEEL AND BRAKE

1 Brake rod adjusting nut 0 Cotter pin
2 Brake camshaft lever q Brake torque rod
3 Pin w Rear wheel drive hub damper
4 Drive chain puller (right) e Rear wheel drive hub
5 Brake shoe wear indicator r Drive chain puller (left)
6 Brake shoe plate t Rear wheel axle
7 Brake camshaft y Brake rod
8 Brake shoe
9 Rear wheel

6-9
3P9-F8197-E0_6 11/8/05 3:13 PM Page 10

REAR WHEEL AND BRAKE CHAS

EAS00563

REMOVING THE REAR WHEEL

1. Stand the vehicle on a level surface.

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

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

1. Remove:
9brake rod adjusting nut 1
9brake rod 2
9compression spring 3
9washer
9pin 4
NOTE:
1 4 3 2 Press down on the brake pedal to remove the
pin from the brake rod.

2. Remove:
9cotter pin
9brake torque rod nut 1
2 9washer
9brake torque rod bolt
9brake torque rod 2
1

3. Loosen:
9chain puller locknuts (left and right) 1
9chain puller adjusting nuts (left and right) 2

12

6-10
3P9-F8197-E0_6 11/8/05 3:13 PM Page 11

REAR WHEEL AND BRAKE CHAS

4. Remove:
1 9rear wheel axle nut 1
9washer
9rear wheel axle 2
9washer
9collar

5. Remove:
1 9rear wheel assembly 1
NOTE:
Push the rear wheel forward and remove the
drive chain from the driven sprocket.

6. Remove:
9brake shoe plate assembly 1

7. Remove:
9collar 1
1
9rear wheel drive hub assembly 2
2

8. Remove:
1 9spacer 1

6-11
3P9-F8197-E0_6 11/8/05 3:13 PM Page 12

REAR WHEEL AND BRAKE CHAS

9. Remove:
9O-ring
1 9rear wheel drive hub dampers 1

DISASSEMBLING THE BRAKE SHOE

1 PLATE
1. Remove:
2 9brake shoes 1
3 9brake shoe spring 1 2 (52 mm, 2.01 in)
9brake shoe spring 2 3 (48 mm, 1.89 in)

å : Rear wheel side

2
3

2. Remove:
9brake camshaft lever nut
9brake camshaft lever bolt
9brake camshaft lever 1
9brake shoe wear indicator
9brake camshaft
1 NOTE:
When removing the brake camshaft lever, mark
the position on the brake camshaft lever where it
is aligned with the punch mark in the brake
camshaft.

6-12
3P9-F8197-E0_6 11/8/05 3:13 PM Page 13

REAR WHEEL AND BRAKE CHAS

EAS00566

CHECKING THE REAR WHEEL

1. Check:
9wheel axle
9rear wheel
9wheel bearings
9oil seals
Refer to “FRONT WHEEL AND DRUM-
BRAKE”.
2. Check:
9tire
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” in chap-
ter 3.
3. Measure:
9radial wheel runout
9lateral wheel runout
Refer to “FRONT WHEEL AND DRUM-
BRAKE DISC”.

EAS00567

CHECKING THE REAR WHEEL DRIVE

HUB
1. Check:
9rear wheel drive hub
Cracks/damage → Replace.

9rear wheel drive hub dampers

Damage/wear → Replace.

6-13
3P9-F8197-E0_6 11/8/05 3:13 PM Page 14

REAR WHEEL AND BRAKE CHAS

EAS00526

CHECKING THE BRAKE

The following procedure applies to all of the
brake shoes.
1. Check:
9brake shoe lining
Refer to “FRONT WHEEL AND DRUM
BRAKE”.
2. Measure:
9brake shoe lining thickness
9brake drum inside diameter
Refer to “FRONT WHEEL AND DRUM
BRAKE”.
3. Check:
9brake drum inner surface
9brake camshaft
Refer to “FRONT WHEEL AND DRUM
BRAKE”.

EAS00570

ASSEMBLING THE BRAKE SHOE

PLATE
1. Install:
9brake camshaft 1
9brake shoe wear indicator 2
9brake camshaft lever
7 Nm (0.7 m·kg, 5.0 ft·lb)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the brake camshaft so its punch mark
a is positioned as shown.
b. Align the projection b on the brake shoe
wear indicator with the notch in the brake
camshaft.
c. Align the punch mark in the brake camshaft
with the mark on the brake camshaft lever.
d. Check that the brake shoes are properly
positioned.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6-14
3P9-F8197-E0_6 11/8/05 3:13 PM Page 15

REAR WHEEL AND BRAKE CHAS

EAS00571

INSTALLING THE REAR WHEEL

1. Lubricate:
9spacer
9collar
9wheel axle
9wheel bearings
9rear brake camshaft
9brake torque rod bolt
9oil seal lips

Recommended lubricant
Lithium-soap-based grease
2. Install:
9brake torque rod (to brake shoe plate)
19 Nm (1.9 m·kg, 14 ft·lb)
9washer
9cotter pin
3. Install:
9pin
9washer
9compression spring
9brake rod
9brake rod adjusting nut
NOTE:
Press down on the brake pedal to install the
brake rod.

4. Adjust:
9drive chain slack
Drive chain slack
25–35 mm (0.98–1.38 in)

Refer to “ADJUSTING THE DRIVE CHAIN

SLACK” in chapter 3.
5. Tighten:
9wheel axle nut 60 Nm (6.0 m·kg, 43 ft·lb)

cC
Do not loosen the wheel axle nut after tight-
ening it to the specified torque.

6. Install:
9drive chain case
7 Nm (0.7 m·kg, 5.0 ft·lb)

6-15
3P9-F8197-E0_6 11/8/05 3:13 PM Page 16

FRONT FORK CHAS

EASF0054

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

6-16
3P9-F8197-E0_6 11/8/05 3:13 PM Page 17

FRONT FORK CHAS

EAS00649

REMOVING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.

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

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

2. Remove:
9front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
3. Remove:
9front wheel
Refer to “FRONT WHEEL AND DRUM
1
BRAKE”.
4. Remove:
9front fender bolts (left and right)
9screws (left and right)
9front fender (upper) 1

5. Remove:
9front fender bolts
9collars
9front fender (lower) 1

6. Remove:
9front fork cap bolt 1
(with a 10-mm hexagonal wrench)
7. Loosen:
1 9lower bracket pinch bolt 2

w
Before loosening the lower bracket pinch
bolt, support the front fork leg.
2
8. Remove:
9front fork leg

6-17
3P9-F8197-E0_6 11/8/05 3:13 PM Page 18

FRONT FORK CHAS

EAS00655

DISASSEMBLING THE FRONT FORK

LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
9fork spring

2. Drain:
1 9fork oil
NOTE:
Stroke the inner tube 1 several times while
draining the fork oil.

3. Remove:
9dust seal 1
9oil seal clip 2
(with a flat-head screwdriver)
cC
Do not scratch the inner tube.

4. Remove:
9damper rod assembly bolt
9copper washer
NOTE:
While holding the damper rod assembly with a
10 mm hexagon nut/socket wrench 1 and the
Thandle 2, loosen the damper rod assembly
bolt 3.

T-handle
90890-01326

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

6-18
3P9-F8197-E0_6 11/8/05 3:13 PM Page 19

FRONT FORK CHAS

6. Remove:
9oil seal 1
92 Rag

EAS00657

1 CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Check:
9inner tube 1
9outer tube 2
Bends/damage/scratches → Replace.
2
w
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.

2. Measure:
9spring free length a
Out of specifications → Replace.

Spring free length

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

3. Check:
9damper rod 1
Damage/wear → Replace.
1 Obstructions → Blow out all of the oil pas-
sages with compressed air.
cC
9The front fork leg has a built-in damper
adjusting rod and a very sophisticated inter-
nal construction, which are particularly sen-
sitive to foreign material.
9When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.

6-19
3P9-F8197-E0_6 11/8/05 3:13 PM Page 20

FRONT FORK CHAS

EAS00659

ASSEMBLING THE FRONT FORK LEGS

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

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

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

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

2. Lubricate:
9inner tube outer surface

Recommended lubricant
Fork oil 10W or equivalent

3. Tighten:
9damper rod assembly bolt 1
23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE®

6-20
3P9-F8197-E0_6 11/8/05 3:13 PM Page 21

FRONT FORK CHAS

NOTE:
Tighten the damper rod assembly bolt 1 while
holding the damper rod with the T-handle 2 and
a 10 mm hexagon nut/socket wrench 3.

T-handle
90890-01326

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

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

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

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

6-21
3P9-F8197-E0_6 11/8/05 3:13 PM Page 22

FRONT FORK CHAS

6. Fill:
9front fork leg
(with the specified amount of the recom-
mended fork oil)
Quantity (each front fork leg)
0.061 L (61cm3)
Recommended oil
Fork oil 10W or equivalent

Front fork leg oil level a (from the

top of the inner tube, with the inner
tube fully compressed and without
the fork spring)
87.0 mm (3.43 in)

NOTE:
9While filling the front fork leg, keep it upright.
9After filling, slowly pump the front fork leg up
and down to distribute the fork oil.

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

EAS00662

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Install:
9front fork leg 1
9front fork cap bolt 2
Temporarily tighten the lower bracket pinch
bolt.
NOTE:
Pull up the inner tube until it is stopped, then
install the front fork cap bolt 2.

2. Tighten:
9lower bracket pinch bolt 1
38 Nm (3.8 m·kg, 27 ft·lb)
9front fork cap bolt 2
20 Nm (2.0 m·kg, 15 ft·lb)

6-22
3P9-F8197-E0_6 11/8/05 3:13 PM Page 23

FRONT FORK CHAS

3. Install:
9front fender (lower)
10 Nm (1.0 m·kg, 7.2 ft·lb)

9front fork cover (upper)

7 Nm (0.7 m·kg, 5.0 ft·lb)

4. Install:
9front wheel
Refer to “FRONT WHEEL AND DRUM
BRAKE”.
5. Install:
9front cowlings (left and right)
Refer to “INSTALLING THE FRONT COWL-
INGS” in chapter 3.

6-23
3P9-F8197-E0_6 11/8/05 3:14 PM Page 24

HANDLEBAR CHAS
EASF0055

HANDLEBAR
1 Rear view mirror (left and right)
2 Throttle grip
3 Right handlebar switch
4 Handlebar
5 Left handlebar switch
6 Handlebar grip
7 Starter cable
8 Throttle cable
9 Handlebar bracket

32 Nm (3.2 m•kg, 23 ft•lb )

53 Nm (5.3 m•kg, 38 ft•lb )

16 Nm (1.6 m•kg, 12 ft•lb )

6-24
3P9-F8197-E0_6 11/8/05 3:14 PM Page 25

HANDLEBAR CHAS
EAS00666

REMOVING THE HANDLEBAR

1. Stand the vehicle on a level surface.

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

2. Remove:
9front cowlings (left and right)
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
9headlight assembly
Refer to “REPLACING THE HEADLIGHT
BULBS” in chapter 3.
9rear view mirrors (left and right)

2 3. Disconnect:
9speedometer cable 1
9speedometer assembly 2

4. Disconnect:
1 3
9meter assembly couplers 1
4
9right handlebar switch couplers 2
9left handlebar switch coupler 3
9front brake light switch coupler 4
5. Remove:
9plastic locking ties 5
5 5
2

6. Remove:
9brake lever holder

6-25
3P9-F8197-E0_6 11/8/05 3:14 PM Page 26

HANDLEBAR CHAS
7. Remove:
1 9right handlebar switch 1

8. Remove:
9throttle cable 1
9throttle grip 2
2

9. Remove:
9washer
9starter lever 1
9starter cable 2
9spring washer

2 1

10. Remove:
1 9left handlebar switch 1

11.Remove:
9handlebar grip 1
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.

6-26
3P9-F8197-E0_6 11/8/05 3:14 PM Page 27

HANDLEBAR CHAS
12. Remove:
9wire harness strap 1

13. Remove:
9handlebar 1
9washers
1 9bushings
9handlebar bracket 2
2

EAS00668

CHECKING THE HANDLEBAR

1 1. Check:
9handlebar 1
Bends/cracks/damage → Replace.

w
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.

EAS00670

INSTALLING THE HANDLEBAR

1. Stand the vehicle on a level surface.

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

2. Install:
a b 9handlebar bracket 1
53 Nm (5.3 m·kg, 38 ft·lb)
NOTE:
Align the projection a in the handlebar bracket
1
with the slit b in the steering shaft.

6-27
3P9-F8197-E0_6 11/8/05 3:14 PM Page 28

HANDLEBAR CHAS
3. Install:
9bushings
9washers
9handlebar 16 Nm (1.6 m·kg, 12 ft·lb)
9wire harness strap
Refer to “CABLE ROUTING” in chapter 2.
4. Install:
9handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.

w
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
5. Install:
9left handlebar switch 1
NOTE:
Align the projection a on the left handlebar
switch with the hole in the handlebar.

6. Install:
9throttle grip 1
9throttle cable 2
NOTE:
1 Lubricate the inside of the throttle grip with a thin
2 coat of lithium-soap-based grease and install it
onto the handlebar.

7. Install:
9right handlebar switch 1

1 NOTE:
Align the projection a on the right handlebar
switch with the hole in the handlebar.

w
Make sure the throttle grip operates smooth-
a ly.

6-28
3P9-F8197-E0_6 11/8/05 3:14 PM Page 29

HANDLEBAR CHAS
8. Install:
9brake lever holder
7 Nm (0.7 m·kg, 5.0 ft·lb)
9. Install:
9plastic locking ties
Refer to “CABLE ROUTING” in chapter 2.
10. Adjust:
9throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.

Throttle cable free play (at the

flange of the throttle grip)
3–7 mm (0.12–0.28 in)
11.Adjust:
9brake lever free play
Refer to “ADJUSTING THE FRONT
BRAKE” in chapter 3.
Brake lever free play
10–20 mm (0.39–0.79 in)

6-29
3P9-F8197-E0_6 11/8/05 3:14 PM Page 30

STEERING HEAD CHAS

EASF0057

STEERING HEAD
1 Rubber cover
2 Upper ring nut
3 Lower ring nut
4 Ball race cover
5 Bearing inner race
6 Upper bearing
7 Bearing outer race
8 Lower bearing
9 Lower bracket

6-30
3P9-F8197-E0_6 11/8/05 3:14 PM Page 31

STEERING HEAD CHAS

EAS00679

REMOVING THE LOWER BRACKET

1. Stand the vehicle on a level surface.

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

2. Remove:
9front panel
Refer to “REMOVING THE FRONT COWL-
INGS” in chapter 3.
9front fork
Refer to “FRONT FORK”.
9handlebar
Refer to “HANDLEBAR”.

3. Remove:
9rubber cover
9upper ring nut 1
9lower ring nut 2
NOTE:
Hold the lower ring nut with the steering nut
1 wrench, and then remove the upper ring nut with
2
the ring nut wrench.

Steering nut wrench

90890-01403
Ring nut wrench
90890-01268

w
Securely support the lower bracket so that
there is no danger of it falling.

6-31
3P9-F8197-E0_6 11/8/05 3:14 PM Page 32

STEERING HEAD CHAS

EAS00681

CHECKING THE STEERING HEAD

1. Wash:
9bearings
9bearing races

Recommended cleaning solvent

Kerosene

2. Check:
2 9bearings 1
1
9bearing races 2
Damage/pitting → Replace.

3. Replace:
9bearings
9bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering
head pipe with a long rod 1 and hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install a new rubber seal and new bearing
races.
cC
If the bearing race is not installed properly,
the steering head pipe could be damaged.

NOTE:
9Always replace the bearings and bearing races
as a set.
9Whenever the steering head is disassembled,
replace the rubber seal.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
1
9lower bracket 1
(along with the steering stem)
Bends/cracks/damage → Replace.

6-32
3P9-F8197-E0_6 11/8/05 3:14 PM Page 33

STEERING HEAD CHAS

EAS00683

INSTALLING THE STEERING HEAD

1. Lubricate:
9upper bearing
9lower bearing
9bearing races

Recommended lubricant
Lithium-soap-based grease
2. Install:
9lower ring nut
9upper ring nut
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
3. Install:
9front fork legs
Refer to “FRONT FORK”.

6-33
3P9-F8197-E0_6 11/8/05 3:14 PM Page 34

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM CHAS

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
1 Rear shock absorber
2 Brake torque rod
3 Swingarm
4 Bushing
5 Swingarm pivot shaft
6 Drive chain case (upper)

6-34
3P9-F8197-E0_6 11/8/05 3:14 PM Page 35

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM CHAS

EAS00691/EAS00702

REMOVING THE REAR SHOCK

ABSORBER ASSEMBLIES AND
SWINGARM
1. Stand the vehicle on a level surface.

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

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

2. Remove:
9rear cowlings (left and right)
Refer to “REMOVING THE REAR COWL-
INGS” in chapter 3.
9muffler
Refer to “REMOVING THE ENGINE” in
chapter 4.
9rear wheel
Refer to “REAR WHEEL AND BRAKE”.

3. Remove:
9drive chain case screws
9drive chain case 1

4. Remove:
9cotter pin
9nut
9washer
9brake torque rod 1

6-35
3P9-F8197-E0_6 11/8/05 3:14 PM Page 36

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM CHAS

5. Remove:
9rear shock absorber bolt (left and right) 1
9washer
2 9rear shock absorber nut (left and right) 2
9washers
3
9rear shock absorber assembly (left and
right) 3

6. Measure:
9swingarm side play
9swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the
∫ swingarm pivot shaft nut.

å Pivot shaft nut

51 Nm (5.1 m·kg, 37 ft·lb)

b. Measure the swingarm side play å by mov-

ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers and bearings.
Swingarm side play (at the end of
the swingarm)
1 mm (0.04 in)

d. Check the swingarm vertical movement ∫

by moving the swingarm up and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
washer and bushings.
3 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Remove:
1 9swingarm pivot shaft nut 1
9muffler stay
9washer 2
4 9swingarm pivot shaft 3
9swingarm 4

6-36
3P9-F8197-E0_6 11/8/05 3:14 PM Page 37

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM CHAS

EAS00695

CHECKING THE REAR SHOCK

ABSORBER ASSEMBLIES
The following procedure applies to both rear
shock absorber assemblies.
1. Check:
9rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
9rear shock absorber
Oil leaks → Replace the rear shock
absorber assembly.
9spring
Damage/wear → Replace the rear shock
absorber assembly.
9bushings
Damage/wear → Replace.
9bolts
Bends/damage/wear → Replace.

EAS00707

CHECKING THE SWINGARM

1. Check:
9swingarm
Bends/cracks/damage → Replace.

2. Check:
9swingarm pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.

w
Do not attempt to straighten a bent pivot
shaft.

3. Wash:
9swingarm pivot shaft
9washer
9bushings
Recommended cleaning solvent
Kerosene

4. Check:
9washer
Damage/wear → Replace.
9bushings
Damage/wear → Replace.
6-37
3P9-F8197-E0_6 11/8/05 3:14 PM Page 38

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM CHAS

EAS00711/EAS00699

INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLIES AND
SWINGARM
1. Lubricate:
9swingarm pivot shaft

Recommended lubricant
Lithium-soap-based grease

2. Install:
9swingarm
9swingarm pivot shaft
9washer
9swingarm pivot shaft nut
51 Nm (5.1 m·kg, 37 ft·lb)
3. Install:
9rear shock absorber assemblies
9rear shock absorber nuts
9rear shock absorber bolts
32 Nm (3.2 m·kg, 23 ft·lb)
4. Install:
9brake torque rod (to swingarm)
16 Nm (1.6 m·kg, 12 ft·lb)
5. Install:
9drive chain case
7 Nm (0.7 m·kg, 5.0 ft·lb)
6. Install:
9rear wheel
Refer to “REAR WHEEL AND BRAKE”.
9muffler
Refer to “REMOVING THE ENGINE” in
chapter 4.
9rear cowlings (left and right)
Refer to “INSTALLING THE REAR COWL-
INGS” in chapter 3.

6-38
3P9-F8197-E0_6 11/8/05 3:14 PM Page 39

DRIVE CHAIN AND SPROCKETS CHAS

DRIVE CHAIN AND SPROCKETS
1 Rear wheel drive hub 0 Circlip
2 Driven sprocket q Drive sprocket cover
3 Lock washer
4 Collar
5 Oil seal
6 Bearing
7 Master link
8 Drive chain
9 Drive sprocket

6-39
3P9-F8197-E0_6 11/8/05 3:14 PM Page 40

DRIVE CHAIN AND SPROCKETS CHAS

EAS00706

REMOVING THE DRIVE CHAIN AND

SPROCKETS
1. Stand the vehicle on a level surface.

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

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

2. Remove:
9rear wheel
9rear wheel drive hub assembly
Refer to “REAR WHEEL AND BRAKE”.

3. Remove:
1 9drive sprocket cover bolts
9drive sprocket cover 1

4. Remove:
9master link clip 1
9master link plate 2
9master link body 3
5. Remove:
9drive chain

6. Remove:
9circlip 1
1 9drive sprocket 2

6-40
3P9-F8197-E0_6 11/8/05 3:14 PM Page 41

DRIVE CHAIN AND SPROCKETS CHAS

7. Straighten the lock washer tabs.
1 8. Remove:
9driven sprocket nuts
2 9driven sprocket bolts
9lock washers 1
9driven sprocket 2
1

EAS00710

CHECKING THE DRIVE CHAIN

1 2 34 56 789 0 q werty 1. Measure:
9Measure the length of 15 links on the inner
side a and outer side b of the pin and cal-
culate the length between pin centers.
a 9Length c between pin centers = (inner
b dimension a + outer dimension b)/2
915-Link section c of the drive chain
Out of specification → Replace the drive
chain, drive sprocket and rear wheel sprock-
et as a set.
1 2 34 56 789 0 q werty
15-link drive chain section limit
(maximum)
194.3 mm (7.65 in)

NOTE:
c
9While measuring the 15-link section, push
down on the drive chain to increase its tension.
9Perform this measurement at two or three dif-
ferent places.

2. Check:
9drive chain
Stiffness → Clean and lubricate or replace.

3. Clean:
9drive chain
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6-41
3P9-F8197-E0_6 11/8/05 3:14 PM Page 42

DRIVE CHAIN AND SPROCKETS CHAS

4. Check:
9drive chain rollers 1
Damage/wear → Replace the drive chain.
9drive chain side plates 2
Cracks/damage/wear → Replace the drive
chain.
5. Lubricate:
9drive chain

Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains

6. Check:
9drive sprocket
9driven sprocket
Worn more than 1/4 tooth a → Replace the
drive chain and sprockets as a set.
Bent teeth → Replace the drive chain and
sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket

EAS00714

INSTALLING THE DRIVE CHAIN AND

1 New SPROCKETS
1. Install:
2
9driven sprocket 2
30 Nm (3.0 m·kg, 22 ft·lb)
9lock washers 1
1 9driven sprocket bolts
9driven sprocket nuts
NOTE:
Tighten the bolts in a crisscross pattern.

2. Bend:
9lock washer tab 1
NOTE:
Bend the lock washer tabs along a flat side of
each bolt.

6-42
3P9-F8197-E0_6 11/8/05 3:14 PM Page 43

DRIVE CHAIN AND SPROCKETS CHAS

3. Install:
9drive sprocket 1
a 9circlip 2
1
NOTE:
Install the drive sprocket with the flat side a
towards the engine.

4. Lubricate:
9drive chain
9master link

Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
5. Install:
9master link body
9master link plate
6. Install:
9master link clip 1
cC
9The closed end of the master link clip must
face in the direction of drive chain rotation.
9Never install a new drive chain onto worn
drive chain sprockets; this will dramatically
shorten the drive chain’s life.

7. Adjust:
9drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.

Drive chain slack

25–35 mm (0.98–1.38 in)

cC
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.

6-43
3P9-F8197-E0_7 05.11.8 14:14 Page A

ELEC
CHAPTER 7
ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS .............................................................................. 7-1

CHECKING SWITCH CONTINUITY ...................................................................... 7-3

CHECKING THE SWITCHES ................................................................................ 7-5

CHECKING THE BULBS AND BULB SOCKETS ................................................. 7-7

TYPES OF BULBS ........................................................................................... 7-7
CHECKING THE CONDITION OF THE BULBS ............................................... 7-8
CHECKING THE CONDITION OF THE BULB SOCKETS ............................... 7-9

IGNITION SYSTEM ............................................................................................... 7-10

CIRCUIT DIAGRAM .......................................................................................... 7-10
TROUBLESHOOTING ...................................................................................... 7-11

ELECTRIC STARTING SYSTEM........................................................................... 7-15

CIRCUIT DIAGRAM .......................................................................................... 7-15
TROUBLESHOOTING ...................................................................................... 7-16

STARTER MOTOR ................................................................................................. 7-18

REMOVING THE STARTER MOTOR .............................................................. 7-19
DISASSEMBLING THE STARTER MOTOR ..................................................... 7-19
CHECKING THE STARTER MOTOR ............................................................... 7-19
ASSEMBLING THE STARTER MOTOR ........................................................... 7-21
INSTALLING THE STARTER MOTOR ............................................................. 7-21

CHARGING SYSTEM ............................................................................................ 7-22

CIRCUIT DIAGRAM .......................................................................................... 7-22
TROUBLESHOOTING ...................................................................................... 7-23

LIGHTING SYSTEM ............................................................................................... 7-25

CIRCUIT DIAGRAM .......................................................................................... 7-25
TROUBLESHOOTING ...................................................................................... 7-26
CHECKING THE LIGHTING SYSTEM ............................................................. 7-27

SIGNALING SYSTEM ............................................................................................ 7-30

CIRCUIT DIAGRAM .......................................................................................... 7-30
TROUBLESHOOTING ...................................................................................... 7-32
CHECKING THE SIGNALING SYSTEM .......................................................... 7-33
3P9-F8197-E0_7 05.11.8 14:14 Page B

ELEC
3P9-F8197-E0_7 05.11.8 14:14 Page 1

ELECTRICAL COMPONENTS ELEC

EAS00729

ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1 Main switch 7 Ignition coil
2 Positive battery lead 8 Wire harness
3 Negative battery lead
4 Battery
5 Fuse
6 Rear brake light switch

8 2

7 5
6 4

7-1
3P9-F8197-E0_7 05.11.8 14:14 Page 2

ELECTRICAL COMPONENTS ELEC

1 Horn
2 Turn signal relay
3 Fuel gauge
4 Starter relay
5 C.D.I. unit
6 Neutral switch
7 Rectifier/regulator

2 4

7-2
3P9-F8197-E0_7 05.11.8 14:14 Page 3

CHECKING SWITCH CONTINUITY ELEC

EAS00730

CHECKING SWITCH CONTINUITY

Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect,
check the wiring connections and if necessary,
replace the switch.
cC
Never insert the tester probes into the cou-
1 pler terminal slots 1. Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.

Pocket tester
90890-03112
NOTE:
9Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
9When checking for continuity, switch back and
forth between the switch positions a few times.

b
The terminal connections for switches (e.g.,
Br R
main switch, engine stop switch) are shown in
a OFF
ON an illustration similar to the one on the left.
The switch positions a are shown in the far left
Br R column and the switch lead colors b are shown
in the top row in the switch illustration.
NOTE:
“1—1” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit at
the respective switch position).

The example illustration on the left shows

that:
There is continuity between red and brown
when the switch is set to “ON”.

7-3
3P9-F8197-E0_7 05.11.8 14:14 Page 4

CHECKING SWITCH CONTINUITY ELEC

7-4
3P9-F8197-E0_7 05.11.8 14:14 Page 5

CHECKING THE SWITCHES ELEC

EAS00731

CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.

1 2 3 4
P B Y L/B G Ch Br/W Dg
OFF HI L
P Dg
PUSH LO N B Br/W
R L/B Ch
Y G
(RED)
P W
Y/W Sb
L/W

5 6 7 8
R L/W B Y/R L L/B L Y/R
OFF
L/B
OFF
START PO
L/W
ON B
R

B
B
(BLACK)

0
Br R
OFF R
ON Br

7-5
3P9-F8197-E0_7 05.11.8 14:14 Page 6

CHECKING THE SWITCHES ELEC

1 Horn switch
2 Dimmer switch
3 Turn signal switch
4 Neutral switch
5 Rear brake light switch
6 Fuse
7 Start switch
8 Light switch
9 Front brake light switch
0 Main switch

7-6
3P9-F8197-E0_7 05.11.8 14:14 Page 7

CHECKING THE BULBS AND BULB SOCKETS ELEC

EAS00732

CHECKING THE BULBS AND

BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage/wear → Repair or replace the
bulb, bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,
bulb socket or both.

TYPES OF BULBS
The bulbs used on this vehicle are shown in the
A B
illustration on the left.
9Bulbs A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The major-
ity of these types of bulbs can be removed
from their respective socket by turning them
counterclockwise.
9Bulb C is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclockwise.
C 9Bulbs D and E are used for meter and indica-
D E tor lights and can be removed from their
respective sockets by carefully pulling them
out.

7-7
3P9-F8197-E0_7 05.11.8 14:14 Page 8

CHECKING THE BULBS AND BULB SOCKETS ELEC

CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
9bulb

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

cC
9Be sure to hold the socket firmly when
removing the bulb. Never pull the lead, oth-
erwise it may be pulled out of the terminal
in the coupler.
9Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb, and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.

2. Check:
9bulb (for continuity)
(with the pocket tester)
No continuity → Replace.

Pocket tester
90890-03112

NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 2, and check for continuity.
b. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 3, and check for continuity.
1 1
c. If either of the readings indicate no continu-
2 ity, replace the bulb.
3 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3

7-8
3P9-F8197-E0_7 05.11.8 14:14 Page 9

CHECKING THE BULBS AND BULB SOCKETS ELEC

CHECKING THE CONDITION OF THE
BULB SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
9bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.

Pocket tester
90890-03112

NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7-9
 3P9-F8197-E0_7

1
OFF R R Br B O EAS00734
ON Br Br R W

Br R W W R R
0 q O O
R 9 Y Y/R W W w
W B W W B
R Y Y/R Y
B B e
Br B
B
05.11.8 14:14

R W R R W
CIRCUIT DIAGRAM

B
R R/W Br Br
IGNITION SYSTEM

Br L/W L/W L/W

2
Page 10

R Br Br
R R

4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7 L Y/R Y/R L
R R 8
Br L/W L/B L/B
R
3 OFF OFF
START PO L/W L/W
ON B B
5
B L L/B

7-10
Br

u Br/W
Br
y
Y Br
k Br
Br L Ch Dg
P Br Br/W
Y/W Sb Sb Y/W t
i P L/B Br/W
W W
L/W P P L/W ; zx cvbnm B Br r
(BLACK) (BLACK)
o p a B G/Y
OFF HI L P Dg Dg P (BLACK) (BLACK)
l PUSH LO N B Br/W Br/W B
R L/B Ch Ch L/B
L Br Br L G/Y
Dg Ch Ch Dg G/Y
B G G B
B
Ch Dg
Y G
IGNITION SYSTEM

G B Sb W P Y/W L/W

Sb W P Y/W L/W YY G
1 Main switch L/R Ch Dg
Ch Dg L G/Y
G
2 Fuse , f f
3 Battery L/R L/R
G G j B B dd s
ELEC

0 A. C. magneto B B g B B
P W W P B L
Ch Ch
h Y/W Sb Sb Y/W Y
q C. D. I. unit B Dg Dg
L/W L/W Ch Dg
w Ignition coil B
B B L B
B
e Spark plug G/Y
Dg Ch
3P9-F8197-E0_7 05.11.8 14:14 Page 11

IGNITION SYSTEM ELEC

EAS00736 EAS00739

TROUBLESHOOTING 2. Battery
The ignition system fails to operate (no 9Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Check:
1. fuse Minimum open-circuit voltage
2. battery 12.8 V or more at 20°C
3. spark plug 9Is the battery OK?
4. ignition spark gap
5. spark plug cap resistance
YES NO
6. ignition coil resistance
7. pickup coil resistance
8. main switch 9Clean the battery
9. wiring connections (of the entire ignition terminals.
system) 9Recharge or
replace the battery.
NOTE:
9Before troubleshooting, remove the following EAS00740

part(s): 3. Spark plug

1. front cowling (right)
9Check the condition of the spark plug.
2. rear cowlings (left and right)
9Check the spark plug type.
9Troubleshoot with the following special tool(s).
9Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUG” in
Ignition checker chapter 3.
90890-06754
Pocket tester Standard spark plug
90890-03112 C6HSA (NGK)
Spark plug gap
EAS00738
0.6–0.7 mm (0.024–0.028 in)
1. Fuse 9Is the spark plug in good condition, is it of
9Check the fuse for continuity. the correct type, and is its gap within spec-
Refer to “CHECKING THE FUSE” in chapter ification?
3.
9Is the fuse OK? YES NO

YES NO Re-gap or replace

the spark plug.

Replace the fuse.

7-11
3P9-F8197-E0_7 05.11.8 14:14 Page 12

IGNITION SYSTEM ELEC

EAS00742 EAS00744

4. Ignition spark gap 5. Spark plug cap resistance

9Disconnect the spark plug cap from the 9Remove the spark plug cap from the spark
spark plug. plug lead.
9Connect the ignition checker 1 as shown. 9Connect the pocket tester (“Ω × 1k” range) to
2 Spark plug cap the spark plug cap as shown.
9Set the main switch to “ON”. 9Measure the spark plug cap resistance.
9Crank the engine by pushing the start switch
and gradually increase the spark gap until a
misfire occurs.
9Measure the ignition spark gap a.

a
Spark plug cap resistance
2 7.5–12.5 kΩ at 20°C (68°F)
1
9Is the spark plug cap OK?

Minimum ignition spark gap

6 mm (0.24 in) YES NO

9Is there a spark and is the spark gap within

specification? Replace the spark
plug cap.
NO YES

The ignition system

is OK.

7-12
3P9-F8197-E0_7 05.11.8 14:14 Page 13

IGNITION SYSTEM ELEC

EAS00746 EAS00748

6. Ignition coil resistance 7. Pickup coil resistance

9Disconnect the ignition coil connector from 9Disconnect the pickup coil coupler from the
the ignition coil terminal. wire harness.
9Connect the pocket tester (Ω × 1) to the igni- 9Connect the pocket tester (Ω × 100) to the
tion coil as shown. pickup coil terminal as shown.
Positive tester probe → terminal 1 Positive tester probe → white 1
Negative tester probe → Negative tester probe → red 2
ignition coil base 2

2 B Y W R W

2 1
1
9Measure the pickup coil resistance.
9Measure the primary coil resistance. Pickup coil resistance
Primary coil resistance 248–372 Ω at 20°C (68°F)
0.32–0.48 Ω at 20°C (68°F) (between white and red)
9Connect the pocket tester (Ω × 1k) to the 9Is the pickup coil OK?
ignition coil as shown.
Negative tester probe → terminal 1 YES NO
Positive tester probe → spark plug lead 2
Replace the stator
coil/pickup coil
assembly.

EAS00749

8. Main switch

2 1 9Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.
9Measure the secondary coil resistance. 9Is the main switch OK?

Secondary coil resistance

5.68–8.52 kΩ at 20°C (68°F) YES NO
9Is the ignition coil OK?
Replace the main
switch.
YES NO

Replace the ignition

coil.

7-13
3P9-F8197-E0_7 05.11.8 14:14 Page 14

IGNITION SYSTEM ELEC

EAS00754

9. Wiring
9Check the entire ignition system wiring.
Refer to “CIRCUIT DIAGRAM”.
9Is the ignition system wiring properly con-
nected and without defects?

YES NO

Replace the C.D.I. Properly connect or

unit. repair the ignition
system wiring.

7-14
 3P9-F8197-E0_7

1
OFF R R Br
R
B
W
O
EAS00755
ON Br Br

Br R W W R R
0 q O O
R 9 Y Y/R W W w
W B W W B
R Y Y/R Y
B B e
Br B
B
R
05.11.8 14:14

W R R W
CIRCUIT DIAGRAM

B
R R/W Br Br
Br L/W L/W L/W
2
R Br Br
Page 15

R R

4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7 L Y/R Y/R L
R R 8
Br L/W L/B L/B
R
3 OFF OFF
START PO L/W L/W
ELECTRIC STARTING SYSTEM

ON B B
5
B L L/B

7-15
Br

u Br/W
Br
y
Y Br
k Br
Br L Ch Dg
P Br Br/W
Y/W Sb Sb Y/W t
i P L/B Br/W
W W
L/W P P L/W ; zx cvbnm B Br r
(BLACK) (BLACK)
o p a B G/Y
OFF HI L P Dg Dg P (BLACK) (BLACK)
l PUSH LO N B Br/W Br/W B
R L/B Ch Ch L/B
L Br Br L G/Y
Dg Ch Ch Dg G/Y
B G G B
B
Ch Dg
Y G
ELECTRIC STARTING SYSTEM

G B Sb W P Y/W L/W

Sb W P Y/W L/W YY G
L/R Ch Dg
1 Main switch Ch Dg L G/Y
G

2 Fuse , f f
L/R L/R
3 Battery G G j B B dd s
ELEC

B B g B B
4 Starter motor P W W P B L
Ch Ch
h Y/W Sb Sb Y/W Y
B Dg Dg
5 Starter relay L/W L/W Ch Dg

6 Right handlebar switch B B B L B

B
G/Y
7 Start switch Dg Ch
3P9-F8197-E0_7 05.11.8 14:14 Page 16

ELECTRIC STARTING SYSTEM ELEC

EAS00757 EAS00739

TROUBLESHOOTING 2. Battery
The starter motor fails to turn. 9Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
Check:
BATTERY” in chapter 3.
1. fuse
2. battery Minimum open-circuit voltage
3. starter motor 12.8 V or more at 20 °C
4. starter relay 9Is the battery OK?
5. main switch
6. start switch YES NO
7. wiring connections
(of the entire starting system)
9Clean the battery
NOTE: terminals.
9Before troubleshooting, remove the following 9Recharge or
part(s): replace the
1. front cowling (right) battery.
2. rear cowling
3. headlight assembly EAS00758

4. engine guard 3. Starter motor

9Troubleshoot with the following special tool(s).
9Connect the positive battery terminal 1 and
starter motor lead 2 with a jumper lead 3.
Pocket tester
90890-03112

EAS00738

1. Fuse
9Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter
3.
9Is the fuse OK?

YES NO
w
9A wire that is used as a jumper lead must
have at least the same capacity or more
Replace the fuse. as that of the battery lead, other-wise the
jumper lead may burn.
9This check is likely to produce sparks,
therefore make sure nothing flammable is
in the vicinity.

9Does the starter motor turn?

YES NO

Repair or replace
the starter motor.

7-16
3P9-F8197-E0_7 05.11.8 14:14 Page 17

ELECTRIC STARTING SYSTEM ELEC

EAS00761 EAS00764

4. Starter relay 6. Start switch

9Remove the starter relay from the starter 9Check the start switch for continuity.
relay coupler on the wire harness. Refer to “CHECKING THE SWITCHES”.
9Connect the pocket tester (Ω × 1) and bat- 9Is the start switch OK?
tery (DC 12 V) to the starter relay coupler as
shown. YES NO
Positive battery terminal → brown 1
Negative battery terminal → blue/white 2 Replace the right
Positive tester probe → red 3 handlebar switch.
Negative tester probe → red/white 4 EAS00766

3 7. Wiring
9Check the entire starting system wiring.
R 2
Refer to “CIRCUIT DIAGRAM”.
R R/W R/W R 9Is the starting system wiring properly con-
Br L/W L/W Br nected and without defects?
R/W
1 YES NO
4
The starting sys- Properly connect or
9Does the starter relay have continuity
tem circuit is OK. repair the starting
between red and red/white?
system wiring.

YES NO

Replace the starter

relay.

EAS00749

5. Main switch
9Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
9Is the main switch OK?

YES NO

Replace the main

switch.

7-17
3P9-F8197-E0_7 05.11.8 14:14 Page 18

STARTER MOTOR ELEC

EASF0061

STARTER MOTOR
1 Starter motor yoke
2 Armature
3 Brush set
4 Starter motor lead
5 Starter motor front cover

7-18
3P9-F8197-E0_7 05.11.8 14:14 Page 19

STARTER MOTOR ELEC

REMOVING THE STARTER MOTOR
1. Remove:
9footrest assembly
9starter motor guard
Refer to “REMOVING THE ENGINE” in
chapter 4.

2. Remove:
9starter motor 1

3. Remove:
1 9starter motor lead 1

DISASSEMBLING THE STARTER

MOTOR
1 1. Remove:
9starter motor front cover bolts
(with washers)
9starter motor front cover 1
4
9gasket 2
23 9washer 3
9armature 4

EAS00769

CHECKING THE STARTER MOTOR

1. Check:
9commutator
Dirt → Clean with 600-grit sandpaper.

7-19
3P9-F8197-E0_7 05.11.8 14:14 Page 20

STARTER MOTOR ELEC

2. Measure:
9commutator diameter a
Out of specification → Replace the starter
motor.
Commutator wear limit
16.6 mm (0.65 in)

3. Measure:
9mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
1.35 mm (0.05 in)

NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.

4. Measure:
9armature assembly resistances (commuta-
tor and insulation)
Out of specification → Replace the starter
motor.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resis-
tances with the pocket tester.
Pocket tester
90890-03112

Armature coil
Commutator resistance 1
0.018–0.022 Ω at 20°C (68°F)
Insulation resistance 2
Above 1 MΩ at 20°C (68°F)

b. If any resistance is out of specification,

replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7-20
3P9-F8197-E0_7 05.11.8 14:14 Page 21

STARTER MOTOR ELEC

5. Measure:
9brush length a
Out of specification → Replace the brush-
es as a set.
Brush length wear limit
3.5 mm (0.14 in)

6. Measure:
9brush spring force
Out of specification → Replace the brush
springs as a set.

Brush spring force

3.92–5.88 N (400–600 gf)
7. Check:
9gear teeth
Damage/wear → Replace the armature.

EAS00772

ASSEMBLING THE STARTER MOTOR

1. Install:
9washer (to armature)
9armature
(in start motor front cover 1)
9gasket
9starter motor yoke
9starter motor front cover bolts
(with washers)
9O-ring

NOTE:
Align the mark a on the starter motor yoke with
the mark b on the starter motor front cover.

INSTALLING THE STARTER MOTOR

For installation, reverse the removal procedure.

7-21
 3P9-F8197-E0_7

1
OFF R R Br
R
B
W
O EAS00773
ON Br Br

Br R W W R R
0 q O O
R 9 Y Y/R W W w
W B W W B
R Y Y/R Y
B B e
Br B
B
05.11.8 14:14

R W R R W
CIRCUIT DIAGRAM

B
R R/W Br Br
Br L/W L/W L/W
2
CHARGING SYSTEM

R Br Br
Page 22

R R

4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7 L Y/R Y/R L
R R 8
Br L/W L/B L/B
R
3 OFF OFF
START PO L/W L/W
ON B B
5
B L L/B

7-22
Br

u Br/W
Br
y
Y Br
k Br
Br L Ch Dg
P Br Br/W
Y/W Sb Sb Y/W t
i P L/B Br/W
W W
L/W P P L/W ; zx cvbnm B Br r
(BLACK) (BLACK)
o p a B G/Y
OFF HI L P Dg Dg P (BLACK) (BLACK)
l PUSH LO N B Br/W Br/W B
R L/B Ch Ch L/B
L Br Br L G/Y
Dg Ch Ch Dg G/Y
B G G B
B
Ch Dg
Y G
CHARGING SYSTEM

G B Sb W P Y/W L/W

Sb W P Y/W L/W YY G
L/R Ch Dg
Ch Dg L G/Y
G
, f f
L/R L/R
G G j B B dd s
ELEC

2 Fuse B B g B B
P W W P B L
Ch Ch
3 h Y/W Sb Sb Y/W Y
Battery B Dg Dg
L/W L/W Ch Dg
9 Rectifier/ regulator B
B B L B
B
0 A. C. magneto G/Y
Dg Ch
3P9-F8197-E0_7 05.11.8 14:14 Page 23

CHARGING SYSTEM ELEC

EAS00774 EAS00739

TROUBLESHOOTING 2. Battery
The battery cannot be charged. 9Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
Check:
BATTERY” in chapter 3.
1. fuse
2. battery Minimum open-circuit voltage
3. charging voltage 12.8 V or more at 20 °C
4. charging coil resistance 9Is the battery OK?
5. wiring connections
(of the entire charging system) YES NO
NOTE:
9Before troubleshooting, remove the following 9Clean the battery
part(s): terminals.
1. rear cowlings 9Recharge or
9Troubleshoot with the following special tool(s). replace the
battery.

Engine tachometer
90890-03113
Pocket tester
90890-03112

EAS00738

1. Fuse
9Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter
3.
9Is the fuse OK?

YES NO

Replace the fuse.

7-23
3P9-F8197-E0_7 05.11.8 14:14 Page 24

CHARGING SYSTEM ELEC

EAS00775 EAS00776

3. Charging voltage 4. Charging coil resistance

9Connect the engine tachometer to the spark 9Disconnect the stator coil coupler from the
plug lead. wire harness.
9Connect the pocket tester (DC 20 V) to the 9Connect the pocket tester (Ω × 1) to the
battery as shown. charging coil terminals as shown.
Positive tester probe → Positive tester probe → white 1
positive battery terminal 1 Negative tester probe → black 2
Negative tester probe →
negative battery terminal 2

B Y W R W

2 1

9Measure the charging coil resistances.

Charging coil resistance
9Start the engine and let it run at approxi- 0.32–0.48 Ω at 20°C (68°F) (W – B)
mately 5,000 r/min.
9Is the charging coil OK?
9Measure the charging voltage.

Charging voltage YES NO

14 V at 5,000 r/min
Replace the stator
NOTE: coil/pickup coil
Make sure the battery is fully charged.
assembly.
EAS00779

9Is the charging voltage within specification? 5. Wiring

9Check the wiring connections of the entire
NO YES
charging system.
Refer to “CIRCUIT DIAGRAM”.
The charging circuit 9Is the charging system wiring properly con-
is OK. nected and without defects?

YES NO

Replace the rectifi- Properly connect or

er/regulator. repair the charging
system wiring.

7-24
 1
8 Light switch
3P9-F8197-E0_7

OFF Br B O 9 Rectifier/ regulator

EAS00780
R R
ON Br Br R W
0 A. C. magneto
p Dimmer switch
Br R W W R R
0 q O O
R 9 Y Y/R W W s brake light
Tail/w
W B W W B g Headlight
R Y Y/R Y
B B ; Metere light
Br B
B
R W R R W z High beam indicator light
05.11.8 14:14

, Auxiliary light
CIRCUIT DIAGRAM

B
R R/W Br Br
Br L/W L/W L/W
2
LIGHTING SYSTEM

R Br Br
Page 25

R R

4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7 L Y/R Y/R L
R R 8
Br L/W L/B L/B
R
3 OFF OFF
START PO L/W L/W
ON B B
5
B L L /B

Br

7-25
u Br/W
Br
Y
y
Br
k Br
Br L Ch Dg
P Br Br/W
Y/W Sb Sb Y/W t
i P L/B Br/W
W W
L/W P P L/W ; zx cvbnm B Br r
(BLACK) (BLACK)
o p a B G/Y
OFF HI L P Dg Dg P (BLACK) (BLACK)
l PUSH LO N B Br/W Br/W B
R L/B Ch Ch L/B
L Br Br L G/Y
Dg Ch Ch Dg G/Y
B G G B
B
Ch Dg
Y G
G B Sb W P Y/W L/W
LIGHTING SYSTEM

Sb W P Y/W L/W YY G
L/R Ch Dg
Ch Dg L G/Y
G
, f f
L/R L/R
G G j B B dd s
B B
ELEC

g B B
P W W P B L
Ch Ch
h Y/W Sb Sb Y/W Y
B Dg Dg
L/W L/W Ch Dg

B B B L B
B
G/Y
Dg Ch
3P9-F8197-E0_7 05.11.8 14:14 Page 26

LIGHTING SYSTEM ELEC

EAS00781 EAS00776

TROUBLESHOOTING 2. Lighting coil resistance

Any of the following fail to light: head- 9Disconnect the stator coil coupler from the
light, high beam indicator light, taillight, wire harness.
auxiliary light, or meter light. 9Connect the pocket tester (Ω × 1) to the
lighting coil terminals as shown.
Check:
1. light switch Positive tester probe → yellow 1
2. lighting coil resistance Negative tester probe → black 2
3. wiring connections
(of the entire lighting system)
NOTE:
9Before troubleshooting, remove the following
part(s):
1. rear cowlings
B Y W R W
2. headlight assembly
9Troubleshoot with the following special tool(s).
2 1

Pocket tester 9Measure the lighting coil resistances.

90890-03112 Lighting coil resistance
0.24–0.36 Ω at 20°C (68°F) (Y – B)
9Is the lighting coil OK?
1. Light switch
9Check the light switch for continuity. YES NO
Refer to “CHECKING THE SWITCHES”.
9Is the light switch OK? Replace the stator
coil/pickup coil
YES NO assembly.
EAS00787

The light switch is 3. Wiring

faulty. Replace the
9Check the entire lighting system wiring.
right handlebar
Refer to “CIRCUIT DIAGRAM”.
switch.
9Is the lighting system wiring properly con-
nected and without defects?

YES NO

Check the condi- Properly connect or

tion of each of the repair the lighting
lighting system cir- system wiring.
cuits.
Refer to “CHECK-
ING THE LIGHT-
ING SYSTEM”.

7-26
3P9-F8197-E0_7 05.11.8 14:14 Page 27

LIGHTING SYSTEM ELEC

EAS00788
3. Voltage
CHECKING THE LIGHTING SYSTEM
9Connect the pocket tester (AC 20 V) to the
1. The headlight and the high beam indicator
headlight and high beam indicator light con-
light fail to come on.
nectors as shown.
EAS00784
åWhen the dimmer switch is set to “%”.
1. Dimmer switch
∫When the dimmer switch is set to “&”.
9Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
9Is the dimmer switch OK?

YES NO

The dimmer switch

is faulty. Replace
the left handlebar
switch. Headlight
Positive tester probe →
green 1 or yellow 2
2. Headlight bulb and socket
Negative tester probe → black 3
9Check the headlight bulb and socket for con-
tinuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
9Are the headlight bulb and socket OK?

YES NO

Replace the head-

light bulb, socket or High beam indicator light
both. Positive tester probe → yellow 4
Negative tester probe → black 5
9Set the main switch to “ON”.
9Start the engine.
9Set the dimmer switch to “%” or “&”.
9Measure the voltage (AC 12 V) of green 1
(yellow 2) on the headlight connector (wire
harness side) and yellow 4 on the meter
assembly connector (wire harness side).
9Is the voltage within specification?

YES NO

Replace the rectifi-

This circuit is OK.
er/regulator.

7-27
3P9-F8197-E0_7 05.11.8 14:14 Page 28

LIGHTING SYSTEM ELEC

EAS00789 EAS00790

2. The meter light fails to come on. 3. The tail/brake light fails to come on.
1. Meter light bulb and socket 1. Tail/brake light bulb and socket
9Check the meter light bulb and socket for 9Check the tail/brake light bulb and socket for
continuity. continuity.
Refer to “CHECKING THE BULBS AND Refer to “CHECKING THE BULBS AND
BULB SOCKETS”. BULB SOCKETS”.
9Are the meter light bulb and socket OK? 9Are the tail/brake light bulb and socket OK?

YES NO YES NO

Replace the meter Replace the tail/

light bulb, socket or brake light bulb,
both. socket or both.

2. Voltage 2. Voltage
9Connect the pocket tester (AC 20 V) to the 9Connect the pocket tester (AC 20 V) to the
meter light coupler (wire harness side) as tail/brake light coupler (wire harness side) as
shown. shown.
Positive tester probe → blue 1 Positive tester probe → blue 1
Negative tester probe → black 2 Negative tester probe → black 2

1
1 2
Br L L Br
Ch Dg Dg Ch B L L B
G B B G Y G/Y
Ch Dg Dg Ch
2

9Set the main switch to “ON”. 9Set the main switch to “ON”.
9Start the engine. 9Start the engine.
9Measure the voltage (AC 12 V) of blue lead 9Measure the voltage (AC 12 V) of blue lead
terminal 1 on the meter light coupler (wire terminal 1 on the tail/brake light coupler
harness side). (wire harness side).
9Is the voltage within specification? 9Is the voltage within specification?

YES NO YES NO

Replace the rectifi- Replace the rectifi-

This circuit is OK. This circuit is OK.
er/regulator. er/regulator.

7-28
3P9-F8197-E0_7 05.11.8 14:14 Page 29

LIGHTING SYSTEM ELEC

4. The auxiliary light fails to come on.
1. Meter light bulb and socket
9Check the meter light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
9Are the meter light bulb and socket OK?

YES NO

Replace the auxil-

iary light bulb,
socket or both.

2. Voltage
9Connect the pocket tester (AC 20 V) to the
auxiliary light coupler (wire harness side) as
shown.
Positive tester probe → blue/red 1
Negative tester probe → black 2

L/R L/R
B B

9Set the main switch to “ON”.

9Start the engine.
9Measure the voltage (AC 12 V) of blue/red
lead terminal 1 on the auxiliary light coupler
(wire harness side).
9Is the voltage within specification?

YES NO

Replace the rectifi-

This circuit is OK.
er/regulator.

7-29
 1
3P9-F8197-E0_7

OFF R R Br B O
ON Br Br R W EAS00793

Br R W W R R
0 q O O
R 9 Y Y/R W W w
W B W W B
R Y Y/R Y
B B e
Br B
B
R W R R W
05.11.8 14:14

B
CIRCUIT DIAGRAM

R R/W Br Br
Br L/W L/W L/W
2
R Br Br
SIGNALING SYSTEM
Page 30

R R

4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7 L Y/R Y/R L
R R 8
Br L/W L/B L/B
R
3 OFF OFF
START PO L/W L/W
ON B B
5
B L L/B

Br

7-30
u Br/W
Br
Y
y
Br
k Ch Dg Br
Br L
P Br Br/W
Y/W Sb Sb Y/W t
i P L/B Br/W
W W
L/W P P L/W ; zx cvbnm B Br r
(BLACK) (BLACK)
o p a B G/Y
OFF HI L P Dg Dg P (BLACK) (BLACK)
l PUSH LO N B Br/W Br/W B
R L/B Ch Ch L/B
L Br Br L G/Y
Dg Ch Ch Dg G/Y
B G G B
B
Ch Dg
Y G
G B Sb W P Y/W L/W
SIGNALING SYSTEM

Sb W P Y/W L/W YY G
L/R Ch Dg
Ch Dg L G/Y
G
, f f
L/R L/R
G G j B B dd s
B B g
ELEC

B B
P W W P B L
Ch Ch
h Y/W Sb Sb Y/W Y
B Dg Dg
L/W L/W Ch Dg

B B B L B
B
G/Y
Dg Ch
3P9-F8197-E0_7 05.11.8 14:14 Page 31

SIGNALING SYSTEM ELEC

1 Main switch
2 Fuse
3 Battery
r Rear brake light switch
t Front brake light switch
y Turn signal relay
u Horn
o Horn switch
a Turn signal switch
s Tail/brake light
d Rear turn signal light
f Front turn signal light
h Neutral switch
j Fuel sender
l Fuel gauge
x Turn signal indicator light
c Neutral indicator light
v 1st gear position indicator light
b 2nd gear position indicator light
n 3rd gear position indicator light
m 4th gear position indicator light

7-31
3P9-F8197-E0_7 05.11.8 14:14 Page 32

SIGNALING SYSTEM ELEC

EAS00794 EAS00739

TROUBLESHOOTING 2. Battery
9Any of the following fail to light: turn sig- 9Check the condition of the battery.
nal light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE
9The horn fails to sound. BATTERY” in chapter 3.

Check: Minimum open-circuit voltage

1. fuse 12.8 V or more at 20 °C (68 °F)
2. battery 9Is the battery OK?
3. main switch
4. wiring connections YES NO
(of the entire signaling system)

NOTE: 9Clean the battery

9Before troubleshooting, remove the following terminals.
part(s): 9Recharge or
1. front cowling replace the
2. front panel battery.
3. rear cowlings EAS00783

4. headlight assembly
3. Main switch
9Troubleshoot with the following special tool(s).
9Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Pocket tester
9Is the main switch OK?
90890-03112

EAS00738 YES NO
1. Fuse
Replace the main
9Check the fuse for continuity.
switch.
Refer to “CHECKING THE FUSE” in chapter
EAS00795
3.
9Is the fuse OK? 4. Wiring
9Check the entire signaling system wiring.
YES NO
Refer to “CIRCUIT DIAGRAM”.
9Is the signaling system wiring properly con-
Replace the fuse. nected and without defects?

YES NO

Check the condi- Properly connect or

tion of each of the repair the signaling
signaling system system wiring.
circuits.
Refer to “CHECK-
ING THE SIGNAL-
ING SYSTEM”.

7-32
3P9-F8197-E0_7 05.11.8 14:14 Page 33

SIGNALING SYSTEM ELEC

EAS00796
3. Horn
CHECKING THE SIGNALING SYSTEM
9Disconnect the pink connector at the horn
1. The horn fails to sound.
terminal.
1. Horn switch 9Connect a jumper lead 1 to the horn termi-
9Check the horn switch for continuity. nal and ground the jumper lead.
Refer to “CHECKING THE SWITCHES”. 9Set the main switch to “ON”.
9Is the horn switch OK? 9Does the horn sound?

YES NO Br

Replace the left han- 1

dlebar switch.

2. Voltage
9Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown. NO YES
Positive tester probe → brown 1
Negative tester probe → ground The horn is OK.

Br P
4. Voltage
9Connect the pocket tester (DC 20 V) to the
1 horn connector at the pink terminal as
shown.
Positive tester probe → pink 1
Negative tester probe → ground

9Set the main switch to “ON”.

Br P
9Measure the voltage (DC 12 V) of brown
lead terminal at the horn terminal.
9Is the voltage within specification?
1
YES NO

The wiring circuit

from the main switch
9Set the main switch to “ON”.
to the horn connec-
9Measure the voltage (DC 12 V) of pink lead
tor is faulty and must
terminal 1 at the horn terminal.
be repaired.
9Is the voltage within specification?

YES NO

Repair or replace Replace the horn.

the horn.

7-33
3P9-F8197-E0_7 05.11.8 14:14 Page 34

SIGNALING SYSTEM ELEC

EAS00797
3. Voltage
2. The tail/brake light fails to come on.
9Connect the pocket tester (DC 20 V) to the
1. Tail/brake light bulb and socket tail/brake light coupler (wire harness side) as
9Check the tail/brake light bulb and socket for shown.
continuity. Positive tester probe → green/yellow 1
Refer to “CHECKING THE BULBS AND Negative tester probe → black 2
BULB SOCKETS”.
9Are the tail/brake light bulb and socket OK?

1 2
YES NO
B L L B
Y G/Y
Replace the tail/
Ch Dg Dg Ch
brake light bulb,
socket or both.

2. Brake light switches 9Set the main switch to “ON”.

9Pull in the brake lever or push down on the
9Check the brake light switches for continuity.
brake pedal.
Refer to “CHECKING THE SWITCHES”.
9Measure the voltage (DC 12 V) of green/yel-
9Is the brake light switch OK?
low lead terminal 1 on the tail/brake light
coupler (wire harness side).
YES NO 9Is the voltage within specification?

Replace the brake

YES NO
light switch.

The wiring circuit

This circuit is OK.
from the main
switch to the
tail/brake light cou-
pler is faulty and
must be repaired.

7-34
3P9-F8197-E0_7 05.11.8 14:14 Page 35

SIGNALING SYSTEM ELEC

EAS00799
3. Voltage
3. The turn signal light, turn signal indicator
9Connect the pocket tester (DC 20 V) to the
light or both fail to blink.
turn signal relay coupler as shown.
1. Turn signal indicator light bulb and socket
Positive tester probe → brown 1
9Check the turn signal light bulb and socket Negative tester probe → ground
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”. Br/W
9Are the turn signal light bulb and socket OK?
1 Br

YES NO

Replace the turn sig-

nal light bulb, socket
or both. 9Set the main switch to “ON”.
9Measure the voltage (DC 12 V) on brown
lead terminal 1 at the turn signal relay cou-
2. Turn signal switch
pler.
9Check the turn signal switch for continuity. 9Is the voltage within specification?
Refer to “CHECKING THE SWITCHES”.
9Is the turn signal switch OK? YES NO

YES NO
The wiring circuit
from the main switch
Replace the left han- to the turn signal
dlebar switch. relay coupler is
faulty and must be
repaired.

7-35
3P9-F8197-E0_7 05.11.8 14:14 Page 36

SIGNALING SYSTEM ELEC

4. Voltage 5. Voltage
9Connect the pocket tester (DC 20 V) to the 9Connect the pocket tester (DC 20 V) to the
turn signal relay coupler as shown. turn signal light coupler (wire harness side)
Positive tester probe → brown/white 1 as shown.
Negative tester probe → ground Turn signal light
å Rear
∫ Front
1 Br/W Left turn signal light
Br Positive tester probe → chocolate 1
Negative tester probe → ground
Right turn signal light
Positive tester probe → dark green 2
Negative tester probe → ground
ç Turn signal indicator light
9Set the main switch to “ON”. Positive tester probe → chocolate 3
9Measure the voltage (DC 12 V) on Negative tester probe → ground
brown/white lead terminal 1 at the turn sig- Positive tester probe → dark green 4
nal relay coupler. Negative tester probe → ground
9Is the voltage within specification?
A

YES NO
B L L B
Y G/Y
The turn signal relay Ch Dg Dg Ch
is faulty and must be
replaced. 2 1

B B
Ch Ch
Dg Dg
1
2

C
4 3
Br L L Br
Ch Dg Dg Ch
G B B G

Sb Y/W Y/W Sb
W W
P L/W L/W P

7-36
3P9-F8197-E0_7 05.11.8 14:14 Page 37

SIGNALING SYSTEM ELEC

EAS00801
9Set the main switch to “ON”.
9Set the turn signal switch to “4” or “6”. 4. The gear position indicator lights fail to
9Measure the voltage (DC 12 V) of the come on.
chocolate 1 or dark green lead terminal 2 1. Gear position indicator light bulb and socket
at the turn signal light coupler (wire har-
9Check the gear position indicator light bulb
ness side) and chocolate 3 or dark green
and socket for continuity.
4 at the turn signal indicator light coupler
Refer to “CHECKING THE BULBS AND
(wire harness side).
BULB SOCKETS”.
9Is the voltage within specification?
9Are the gear position indicator light bulb and
socket OK?
YES NO
YES NO
This circuit is OK. The wiring circuit
from the turn signal
Replace the gear
switch to the turn
position indicator
signal light coupler
light bulb, socket or
is faulty and must
both.
be repaired.

2. Neutral switch
9Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
9Is the neutral switch OK?

YES NO

Replace the neutral

switch

7-37
3P9-F8197-E0_7 05.11.8 14:14 Page 38

SIGNALING SYSTEM ELEC

EAS00804
3. Voltage
5. The fuel level gauge fails to operate.
9Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side) 1. Fuel sender
as shown. 9Remove the fuel sender from the fuel tank.
Neutral indicator light 9Connect the pocket tester to the fuel sender
Positive tester probe → sky blue 1 coupler (fuel sender side) as shown.
Negative tester probe → ground Positive tester probe → green 1
1st gear position indicator light Negative tester probe → black 2
Positive tester probe → white 2
Negative tester probe → ground 1 2
2nd gear position indicator light
Positive tester probe → pink 3
B G

Negative tester probe → ground

3rd gear position indicator light
å
Positive tester probe → yellow/white 4
Negative tester probe → ground
4th gear position indicator light ∫
Positive tester probe → blue/white 5
9Measure the fuel sender resistances.
Negative tester probe → ground
Fuel sender resistance
(up position å )
Br L L Br
Ch Dg Dg Ch
(Ω × 1)
G B B G 4–10 Ω at 20°C (68°F)
1 Fuel sender resistance
Sb Y/W Y/W Sb
W W
(down position ∫ )
P L/W L/W P (Ω × 10)
2
45 3 90–100 Ω at 20°C (68°F)
9Is the fuel sender OK?
9Set the main switch to “ON”.
9Shift the transmission into each gear. YES NO
9Measure the voltage (DC 12 V) of the sky
blue 1, white 2, pink 3, yellow/white 4, or Replace the fuel
blue/white 5 lead terminal at the meter sender.
assembly coupler (wire harness side).
9Is the voltage within specification?

YES NO

This circuit is OK. The wiring circuit

from the main
switch to the meter
assembly coupler
is faulty and must
be repaired.

7-38
3P9-F8197-E0_7 05.11.8 14:14 Page 39

SIGNALING SYSTEM ELEC

2. Voltage 3. Fuel level gauge

9Connect the pocket tester (DC 20 V) to the 9Set the main switch to “ON”.
meter assembly coupler (wire harness side) 9Move the float up 1 or down 2.
as shown. 9Check that the fuel level gauge needle
Positive tester probe → brown 1 moves to “F” or “E”.
Negative tester probe → ground
NOTE:
Before reading the fuel level gauge, leave the
float in one position (either up or down) for at
least three minutes.
1

Br L L Br
Ch Dg Dg Ch
G B B G
1

9Set the main switch to “ON”.

9Measure the voltage (DC 12 V) of brown
lead terminal 1 on the meter assembly cou- 2
pler (wire harness side).
9Is the voltage within specification?
9Does the fuel level gauge needle move
appropriately?
YES NO

YES NO
Check the wiring
connections of the
Replace the fuel
entire signaling sys-
level gauge.
tem

4. Wiring
Check the entire signaling system’s wiring.

7-39
3P9-F8197-E0_8 05.11.3 2:21 PM Page 1

TRBL
SHTG
CHAPTER 8
TROUBLESHOOTING

TROUBLESHOOTING ........................................................................................... 8-1

ELECTRICAL SYSTEM .................................................................................... 8-1
COMPRESSION SYSTEM ............................................................................... 8-2
INTAKE AND EXHAUST SYSTEM ................................................................... 8-3
3P9-F8197-E0_8 05.11.3 2:21 PM Page 2

TRBL
SHTG
3P9-F8197-E0_8 05.11.3 2:21 PM Page 3

TRBL
TROUBLESHOOTING SHTG
EASF0062

TROUBLESHOOTING
TROUBLESHOOTING
ELECTRICAL SYSTEM

*CHECK ALL WIRES CONNECTIONS

IGNITION COIL (see page 7-13)

8 Primary or secondary windings
MAIN SWITCH (see page 7-5) are broken or faulty
8 Spark plug wire is faulty
8 Main switch is shorted
8 Spark plug cap is faulty

SPARK PLUG C.D.I. unit

8 Wet carbon deposits 8 C.D.I. unit is broken
8 Electrodes
8 Improper gap
8 Broken

STARTER MOTOR(see page 7-18)

CHARGING COIL (see page 7-24)/
8 Starter motor is broken or faulty PICKUP COIL (see page 7-13)
8 Starter relay is broken
8 Starter switch is broken 8 Windings are broken

8-1
3P9-F8197-E0_8 05.11.3 2:21 PM Page 4

TRBL
TROUBLESHOOTING SHTG
COMPRESSION SYSTEM

8-2
3P9-F8197-E0_8 05.11.3 2:21 PM Page 5

TRBL
TROUBLESHOOTING SHTG
INTAKE AND EXHAUST SYSTEM

FUEL COCK
8 Clogged FUEL TANK CAP
DRY TYPE
FUEL HOSE 8 Clogged AIR FILTER ELEMENT
8 Clogged, damaged 8 Dirty or clogged
or kinked

SILENCER
EXHAUST PIPE
8 Clogged
8 Cracked or broken
8 Carbon deposits

8-3
3P9-F8197-E0_8 05.11.3 2:21 PM Page 6

TRBL
SHTG
3P9-F8197-E0_ cover 05.11.3 2:46 PM Page 2

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN
3P9-F8197-E0_A3yoko 05.11.3 10:31 Page 1

T110LE WIRING DIAGRAM

1 Main switch
2 Fuse
3 Battery
4 Starter relay
5 Starter motor
1 6 Right handlebar switch
OFF R R Br B O 7 Start switch
ON Br Br R W
8 Light switch
9 Rectifier/ regulator
W W R R
Br R
R 9 Y Y/R
0 W W
q O O
w 0 A. C. magneto
W B W W B q C. D. I. unit
R Y Y/R
B
Y
B e w Ignition coil
R
B
Br B
e Spark plug
W R R W
r Rear brake light switch
B t Front brake light switch
R R/W Br Br
y Turn signal relay
2 Br L/W L/W L/W
u Horn
R Br Br i Left handlebar switch
R R
o Horn switch
4 p Dimmer switch
Y/R
R R/W R/W
R/W
L/W
R/W
L/W
6 a Turn signal switch
7 s Tail/ brake light
R R
L/W
Br L/W 8 L Y/R
L/B
Y/R L
L/B
3
R
OFF OFF
d Rear turn signal light
START PO L/W L/W f Front turn signal light
5 ON B B
g Headlight
B L L /B h Neutral switch
j Fuel sender
k Meter assembly
Br l Fuel gauge
; Meter light
u Br/W
z High beam indicator light
Br
y
Y Br x Turn signal indicator light
k Br L Ch Dg
Br
c Neutral indicator light
P Br Br/W
t v 1st gear position indicator light
Y/W Sb Sb Y/W
i P L/B Br/W
b 2nd gear position indicator light
W W
; zx cvbnm r
L/W P
(BLACK)
P L/W
(BLACK)
o p a B
B
Br
G/Y n 3rd gear position indicator light
OFF HI L P Dg Dg P
l PUSH LO N B Br/W Br/W B
(BLACK) (BLACK)
m 4th gear position indicator light
L Br Br L
R L/B Ch Ch L/B
G/Y , Auxilialy light
Dg Ch Ch Dg G/Y
B G G B
B
Ch Dg
Y G
G B Sb W P Y/W L/W

Sb W P Y/W L/W YY G
L/R Ch Dg
Ch Dg L G/Y
G
, f f
G G j L/R
B
L/R
B dd s
B B g B B
P W W P B L
Ch Ch
B
h Y/W Sb Sb Y/W Dg Dg
Y
Ch Dg
L/W L/W

B B B L B
B
G/Y
Dg Ch

COLOR CORD
B...................Black Sb ................Sky blue L/B................Blue/Black
Br .................Brown P...................Pink L/R................Blue/Red
Ch ................Chocolate R...................Red L/W ..............Blue/White
Dg ................Dark green W .................White R/W ..............Red/White
G ..................Green Y...................Yellow Y/R ...............Yellow/Red
L ...................Blue Br/W.............Brown/White Y/W ..............Yellow/White
O ..................Orange G/Y...............Green/Yellow