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EB000000

XVS650 SERVICE MANUAL 1996 by Yamaha Motor Co.Ltd. First edition, September 1996 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

EB001000

NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. Yamaha Motor Company, Ltd.is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice.

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

CAUTION:
NOTE:

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.

EB002000

HOW TO USE THIS MANUAL
MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols") 1st title 1 : 2nd title 2 : 3rd title 3 : This is the title of the chapter with its symbol in the upper right corner of each page. This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs. 2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6 . The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

2

1

6 3

8 5 4

7

EB003000

1

2

ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter.
1 2 3 4 5 6 7 8 9
General information Specifications Periodic inspections and adjustments Engine Cooling system Carburetion Chassis Electrical Troubleshooting

3

4

5

6

7

8

9

10

Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text.
10 11 12 13 14 15 16 17

11

12

13

14

Can be serviced with engine mounted Filling fluid Lubricant Special tool Torque Wear limit, clearance Engine speed , V, A

15

16

17

Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18 19 20 18 19 20 21 22 23

21

22

23

Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium-soap base grease Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply locking agent 24 and when to install new parts 25 .
24 25 24 Apply locking agent (LOCTITE)) 25 Replace

E004000

CHAPTER TITLES
GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING
GEN INFO

1 2 3 4 5 6 7 8

SPEC

INSP ADJ

ENG

CARB

CHAS

ELEC

TRBL SHTG

GEN INFO
CHAPTER 1. GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL PROCEDURES . . . . . . . . . . . . . . . REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-2 1-2 1-3 1-3 1-3

CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

GEN INFO

MOTORCYCLE IDENTIFICATION
EB100000

GEN INFO

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010

VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head.

MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

1-1

IMPORTANT INFORMATION
EB101000

GEN INFO

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly.

2. Use proper tools and cleaning equipment. Refer to the "SPECIAL TOOLS" section. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been "mated" through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS 1. Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

1-2

IMPORTANT INFORMATION
EB101030

GEN INFO

LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification.

EB101040

BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer's marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate. 1 Oil seal

CAUTION:
Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.
1 Bearing

EB101050

CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1 , make sure that the sharp-edged corner 2 is positioned opposite the thrust 3 it receives. See sectional view. 4 Shaft

1-3

CHECKING OF CONNECTIONS
EB801000

GEN INFO

CHECKING OF CONNECTIONS
Check the connectors for stains, rust, moisture, etc. 1. Disconnect: S Connector 2. Check: S Connector Moisture ! Dry each terminal with an air blower. Stains/rust ! Connect and disconnect the terminals several times. 3. Check: S Connector leads Looseness ! Bend up the pin 1 and connect the terminals.

4. Connect: S Connector terminals NOTE: The two terminals "click" together.

5. Check: S Continuity (using a pocket tester) NOTE: D If there is no continuity, clean the terminals. D When checking the wire harness be sure to perform steps 1 to 3. D As a quick remedy, use a contact revitalizer available at most part stores. D Check the connector with a pocket tester as shown.

1-4

SPECIAL TOOLS
EB102001

GEN INFO

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. Weight 90890-01084 Bolt 90890-01085 Tool name/How to use Slide hammer bolt/weight Illustration

These tools are used to remove the rocker arm shaft. Final gear backlash band

90890-01231 This tool is needed when measuring final gear backlash. Piston pin puller 90890-01304 This tool is used to remove the piston pin. Fuel level gauge 90890-01312 This gauge is used to measure the fuel level in the float chamber. T-handle 90890-01326 Holder 90890-01388 Puller 90890-01362 Adapter 90890-04089 Weight 90890-01367 Adapter 90890-01381 T-handle/damper rod holder

These tools are needed to loosen and tighten the damper rod holding bolt. Flywheel puller/adapter

These tools are needed to remove the rotor. Fork seal driver weight/adapter These tools are needed when installing the slide metal, oil seal and dust seal into the fork. Ring nut wrench

90890-01403 This tool is needed to loosen and tighten the steering stem ring nut.

1-5

SPECIAL TOOLS
Tool No. Tool name/How to use Sheave holder 90890-01701 This tool is needed to hold the rotor when removing or installing the rotor bolt. Compression gauge set 90890-03081 These tools are needed to measure engine compression. Vacuum gauge 90890-03094 This gauge is needed for carburetor synchronization. Pocket tester 90890-03112 This instrument is needed for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for observing engine rpm. Timing light 90890-03141 This tool is necessary for checking ignition timing. Valve guide remover & installer 90890-04018 This tool is needed to remove and install the valve guide. Valve spring compressor 90890-04019 This tool is needed to remove and install the valve assemblies. Bearing retainer wrench 90890-04050 This tool is needed when removing or installing the final drive shaft bearing.

GEN INFO
Illustration

1-6

SPECIAL TOOLS
Tool No. Tool name/How to use Bearing retainer wrench 90890-04057 This tool is needed when removing or installing the middle driven shaft bearing. Middle driven shaft bearing driver Plain bearing installer/remover These tools are needed when removing or installing the main journal bearing. Universal joint holder 90890-04062 This tool is needed when removing or installing the driven pinion gear nut. Middle gear backlash tool 90890-04080 This tool is needed for the gear backlash adjustment. Clutch holding tool 90890-04086 This tool is needed to hold the clutch when removing or installing the clutch boss nut. Damper spring compressor 90890-04090 This tool is needed when removing or installing the damper spring. Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. Yamaha bond No.1215 90890-85505 This sealant (bond) is used on crankcase mating surfaces, etc.

GEN INFO
Illustration

Driver 90890-04058 Installer/ remover 90890-04074

1-7

GEN INFO

SPEC
CHAPTER 2. SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2-4 2-13 2-17

GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-20 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

SPEC

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS Item Model code: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and a full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure (STD) Starting system Lubrication system: Oil type or grade: Engine oil Standard XVS650: 4VR1, 4VR2 2,340 mm 2,880 mm 1,065 mm 2,695 mm 1,610 mm 2,140 mm 3,100 mm 227 kg Air cooled 4-stroke, SOHC V-type 2-cylinder 0.649 L 81 63 mm 9:1 1,000 kPa (10 kg/cm2, 10 bar) at 300 r/min Electric starter Wet sump

Temp.

_C

API standard: Final gear oil: Oil quantity: Engine oil Periodic oil change With oil filter replacement Total amount Final gear case oil Total amount Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount

API SE or higher grade SAE80API "GL-4" Hypoid Gear Oil

2.6 L 2.8 L 3.2 L 0.19 L Dry type element Regular unleaded gasoline 16 L 3.0 L
2-1

GENERAL SPECIFICATIONS
Item Carburetor: Type/quantity Manufacturer Spark plug: Type Manufacturer Spark plug gap Clutch type: Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail Tire: Type Size Manufacturer Type BDS28/2 MIKUNI DPR7EA-9/X22EPR-U9 NGK/DENSO 0.8 X 0.9 mm Wet, multiple-disc Spur gear 68/38 (1.789) Shaft drive 19/18 32/11 (3.071) Constant mesh 5-speed Left foot operation 38/14 (2.714) 38/20 (1.900) 35/24 (1.458) 28/24 (1.167) 29/30 (0.967) Double cradle 35_ 153 mm With tube 100/90-19 57S 170/80-15M/C 77S BRIDGESTONE/DUNLOP BRIDGESTONE/DUNLOP L309/F24 G546/K555 180 kg Standard

SPEC

front rear front rear front rear

Maximum load-except motorcycle: Tire pressure (cold tire): 0 X 90 kg load * front rear 90 kg X Maximum load * front rear

200 kPa (2.00 kg/cm2, 2.00 bar) 225 kPa (2.25 kg/cm2, 2.25 bar) 200 kPa (2.00 kg/cm2, 2.00 bar) 250 kPa (2.50 kg/cm2, 2.50 bar) * Load is the total weight of the cargo, rider, passenger and accessories. Single disc brake Right hand operation Drum brake Right foot operation
2-2

Brake: Front brake Rear brake

type operation type operation

GENERAL SPECIFICATIONS
Item Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight type: Bulb wattage quantity: Headlight Tail/brake light Turn signal Auxiliary light Licence light Meter light Neutral indicator light High beam indicator light Turn indicator light Standard Telescopic fork Swingarm (Monocross) Coil spring/Oil damper Coil spring/Gas-oil damper 140 mm 86 mm T.C.I. (digital) A.C. magneto GT12B-4 12 V 10 AH Quartz bulb (halogen) 12 V 60 W/55 W 12 V 5 W/21 W 12 V 21 W 4 12 V 4 W 1 12 V 5 W 1 12 V 1.7 W 1 12 V 3 W 1 12 V 1.7 W 1 12 V 3 W 1

SPEC

2-3

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS
ENGINE Item Cylinder head: Warp limit SSS Standard Limit 0.03 mm

Cylinder: Bore size Measuring point*

80.945 X 80.995 mm 40 mm

81.1 mm SSS

Camshaft: Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam dimensions

Chain drive (left & right) 28.000 X 28.021 mm 27.96 X 27.98 mm 0.020 X 0.061 mm

SSS SSS SSS SSS

Intake

Exhaust

"A" "B" "C" "A" "B" "C"

Camshaft runout limit

39.733 mm 32.217 mm 7.733 mm 39.772 mm 32.302 mm 7.772 mm SSS

39.63 mm 32.12 mm SSS 39.67 mm 32.20 mm SSS 0.03 mm

2-4

MAINTENANCE SPECIFICATIONS
Item Timing chain: Timing chain type/No. of links Timing chain adjustment method Rocker arm/rocker arm shaft: Bearing inside diameter Shaft outside diameter Arm-to-shaft clearance Valve, valve seat, valve guide: Valve clearance (cold) IN EX Valve dimensions: Standard SILENT CHAIN/118 Automatic 14.000 mm X 14.018 mm 13.980 mm X 13.991 mm 0.009 mm X 0.038 mm 0.07 X 0.12 mm 0.12 X 0.17 mm

SPEC
Limit SSS SSS SSS SSS SSS SSS SSS

Head Dia

Face width

Seat Width

Margin Thickness

"A" head diameter "B" face width "C" seat width "D" margin thickness Stem outside diameter Guide inside diameter Stem-to-guide clearance Stem runout limit

IN EX IN EX IN EX IN EX IN EX IN EX IN EX

36.9 X 37.1 mm 31.9 X 32.1 mm 2.3 mm 2.3 mm 1.0 X 1.2 mm 1.0 X 1.2 mm 1.0 X 1.4 mm 1.0 X 1.4 mm 6.975 X 6.990 mm 6.960 X 6.975 mm 7.000 X 7.012 mm 7.000 X 7.012 mm 0.010 X 0.037 mm 0.025 X 0.052 mm SSS

SSS SSS SSS SSS 1.8 mm 1.8 mm 0.8 mm 0.8 mm 6.955 mm 6.935 mm 7.042 mm 7.042 mm 0.08 mm 0.10 mm 0.03 mm

Valve seat width Valve spring: Free length Set length (valve closed)

IN EX IN EX IN EX

1.0 X 1.2 mm 1.0 X 1.2 mm 43.2 mm 43.2 mm 37.1 mm 37.1 mm

1.8 mm 1.8 mm 42.0 mm 42.0 mm SSS SSS

2-5

MAINTENANCE SPECIFICATIONS
Item Compressed pressure (installed) Tilt limit * IN EX IN EX 21.8 X 25.6 kg 21.8 X 25.6 kg SSS SSS Standard

SPEC
Limit SSS SSS 2.5_/1.9 mm 2.5_/1.9 mm

Direction of winding (top view)IN EX Piston: Piston to cylinder clearance Piston size "D"

Counter clockwise Counter clockwise 0.035 X 0.055 mm 80.90 X 80.95 mm

SSS SSS 0.15 mm SSS

Measuring point "H" Oversize 2nd Oversize 4th Piston off-set Piston pin bore inside diameter Piston pin outside diameter Piston rings: Top ring:

6 mm 81.5 mm 82 mm 0 mm 20.004 X 20.015 mm 19.995 X 20.000 mm

SSS SSS SSS SSS SSS SSS

Type Dimensions (B T) End gap (installed) Side clearance (installed)

Plain 1.2 3.2 mm 0.15 X 0.30 mm 0.03 X 0.07 mm

SSS SSS 0.55 mm 0.12 mm

2-6

MAINTENANCE SPECIFICATIONS
Item 2nd ring: Standard

SPEC
Limit

Type Dimensions (B T) End gap (installed) Side clearance Oil ring:

Taper 1.5 3.6 mm 0.30 X 0.45 mm 0.02 X 0.06 mm

SSS SSS 0.8 mm 0.12 mm

Dimensions (B T) End gap (installed) Connecting rod: Oil clearance Color code (corresponding size) Crankshaft:

2.5 3.1 mm 0.2 X 0.7 mm 0.026 X 0.050 mm 1 Blue 2 Black 3 Brown 4 Green

SSS SSS SSS SSS

Crank width "A" Runout limit "C" Big end side clearance "D" Big end radial clearance "E" Journal oil clearance Clutch: Friction plate thickness Quantity Clutch plate thickness Quantity Clutch spring free length Quantity Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Push rod bending limit

93.95 X 94.00 mm SSS 0.270 X 0.424 mm 0.026 X 0.050 mm 0.020 X 0.052 mm 2.9 X 3.1 mm 7 1.5 X 1.7 mm 6 39.5 mm 5 0.10 X 0.37 mm 0.015 X 0.043 mm Inner push, cam push SSS

SSS 0.02 mm SSS SSS SSS 2.6 mm SSS 0.2 mm SSS 38.5 mm SSS SSS SSS SSS 0.5 mm

2-7

MAINTENANCE SPECIFICATIONS
Item Transmission: Main axle deflection limit Drive axle deflection limit Shifter: Shifter type Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw Valve seat size Starter jet Starter jet Throttle valve size Fuel level Engine idle speed Intake vacuum CO % Engine oil temperature Fuel pump: Type Model/manufacturer Consumption amperage Output pressure SSS SSS Guide bar 4VR 00 #90 #50 4CP10-3 O-6 #100 0.85 #20 0.8 0.8 0.8 2 1.0 #17.5 0.9 #140 7.5 X 8.5 mm 1,150 X 1,250 r/min 29.0 kPa (0.29 kg/cm2, 220 mmHg) 3X4% 80 X 90 _C Electrical type UC-Z6M/MITSUBISHI 0.8 A 12 kPa (0.12 kg/cm2, 0.12 bar) Paper type Trochoid type 0.12 mm 0.03 X 0.08 mm 440 X 540 kPa (4.5 X 5.5 kg/cm2, 4.5 X 5.5 bar) 10 kPa (0.1 kg/cm2, 0.1 bar) at 1,200 r/min H/C UNION BOLT 0.05 X 0.10 mm 0.1 X 0.2 mm Standard

SPEC
Limit 0.06 mm 0.06 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 0.2 mm 0.15 mm SSS SSS SSS SSS SSS

(M.J) (M.A.J) (J.N) (N.J) (P.A.J.1) (P.O) (P.J) (B.P.1) (B.P.2) (B.P.3) (P.S) (V.S) (G.S.1) (G.S.2) (Th.V) (F.L)



Lubrication system: Oil filter type Oil pump type Tip clearance "A" or "B" Side clearance Relief valve operating pressure Oil pressure (hot) Pressure check location Shaft drive: Middle gear backlash Final gear backlash

2-8

MAINTENANCE SPECIFICATIONS
Item Lubrication chart: Standard

SPEC

Pressure feed Splashed

Camshaft

Rocker arm shaft

Piston

Middle gear housing

Drive axle

Starter clutch

Crankshaft

Main axle

Oil filter

Oil pump

Relief valve

Oil strainer

2-9

MAINTENANCE SPECIFICATIONS
Cylinder head tightening sequence:

SPEC

Crankcase tightening sequence:

Left crankcase

Right crankcase

2-10

MAINTENANCE SPECIFICATIONS
Tightening torques g Part to be tightened Cylinder head Cylinder head Cylinder head Cylinder head cover bracket Cylinder head (exhaust pipe) Camshaft sprocket cover Tappet cover Rocker arm shaft (oil passage) Bearing retainer (camshaft) Spark plug Cylinder Lower cylinder head cover Upper cylinder head cover Connecting rod Rotor Valve adjusting locknut Camshaft sprocket Timing chain tensioner Timing chain guide Oil pump Oil strainer cover Oil filter cover Carburetor joint Air filter case stay Air filter case assembly Exhaust pipe joint (rear) and cylinder head Exhaust pipe joint (rear) and muffler assembly (rear) Exhaust pipe (front) Exhaust pipe and muffler Muffler Crankcase (cylinder) Crankcase (cylinder) Crankcase Crankcase Bearing retainer (middle drive pinion gear) Crankcase cover (left) Crankcase cover (right) Clamp One-way clutch Primary drive gear Part name Nut Nut Bolt Nut Stud bolt Bolt Bolt Bolt Bolt -- Bolt Bolt Screw Nut Bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Nut Screw Bolt Stud bolt Stud bolt Bolt Bolt
Torx screw

SPEC

Thread size M10 M8 M8 M10 M8 M6 M6 M16 M8 M12 M6 M6 M6 M8 M10 M6 M10 M6 M6 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M10 M10 M8 M8 M6 M8 M6 M6 M6 M8 M10

Q'ty y 8 2 4 8 4 4 8 4 4 2 2 6 8 4 1 4 2 4 4 3 3 5 4 2 2 2 2 2 2 2 8 2 4 10 4 13 11 1 6 1

Tightening torque Nm 35 20 20 35 15 10 10 38 20 18 10 10 5 36 80 14 55 12 10 7 10 10 12 12 12 20 20 25 20 25 20 13 24 10 25 10 10 10 20 70 mSkg 3.5 2.0 2.0 3.5 1.5 1.0 1.0 3.8 2.0 1.8 1.0 1.0 0.5 3.6 8.0 1.4 5.5 1.2 1.0 0.7 1.0 1.0 1.2 1.2 1.2 2.0 2.0 2.5 2.0 2.5 2.0 1.3 2.4 1.0 2.5 1.0 1.0 1.0 2.0 7.0

Remarks

Use lock washer

Stake

Bolt Bolt Bolt Bolt Nut

Use lock washer

2-11

MAINTENANCE SPECIFICATIONS
Thread size M6 M6 M20 M8 M20 M65 M14 M8 M8 M6 M6 M6 M6

SPEC
Remarks

Part to be tightened g Clutch spring Clutch adjuster Clutch boss Push lever axle Middle drive pinion gear Bearing retainer (middle driven shaft) Yoke (middle driven shaft) Bearing housing (middle drive shaft) Shift lever stopper Shift pedal link Shift pedal adjuster Stator coil Pickup coil

Part name Bolt Nut Nut Screw Nut -- Nut Bolt Bolt Bolt Nut Screw Screw

Q'ty y 5 1 1 1 1 1 1 4 1 1 2 3 3

Tightening torque Nm 8 8 70 12 120 110 90 25 22 10 7 7 7 mSkg 0.8 0.8 7.0 1.2 12.0 11.0 9.0 2.5 2.2 1.0 0.7 0.7 0.7

Use lock washer

Stake

Use lock washer

1 of 2 has LH thread

2-12

MAINTENANCE SPECIFICATIONS
CHASSIS Item Steering system: Steering bearing type No./size of steel ball (upper) Front suspension: Front fork travel Fork spring free length Fitting length Spring rate Stroke Optional spring Oil capacity Oil level Oil grade Rear suspension: Shock absorber travel Spring free length Fitting length Spring rate Stroke Optional spring Swingarm: Free play limit Front wheel: Type Rim size Rim material Rim runout limit Rear wheel: Type Rim size Rim material Rim runout limit Front brake: Type Disc outside diameter Pad thickness Pad thickness Standard Ball & taper roller bearing 19 pcs/0.25 in 140 mm 295 mm 249.9 mm 3.5 N/mm (0.35 kg/mm) 0 X 140 mm No 0.454 L 114 mm Fork oil 10W or equivalent 37 mm 168.5 mm 160.5 mm 186 N/mm (18.6 kg/mm) 0 X 37 mm No SSS SSS Spoke wheel 19 MT2.50 Steel 1.0 mm 0.5 mm Spoke wheel 15M/C MT3.50 Steel 1.0 mm 0.5 mm Single disk 298 5 mm 6.2 mm 6.2 mm

SPEC

Limit SSS SSS SSS 289 mm SSS SSS SSS SSS SSS SSS SSS SSS 165 mm SSS SSS SSS SSS 1 mm 1 mm SSS SSS SSS 2 mm 2 mm SSS SSS SSS 2 mm 2 mm SSS SSS 0.8 mm 0.8 mm

(K1) (K1)

(K1) (K1)

end side

radial lateral

radial lateral

thickness inner outer

2-13

MAINTENANCE SPECIFICATIONS
Item Standard

SPEC
Limit

Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear brake: Type Brake drum inside diameter Lining thickness Shoe spring free length Brake lever & brake pedal: Brake lever free play (at pivot) Brake lever free play (at lever end) Brake pedal position Brake pedal free play Clutch lever free play (at pivot) Clutch lever free play (at lever end)

12.7 mm 30.1 mm 33.3 mm DOT 4 Leading, trailing 200 mm 4 mm 68 mm 1 X 2 mm 10 X 15 mm 85 m 20 X 30 mm 2 X 3 mm 10 X 15 mm

SSS SSS SSS SSS SSS 201 mm 2 mm SSS SSS SSS SSS SSS SSS SSS

2-14

MAINTENANCE SPECIFICATIONS
Tightening torques g Part to be tightened Upper bracket and inner tube Lower bracket and inner tube Upper bracket and steering shaft Ring nut (steering shaft) Handlebar holder (lower) and upper bracket Handlebar holder (lower) and handlebar holder (upper) Master cylinder (front brake) Union bolt (brake hose) Brake hose holder and lower bracket Front fender and outer tube Headlight stay and lower bracket Headlight stay and headlight Front flasher light and lower bracket Engine mounting: Frame and stay (front - upper) Frame and stay (front - lower) Stay and engine (front - upper) Stay and engine (front - lower) Frame and engine (rear - upper) Frame and engine (rear - lower) Regulator stay and frame Regulator and regulator stay Muffler stay and frame Rear shock absorber and swingarm Rear shock absorber and frame Pivot shaft (left) and frame Pivot shaft (right) and frame Pivot shaft (right) and locknut Final gear case and swingarm Fuel tank and fuel cock Fuel tank bracket and frame Rider's seat Passenger seat Frame and rear fender stay Rear fender and rear fender stay Rear fender and tail/brake light Rear fender stay and rear flasher light Side cover (lower) Battery cover Side cover (right) Starter relay and leads Thread size M8 M10 M22 -- M12 M8 M6 M10 M6 M8 M6 M6 M6 M8 M8 M10 M10 M10 M12 M6 M6 M8 M12 M12 M22 M22 M22 M10 M6 M8 M6 M6 M10 M8 M6 M12 M6 M6 M6 M6

SPEC

Tightening torque Nm 20 30 110 18 20 23 10 30 9 10 7 8 7 40 30 40 40 40 74 13 7 30 62 62 100 7 100 70 7 23 7 7 26 26 6 23 7 7 7 7 mSkg 2.0 3.0 11.0 1.8 2.0 2.3 1.0 3.0 0.9 1.0 0.7 0.8 0.7 4.0 3.0 4.0 4.0 4.0 7.4 1.3 0.7 3.0 6.2 6.2 10.0 0.7 10.0 7.0 0.7 2.3 0.7 0.7 2.6 2.6 0.6 2.3 0.7 0.7 0.7 0.7

Remarks

See NOTE

2-15

MAINTENANCE SPECIFICATIONS

SPEC
Remarks

Part to be tightened g Passenger footrest and frame Sidestand bracket and frame Sidestand and sidestand bracket Sidestand switch Brake pedal/footrest and frame Front wheel axle Front wheel axle pinch bolt Brake caliper Brake disc and front wheel Caliper bleed screw Rear wheel axle nut Tension bar and swingarm Tension bar and brake shoe plate Brake cam shaft lever Clutch hub and damper Final gear case (housing cover) Bearing housing (final gear case) Bearing housing (final gear case) Bearing retainer (final drive pinion gear) Oil filter bolt (final gear) Oil drain bolt (final gear) Housing cover

Thread size M8 M10 M10 M5 M6 M16 M8 M10 M8 M7 M14 M8 M8 M6 M10 M10 M8 M10 M65 M14 M14 M10

Tightening torque Nm 26 64 56 4 64 59 20 40 23 6 97 20 20 10 62 18 23 23 115 23 23 42 mSkg 2.6 6.4 5.6 0.4 6.4 5.9 2.0 4.0 2.3 0.6 9.7 2.0 2.0 1.0 6.2 1.8 2.3 2.3 11.5 2.3 2.3 4.2

LH thread

NOTE: 1. First, tighten the ring nut approximately 52 Nm (5.2 mSkg) by using the torque wrench, then loosen the ring nut completely. 2. Retighten the ring nut to specification.

2-16

MAINTENANCE SPECIFICATIONS
ELECTRICAL Item Voltage: Ignition system: Ignition timing (B.T.D.C.) Advancer type T.C.I.: Pickup coil resistance/color T.C.I. unit model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Spark plug cap: Type Resistance Charging system: Type Model/manufacturer Nominal output Stator coil resistance/color Voltage regulator: Type Model/manufacturer No load regulated voltage Rectifier: Model/manufacturer Capacity Withstand voltage Battery: Specific gravity Electric starter system: Type Starter motor: Model/manufacturer I.D.number Output Brush overall length Commutator diameter Mica undercut Starter relay: Model/manufacturer Amperage rating 12 V 12_ at 1,200 r/min TPS and electrical type 182 X 222 at 20_C/Gray Black J4T079/MITSUBISHI F6T541 /MITSUBISHI 6 mm 3.8 X 4.6 at 20_C 10.1 X 15.1 k at 20_C Resin type 10 k Standard

SPEC

Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 4 mm 27 mm SSS SSS SSS

A.C. magneto F4T459 /MITSUBISHI 14 V 20 A at 5,000 r/min 0.50 X 0.62 at 20_C/White White Semi-conductor, short-circuit type SH650A-12/SHINDENGEN 14.1 X 14.9 V SH650A-12/SHINDENGEN 25 A 240 V 1.320 Constant mesh type SM-13/MITSUBA SM-13 0.7 kW 12.5 mm 28 mm 0.7 mm MS-5F/JIDECO 100 A

2-17

MAINTENANCE SPECIFICATIONS
Item Horn: Type Quantity Model/manufacturer Maximum amperage Flasher relay: Type Model/manufacturer Self cancelling device Flasher frequency Wattage Fuel pump relay: Model/manufacturer Circuit breaker: Type Amperage for individual circuit MAIN HEAD LIGHT SIGNALS IGNITION Reserve Reserve Reserve Plane type 1 YF-12/NIKKO 1.5 A Full transistor type FE246BH/DENSO No 75 X 95 cycle/min 21 W 2 + 3W G8R-30Y/OMRON Fuse 30 A 15 A 10 A 10 A 30 A 15 A 10 A 1 1 1 1 1 1 1 Standard

SPEC
Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

2-18

GENERAL TORQUE SPECIFICATIONS
EB202001

SPEC
General torque specifications Nm 6 15 30 55 85 130 mSkg 0.6 1.5 3.0 5.5 8.5 13.0

GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature.

A (nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm

B (Bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm

A: Distance between flats B: Outside thread diameter

2-19

LUBRICATION POINTS AND LUBRICANT TYPES
EB203000

SPEC

LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE Lubrication point Oil seal lips O-ring Bearing Connecting rod bolt/nut Connecting rod small end and big end Crankshaft pin Crankshaft journal/big end Piston surface Piston pin Camshaft cam lobe/journal Rocker arm shaft Valve stem (IN, EX) Valve stem end (IN, EX) Oil pump rotor (inner/outer), housing Idle gear surface Starter idle gear Starter idle gear shaft Middle drive gear Primary driven gear Push rod 1 Transmission gear (wheel/pinion) Shift cam Shift fork/guide bar Shift shaft assembly Valve spring (intake) Push rod ball Push lever assembly Symbol

2-20

LUBRICATION POINTS AND LUBRICANT TYPES
EB203010

SPEC

CHASSIS Lubrication point Steering head pipe (upper/lower), bearing Steering head pipe, bearing cover lip Steering head pipe, oil seal lip Front wheel oil seal lip (right/left) Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt, sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever pivot bolt, contact surface Clutch lever pivot bolt, contact surface Rear shock absorber (lower) oil seal lip Swingarm pivot bearing inner surface Swingarm pivot oil seal lip Symbol

2-21

LUBRICATION DIAGRAMS
EB205000

SPEC

LUBRICATION DIAGRAMS
1 Rocker arm (intake) 2 Rocker arm (exhaust) 3 Camshaft 4 Drain bolt 5 Oil strainer 6 Push lever 7 Push rod 1 8 Oil pump

2-22

LUBRICATION DIAGRAMS
1 Rocker arm shaft (intake) 2 Rocker arm shaft (exhaust) 3 Camshaft 4 Drive axle 5 Relief valve 6 Oil pump

SPEC

7 Oil filter 8 Crankshaft

2-23

LUBRICATION DIAGRAMS
1 Crankshaft 2 Oil filter 3 Oil pump

SPEC

2-24

LUBRICATION DIAGRAMS
1 Camshaft 2 Rocker arm 3 Starter idle gear 4 Drive axle 5 Main axle

SPEC

2-25

CABLE ROUTING
EB206000

SPEC

CABLE ROUTING
1 2 3 4 5 6 7 8 9 Clutch cable Left handlebar switch lead Fuel tank breather hose Speedometer cable Speedometer Speedometer light leads Rectifier/ regulator Rear brake switch lead Sidestand switch lead
10 11 12 13 14 15 16 17 18

Horn Headlight lead Right handlebar switch lead Spark plug lead Fuel hose Main switch lead Fuel pump lead Main switch Fuel pump

2-26

CABLE ROUTING
A Pass the front flasher light leads (left and right) and headlight lead through the headlight cover hole. B Pass the left handlebar switch lead behind the upper bracket. C Fasten the left handlebar switch lead with a plastic locking tie. D Pass the speedometer cable, speedometer light leads and fuel tank breather hose through the fuel tank hole.

SPEC

E Connect the rear brake switch coupler in front of the roll over valve stay. F To the speedometer light leads. G Pass the right handlebar switch lead and headlight lead over the other harness and leads. H Pass the clutch cable through the cable guide. I Fasten the sidestand switch lead and rectifier/ regulator lead with a plastic locking tie. J To the engine. K The sidestand switch lead should not touch the shift rod.

2-27

CABLE ROUTING
L Fasten the sidestand switch lead with a metal clamp. M Fasten the rear brake switch lead, sidestand switch lead and rectifier / regulator lead with a metal clamp. N Pass the speedometer cable through the speedometer cable holder. O To the rectifier / regulator. P Pass the rear brake switch lead between the frame and rectifier / regulator. Do not pinch the rear brake switch lead.

SPEC

Q Fasten the rear brake switch lead and rectifier/ regulator lead with a plastic locking tie. R Place the couplers behind the steering head. S Pass the speedometer cable through the holder. T Pass the fuel tank breather hose through the holder. U To the speedometer light leads.

2-28

CABLE ROUTING
Frame bracket Wire harness Fuse box Battery positive (+) lead Spark plug lead Starter cable Right handlebar switch lead Brake hose Throttle cables 10 Thermo switch lead 11 Flasher light relay 1 2 3 4 5 6 7 8 9
12 13 14 15 16 17 18 19 20 21 22

SPEC

Starter relay Carburetor heater relay Neutral switch lead Pickup coil lead A.C. magneto lead Battery negative () lead Starter motor lead Starting circuit cut-off relay Fuel tank breather hose Speedometer cable Ignitor unit

A Pass the tail/brake light lead between the frame bracket and battery box. B Fasten the tail/brake light lead with a battery band. Do not pinch the harness and tail/ brake light lead. C To the ignition coil. D The end of the plastic locking tie should face towards the under the handlebar.

2-29

CABLE ROUTING
E Fasten the right handlebar switch lead with a plastic locking tie. F Pass the right handlebar switch lead behind the upper bracket. G Fasten the brake hose with a brake hose holder. H Pass the left handlebar switch lead under the main switch. I Fasten the spark plug lead with a metal clamp. J Pass the ignition coil lead inside of the starter cable.

SPEC

K Fasten the fuse box lead with a plastic locking tie. L Fasten the battery positive (+) lead with a battery box clamp. M The carburetor heater relay should not touch the wire harness. N Fasten the wire harness with a plastic locking tie. O From the engine. P Pass the starter motor lead over the battery negative () lead.

2-30

CABLE ROUTING
Q Fasten the pickup coil lead, A.C. magneto lead, neutral switch lead and starter motor lead with a plastic locking tie. R Fasten the battery negative () lead, starter motor lead and wire harness with a plastic locking tie. S Fasten the wire harness with a battery band. T Pass the wire harness between the frame and battery box. U Place the end of the plastic locking tie as shown.

SPEC

V Fasten the starter cable with a plastic locking tie. W Inside the motorcycle. X Pass the fuel tank breather hose through the holder. Y Fasten the fuel tank breather hose with a metal clamp. Z Pass the speedometer cable through the front side guide. a Fasten the wire harness and leads with a plastic locking tie.

2-31

CABLE ROUTING
b Fasten the wire harness and leads with a metal clamp. c To the carburetor heater relay. d Fasten the wire harness and leads with a plastic locking tie. e Pass the plastic band through the frame hole. Fasten the wire harness with a plastic band at the point where the tape is located. f The wire harness and leads should not touch the rear shock absorber. g To the starter relay.

SPEC

h To the flasher light relay. i To the rear fender. j To the battery negative () lead. k Pass the ignitor unit leads through the battery box hole.

2-32

CABLE ROUTING
Front flasher light (right) Throttle cables Brake hose Right handlebar switch lead Clutch cable Left handlebar switch lead Front flasher light (left) Ignition coil Spark plug lead 10 Silencer 11 Starter cable 1 2 3 4 5 6 7 8 9
12 13 14 15 16 17 18 19 20

SPEC

Speedometer cable Neutral switch lead Pickup coil lead A.C. magneto lead Thermo switch lead Fuel tank breather hose Frame Wire harness Air filter case

A Pass the throttle cables through the cable guide. B Pass the brake hose in front of the upper bracket. C Pass the left handlebar switch lead over the right handlebar switch lead. D Pass the clutch cable through the cable guide. E Fasten the handlebar switch leads with a plastic band. F Fasten the wire harness with a plastic locking tie.

2-33

CABLE ROUTING
G To the ignition coil. H Pass the starter cable between the ignition coil and spark plug lead. I To the throttle position sensor (TPS). J To the carburetor. K To the fuel tank. L Pass the neutral switch lead, pickup coil lead and A.C. magneto lead under the ignition coil lead, thermo switch lead and throttle position sensor (TPS) lead. M From the engine.

SPEC

N 20 mm O Pass the thermo switch lead inside of the silencer breather hose. P Place the end of the plastic locking tie as shown. Q Inside the motorcycle. R Fasten the wire harness with a plastic locking tie. S Pass the wire harness between the air filter case groove and frame.

2-34

INSP ADJ
CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 3-1 FUEL TANK AND SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . IDLING SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR JOINT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SHOE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE LIGHT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . BRAKE HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) . . . . . . . . . . . . . . . SHIFT PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL GEAR OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . FINAL GEAR OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPOKE INSPECTION AND TIGHTENING . . . . . . . . . . . . . . . . . . . . . CABLE INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . LEVER AND PEDAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . SIDESTAND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-4 3-7 3-9 3-10 3-11 3-12 3-14 3-16 3-17 3-19 3-19 3-20 3-20 3-21 3-21 3-22 3-22 3-23 3-24 3-25 3-25 3-25 3-26 3-26 3-27 3-28 3-29 3-29 3-31 3-32 3-32 3-35 3-35 3-35 3-36 3-36

INSP ADJ
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 3-37 3-42 3-44 3-44

INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS
EB300000

INSP ADJ

PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS
EVERY

ITEM

ROUTINE
S Check fuel hoses for cracks or damage. S Replace if necessary. S Check condition. S Clean or replace if necessary. S Check valve clearance. S Adjust if necessary. S Clean or replace if necessary. S Check loading condition. S Recharge if necessary. S Check operation. S Adjust or replace cable. S Check operation and for fluid leakage. (See NOTE.) S Replace pads if necessary. S Check operation. S Adjust or replace shoes if necessary. S Check balance, runout, spoke tightness and for damage. S Tighten spokes and rebalance / replace if necessary. S Check tread depth and for damage. S Replace if necessary. S Check bearing assembly for looseness or damage. S Replace if damaged. S Check swingarm assembly for looseness. S Repair if necessary. S Grease with molybdenum sulfide grease every 24,000 km or 24 months. S Check steering for looseness and smooth operation. S Repair if necessary. S Grease with lithium soap base grease every 24,000 km or 24 months. S Check all nuts, bolts and screws for tightness. S Tighten if necessary. S Check operation. S Repair if necessary. S Check operation. S Replace if necessary. S Check front fork operation and for oil leakage. S Repair if necessary. S Check operation and for shock absorber oil leakage. S Replace if necessary. S Check idle speed, synchronization and starter operation. S Adjust if necessary.

BREAK-IN BREAK IN 1,000 km

6,000 km or 6 months

12,000 km or 12 months

*

Fuel line Spark plugs





*

Valves Air filter

*

Battery Clutch

* * * * *

Front brake Rear brake Wheels Tires Wheel bearings Swingarm pivoting point

*

*

Steering bearings





*

Chassis fasteners Sidestand

* * * *

Sidestand switch Front suspension Rear suspension Carburetors

3-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS
BREAK-IN BREAK IN 1,000 km

INSP ADJ
EVERY
6,000 km or 6 months 12,000 km or 12 months

ITEM Engine oil Engine oil filter Final gear oil

ROUTINE
S Replace. (Warm engine before draining.) S Replace. S Check oil level and for oil leakage. S Change every 24,000 km or 24 months.


Replace









Items marked with an asterisk (*) require special tools, data and technical skills for servicing. Take the motorcycle to a Yamaha dealer or refer to the Service Manual when servicing these items. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2. Replace the oil seals every two years on the inner parts of the master cylinder and caliper cylinder. 3. Replace the brake hoses every four years, or if cracked or damaged.

3-2

FUEL TANK AND SEATS

INSP ADJ

FUEL TANK AND SEATS

30 Nm (3.0 mSkg) 7 Nm (0.7 mSkg)

7 Nm (0.7 mSkg)

Order 1

Job name/Part name Fuel tank and seats removal Fuel hose

Q'ty 1

Remarks Remove the parts in the order below. NOTE: Set the fuel cock to "OFF" before disconnecting the fuel hose.

2 3 4

Meter assembly Meter lead couper Speedometer cable

1 2 1

NOTE: Disconnect the speedometer cable from the front wheel side first.

5 6 7 8 9

Starter knob bracket Fuel tank assembly Passenger seat Seat bracket Rider's seat

1 1 1 1 1 For installation, reverse the removal procedure.

3-3

VALVE CLEARANCE ADJUSTMENT
EB303003

INSP ADJ

ENGINE
VALVE CLEARANCE ADJUSTMENT NOTE: D Valve clearance adjustment should be made with the engine cool, at room temperature. D When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (T.D.C.) on the compression stroke. 1. Remove: S Meter assembly S Fuel tank Refer to "FUELTANK AND SEATS". 2. Remove: S Carburetor assembly Refer to "CARBURETOR" in CHAPTER 5. 3. Disconnect: S Spark plug caps 4. Remove: S Spark plugs 5. Remove: S Ignition coil 1

6. Remove: S Cylinder head covers Refer to "ENGINE REMOVAL". S Cylinder head cover brackets Refer to "CYLINDER HEADS".

7. Remove: S Tappet covers 1

3-4

VALVE CLEARANCE ADJUSTMENT

INSP ADJ

8. Remove: S Camshaft sprocket covers 1

9. Remove: S Timing plug 1 S Straight plug 2

10. Measure: S Valve clearance Out of specification ! Adjust. Valve clearance (cold): Intake valve: 0.07 X 0.12 mm Exhaust valve: 0.12 X 0.17 mm ***************************************************** Measuring steps: D Turn the crankshaft clockwise with a wrench. D Align the camshaft sprocket mark a with the stationary pointer b on the cylinder head. When the mark is aligned with the pointer, the piston is at Top Dead Center (TDC).

A

B

D Check the front/rear cylinder timing mark c on the rotor. If necessary, turn the crankshaft to align the timing mark with the pointer d on the AC magneto cover. A For rear cylinder ("TI" mark) B For front cylinder ("I" mark)

3-5

VALVE CLEARANCE ADJUSTMENT

INSP ADJ

D Measure the valve clearance using a thickness gauge 1 . *****************************************************

11. Adjust: S Valve clearance ***************************************************** Adjustment steps: D Loosen the locknut 1 . D Insert a thickness gauge between the adjuster end and the valve end. D Turn the adjuster 2 in or out until the specified clearance is obtained. Turning in: Turning out: valve clearance is decreased. valve clearance is increased.

D Hold the adjuster to prevent it from moving and tighten the locknut. Locknut: 14 Nm (1.4 mSkg) D Measure the valve clearance again. D If the clearance is still incorrect, repeat all the clearance adjustment steps until the specified clearance is obtained. *****************************************************

12. Install: S All removed parts NOTE: Install all removed parts in the reverse order of their disassembly. Note the following points.

3-6

VALVE CLEARANCE ADJUSTMENT/ CARBURETOR SYNCHRONIZATION

INSP ADJ
10 Nm (1.0 mSkg)

13. Install: S Camshaft sprocket covers S Tappet covers S Cylinder head cover S Spark plugs
10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 18 Nm (1.8 mSkg)

EB303010

CARBURETOR SYNCHRONIZATION NOTE: Prior to synchronizing the carburetors, the valve clearance should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Remove: S Vacuum plugs 1

3. Attach: S Vacuum gauge 1 S Engine tachometer 2 (to the #1 spark plug lead) Vacuum gauge: 90890-03094 Engine tachometer: 90890-03113 4. Start the engine and let it warm up for several minutes. 5. Check: S Engine idling speed Out of specification ! Adjust. Refer to "IDLING SPEED ADJUSTMENT". Engine idling speed: 1,150 X 1,250 r/min

3-7

CARBURETOR SYNCHRONIZATION

INSP ADJ

6. Adjust: S Carburetor synchronization ***************************************************** Adjustment steps: D Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 until both gauges read the same. D Rev the engine two or three times, each time for less than a second, and check the synchronization again. Vacuum pressure at idle speed: 29.0 kPa (0.29 kg/cm2, 220 mm Hg) NOTE: The difference between the two carburetors should not exceed 1.33 kPa (10 mm Hg). ***************************************************** 7. Check: S Engine idling speed Out of specification ! Adjust. 8. Stop the engine and detach the measuring equipment.

9. Adjust: S Throttle cable free play Refer to "THROTTLE CABLE ADJUSTMENT". Free play (throttle cable): 4 X 6 mm At throttle grip flange 10. Install: S Vacuum plugs

3-8

IDLING SPEED ADJUSTMENT
EB303021

INSP ADJ

IDLING SPEED ADJUSTMENT NOTE: Prior to adjusting the idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Attach: S Engine tachometer (to the #1 spark plug lead) Engine tachometer: 90890-03113

3. Check: S Engine idling speed Out of specification ! Adjust. Engine idling speed: 1,150 X 1,250 r/min

4. Adjust: S Engine idling speed ***************************************************** Adjustment steps: D Turn the throttle stop screw 1 in or out until the specified idling speed is obtained.
Turning in: Turning out: idling speed is increased. idling speed is decreased.

*****************************************************

3-9

IDLING SPEED ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT

INSP ADJ

5. Adjust: S Throttle cable free play Refer to "THROTTLE CABLE ADJUSTMENT". Free play (throttle cable): 4 X 6 mm At throttle grip flange

EB303030

THROTTLE CABLE ADJUSTMENT NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor synchronization should be adjusted properly.

1. Check: S Throttle cable free play a Out of specification ! Adjust. Free play (throttle cable): 4 X 6 mm At throttle grip flange

2. Remove: S Rider's seat S Fuel tank Refer to "FUEL TANK AND SEATS".

3. Adjust: S Throttle cable free play ***************************************************** Adjustment steps: NOTE: When the motorcycle is accelerating, throttle cable #1 1 is pulled and throttle cable #2 2 is pushed.

3-10

THROTTLE CABLE ADJUSTMENT/ SPARK PLUG INSPECTION

INSP ADJ

1st step: D Loosen the locknut 3 on throttle cable #1. D Turn the adjuster 4 in or out until the specified free play is obtained. Turning in: Turning out: free play is increased. free play is decreased.

D Tighten the locknuts. NOTE: If the specified free play cannot be obtained on the carburetor end of the cable, use the adjuster on the handlebar end.

Additional step: D Loosen the locknut 5 . D Turn the adjuster 6 in or out until the specified free play is obtained. Turning in: Turning out: free play is increased. free play is decreased.

D Tighten the locknut.

After adjusting, turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change. ***************************************************** 4. Install: S Fuel tank S Rider's seat Refer to "FUEL TANK AND SEATS".
EB303040

SPARK PLUG INSPECTION 1. Remove: S Spark plug caps S Spark plugs

CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells, to prevent it from falling into the cylinders.
3-11

SPARK PLUG INSPECTION/IGNITION TIMING CHECK
2. Check: S Spark plug type Incorrect ! Replace.

INSP ADJ

Standard spark plug: DPR7EA-9 (NGK) X22EPR-U9 (DENSO)

3. Inspect: S Electrode 1 Wear/damage ! Replace. S Insulator 2 Abnormal color ! Replace. Normal color is a medium-to-light tan color.

4. Clean: S Spark plug (with spark plug cleaner or wire brush) 5. Measure: S Spark plug gap a (with a wire gauge) Out of specification ! Adjust gap. Spark plug gap: 0.8 X 0.9 mm 6. Install: S Spark plug

18 Nm (1.8 mSkg)

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

EB303051

IGNITION TIMING CHECK NOTE: Prior to checking the ignition timing, check all electrical connections related to the ignition system. Make sure all connections are tight and free of corrosion and that all ground connections are tight.

3-12

IGNITION TIMING CHECK
1. Remove: S Timing plug 1

INSP ADJ

2. Attach: S Timing light 1 S Engine tachometer 2 (to the #1 spark plug lead) Timing light: 90890-03141 Engine tachometer: 90890-03113 3. Check: S Ignition timing ***************************************************** Checking steps: D Start the engine and let it warm up for several minutes. Let the engine run at the specified speed. Engine idling speed: 1,150 X 1,250 r/min D Check that the stationary pointer a is within the firing range b on the rotor. Incorrect firing range ! Check the ignition system. ***************************************************** NOTE: Ignition timing is not adjustable.

4. Install: S Timing plug 1

3-13

COMPRESSION PRESSURE MEASUREMENT
EB303060

INSP ADJ

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

1. Check: S Valve clearance Out of specification ! Adjust. Refer to "VALVE CLEARANCE ADJUSTMENT". 2. Start the engine and let it warm up for several minutes. 3. Stop the engine.

4. Remove: S Spark plug caps S Spark plugs

CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells, to prevent it from falling into the cylinders. 5. Attach: S Compression gauge 1 Compression gauge set: 90890-03081 6. Measure: S Compression pressure If it exceeds the maximum pressure allowed ! Inspect the cylinder head, valve surfaces and piston crown for carbon deposits. If it is below the minimum pressure ! Squirt a few drops of oil into the affected cylinder and measure again. S Refer to the table below.

3-14

COMPRESSION PRESSURE MEASUREMENT

INSP ADJ

Compression pressure (with oil applied in the cylinder) Reading Higher than without oil Same as without oil Diagnosis
Worn or damaged pistons ! Repair.

Possible defective ring(s), valves, cylinder head gasket or piston ! Repair.

Compression pressure (at sea level) Standard: 1,100 kPa (11 kg/cm2, 11 bar) Minimum: 1,000 kPa (10 kg/cm2, 10 bar) Maximum: 1,200 kPa (12 kg/cm2, 12 bar)

***************************************************** Measurement steps: D Crank the engine with the throttle wide open until the reading on the compression gauge stabilizes.

To prevent sparking, ground all spark plug leads before cranking the engine. D Repeat the previous steps for the other cylinders. NOTE: The difference in compression pressure between the highest and lowest cylinder compression readings should not exceed 100 kPa (1 kg/cm2, 1 bar). ***************************************************** 7. Install: S Spark plugs S Spark plug caps

18 Nm (1.8 mSkg)

3-15

ENGINE OIL LEVEL INSPECTION

INSP ADJ

ENGINE OIL LEVEL INSPECTION 1. Stand the motorcycle on a level surface. NOTE: D Make sure the motorcycle is upright when inspecting the oil level. D Place the motorcycle on a suitable stand.

2. Inspect: S Oil level Oil level should be between the maximum a and minimum b marks. Oil level is below the minimum mark ! Add oil up to the proper level. Recommended engine oil: Refer to the chart for selection of oils suited to the atmosperic temperature. API Standard: API SE or higher grade

Temp.

CAUTION:
D Do not put in any chemical additives or use oils with a grade of CD a or higher. D Be sure not to use oils labeled "ENERGY CONSERVING ll" b or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage. D Be sure no foreign material enters the crankcase. 3. Start the engine and let it warm up for several minutes. 4. Stop the engine and inspect the oil level once again. NOTE: Wait until the oil settles before inspecting the oil level.

3-16

ENGINE OIL REPLACEMENT
EB303080

INSP ADJ

ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Turn off the engine and place a container under the drain bolt. 3. Remove: S Oil filler plug 1 S O-ring 2 S Drain bolt 3 S Gasket Drain the crankcase of its oil.

4. If the oil filter is to be replaced during this procedure, remove the following parts and reinstall them afterwards. ***************************************************** Replacement steps: D Remove the oil filter element cover 1 and oil filter element 2 . D Check the O-ring 3 . If cracked or damaged, replace them with new one. D Install the oil filter element and oil filter element cover. Oil filter cover: 10 Nm (1.0 mSkg) *****************************************************

5. Install: S Gasket S Drain bolt

43 Nm (4.3 mSkg)

NOTE: Inspect the drain bolt gasket. If it is damaged, replace it.

3-17

ENGINE OIL REPLACEMENT

INSP ADJ

6. Fill: S Crankcase Refer to "ENGINE OIL LEVEL INSPECTION". Oil quantity: Total amount: 3.2 L (2.8 Imp qt) Periodic oil change: 2.6 L (2.3 Imp qt) With oil filter replacement: 2.8 L (2.6 Imp qt) 7. Install: S Oil filler plug, S Warm up the engine for a few minutes, then turn it off. 8. Check: S Engine (for oil leaks) S Oil level 9. Check: S Oil pressure ***************************************************** Checking steps: D Slightly loosen the oil gallery bolt 1 . D Start the engine and keep it idling until oil starts to seep from the oil gallery bolt. If no oil comes out after one minute, turn the engine off so that it will not seize. D Check the oil passages, oil filter and oil pump for damage or leakage. Refer to "INSPECTION AND REPAIR" in CHAPTER 4. D Start the engine after solving the problem(s) and check the oil pressure again. D Tighten the oil gallery bolt to specification. Oil gallery bolt: 8 Nm (0.8 mSkg) *****************************************************

3-18

CLUTCH ADJUSTMENT/AIR FILTER CLEANING
EB303090

INSP ADJ

CLUTCH ADJUSTMENT 1. Check: S Clutch cable free play a Out of specification ! Adjust. Free play (clutch cable): 10 X 15 mm At clutch lever end 2. Adjust: S Clutch cable free play ***************************************************** Adjustment steps: D Loosen the locknuts 1 . D Turn the adjusters 2 in or out until the specified free play is obtained. Turning in: Turning out: free play is increased. free play is decreased.

A

B

D Tighten the locknuts. *****************************************************
A Handlebar end B Engine end

EB303120

AIR FILTER CLEANING 1. Remove: S Air filter case cover 1 2. Remove: S Air filter element 2

CAUTION:
Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating.

3-19

AIR FILTER CLEANING/CARBURETOR JOINT INSPECTION/FUEL LINE INSPECTION
3. Inspect: S Air filter element Damage ! Replace.

INSP ADJ

4. Clean: S Air filter element Blow off the dust from the outside of the element using compressed air.

5. Install: S Air filter element S Air filter case cover NOTE: When installing the element in its case, make sure its sealing surface matches the sealing surface of the filter case so that no air can leak out.

EB303130

CARBURETOR JOINT INSPECTION 1. Inspect: S Carburetor joints 1 Cracks/damage ! Replace. Refer to "CARBURETOR" in CHAPTER 5.

EB303140

FUEL LINE INSPECTION 1. Inspect: S Fuel hose Cracks/damage ! Replace. S Fuel filter Contamination/damage ! Replace.

3-20

BREATHER HOSE INSPECTION/ EXHAUST SYSTEM INSPECTION

INSP ADJ

BREATHER HOSE INSPECTION 1. Remove: S Cylinder head cover (rear cylinder) Refer to "ENGINE REMOVAL" in CHAPTER 4. 2. Inspection: S Breather hose 1 Cracks/damage ! Replace. Loose connection ! Connect properly.

CAUTION:
Make sure that the crankcase breather hose is routed correctly.

EB303160

EXHAUST SYSTEM INSPECTION 1. Inspect: S Exhaust pipe (front) 1 S Exhaust pipe joint (rear) 2 S Muffler assembly (lower) 3 S Muffler assembly (upper) 4 Cracks/damage ! Replace. S Gaskets 5 Exhaust gas leaks ! Replace. 2. Check: 20 Nm (2.0 mSkg) S Nut 6 25 Nm (2.5 mSkg) S Nut 7 S Bolt 8 20 Nm (2.0 mSkg) S Bolts 9 25 Nm (2.5 mSkg) S Screws 10 20 Nm (2.0 mSkg)

3-21

FRONT BRAKE ADJUSTMENT
EB304002

INSP ADJ

CHASSIS
FRONT BRAKE ADJUSTMENT 1. Check: S Brake lever free play a Out of specification ! Adjust. Free play (brake lever): 10 X 15 mm (at brake lever end) 2. Adjust: S Brake lever free play ***************************************************** Adjustment steps: D Loosen the locknut 1 . D Turn the adjuster 2 in or out until the specified free play is obtained. Turning in: Turning out: brake lever free play is decreased. brake lever free play is increased.

D Tighten the locknut.

CAUTION:
After adjusting the front brake lever free play, make sure that there is no brake drag.

A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the brake system will considerably reduce braking performance and could result in a loss of control and possibly an accident. Inspect and if necessary, bleed the brake system. *****************************************************

3-22

REAR BRAKE ADJUSTMENT
EB304012

INSP ADJ

REAR BRAKE ADJUSTMENT 1. Check: S Brake pedal height a Out of specification ! Adjust. Brake pedal height: 85 mm (above the top of the footrest) 2. Adjust: S Brake pedal height ***************************************************** Adjustment steps: D Loosen the locknut 1 . D Turn the adjuster 2 in or out until the specified pedal height is obtained. Turning in: Turning out: brake pedal height is decreased. brake pedal height is increased.

D Tighten the locknut. Locknut: 7 Nm (0.7 mSkg) ***************************************************** 3. Check: S Brake pedal free play a Out of specification ! Adjust. Free play (brake pedal): 20 X 30 mm 4. Adjust: S Brake pedal free play ***************************************************** Adjustment steps: D Turn the adjuster 1 in or out until the specified free play is obtained. Turning in: Turning out: brake pedal free play is decreased. brake pedal free play is increased.

CAUTION:
Make sure that there