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Manuals and User Guides for YAMAHA TDM850. We have 4 YAMAHA TDM850 manuals available for free PDF download: User Manual, Owner’s Manual

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• Page 3
  EB000000 TDM850 ’96 SERVICE MANUAL 1996 by Yamaha Motor Co., Ltd. First edition, March 1996 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
• Page 4
  NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is as- sumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology.

• Page 5: How To Use This Manual

  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 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section.

• Page 6: Periodic Inspection And

  EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on top SPEC right of each page and indicate the subject of each INFO chapter. General information Specifications INSP Periodic inspections and adjustments Engine Cooling system Carburetion Chassis Electrical COOL CARB Troubleshooting CHAS…

• Page 7
  INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND INSP ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM COOL CARBURETION CARB CHASSIS CHAS ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG…
• Page 9
  INFO…

• Page 10: Table Of Contents

  INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ……..FRAME SERIAL NUMBER .

• Page 11
  INFO…

• Page 12: Motorcycle Identification

  MOTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. NOTE: The vehicle identification number is used to identi- fy the motorcycle and may be used to register the motorcycle with a licensing authority.

• Page 13: Important Information

  5. Keep away from fire. ALL REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replace- ments. Use oil and/or grease recommended by Yamaha for assembly and adjustment. Oth- er brands may be similar in function and ap- pearance, but inferior in quality.

• Page 14: Lock Washers/Plates And Cotter Pins

  IMPORTANT INFORMATION INFO LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates 1 and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

• Page 15: Checking Of Connections

  CHECKING OF CONNECTIONS INFO CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the con- nector. 1. Disconnect: S Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5.

• Page 16: How To Use The Conversion Table

  HOW TO USE THE CONVERSION TABLE INFO HOW TO USE THE CONVERSION CONVERSION TABLE TABLE METRIC TO IMPERIAL All specification data in this manual are listed in SI Metric unit Multiplier Imperial unit and METRIC UNITS. mSkg 7.233 ftSlb Use this table to convert METRIC unit data to IM- mSkg 86.794 inSlb…

• Page 17: Special Tools

  SPECIAL TOOLS INFO SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are pro- vided.

• Page 18
  SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration 90890-01701 Sheave holder This tool is used to hold the rotor when loosening and tightening the rotor bolt. 90890-03081 Compression gauge This gauge is used to measure the engine compression. 90890-03094 Vacuum gauge This gauge is needed for carburetor…
• Page 19
  SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration 90890-85505 Yamaha bond No. 1215 This sealant (bond) is used on crankcase mating surfaces, etc.
• Page 20
  SPEC…
• Page 21
  SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ……..MAINTENANCE SPECIFICATIONS .
• Page 22
  SPEC…

• Page 23: General Specifications

  SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model: TDM850 Model code: 4TX1 Dimensions: Overall length 2,165 mm, 2,200 mm (D, DK, SF, N, S) Overall width 790 mm Overall height 1,285 mm Seat height 805 mm Wheelbase 1,475 mm Minimum ground clearance 165 mm Minimum turning radius…

• Page 24
  SPEC GENERAL SPECIFICATIONS Item Standard Air filter: Dry type element Fuel: Type Regular unleaded gasoline Fuel tank capacity 20 L Fuel reserve amount 3.1 L Carburetor: Type/quantity BDST38/2 Manufacturer MIKUNI Spark plug: Type DPR8EA-9/X24EPR-U9 Manufacturer NGK/NIPPONDENSO 0.8 X 0.9 mm Spark plug gap Clutch type: Wet, multiple-disc…
• Page 25
  SPEC GENERAL SPECIFICATIONS Item Standard Tire pressure (cold tire): Maximum load-except motorcycle 180 kg 0 X 90 kg Loading condition A* front 225 kPa (2.25 kg/cm , 2.25 bar) rear 275 kPa (2.75 kg/cm , 2.75 bar) 90 X 180 kg Loading condition B* front 225 kPa (2.25 kg/cm…

• Page 26: Maintenance Specifications

  SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit 0.03 mm Cylinder: 89.500 X 89.505 mm Bore size 89.6 mm Taper limit 0.05 mm Out of round limit 0.03 mm Camshaft: Drive method Timing chain (right) 25.000 X 25.021 mm Camshaft cap inside diameter 24.967 X 24.980 mm…

• Page 27
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 2.06 X 2.46 mm “B” face width 2.06 X 2.46 mm 0.9 X 1.1 mm “C” seat width 0.9 X 1.1 mm 0.8 X 1.2 mm “D” margin thickness 0.8 X 1.2 mm 5.475 X 5.490 mm Stem outside diameter 5.445 mm 5.460 X 5.475 mm…
• Page 28
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston: 0.065 X 0.085 mm Piston to cylinder clearance 0.15 mm 89.420 X 89.435 mm Piston size “D” Measuring point “H” 4.5 mm Piston off-set 1 mm Piston off-set direction IN side 20.002 X 20.013 mm Piston pin bore inside diameter 20.043 mm 19.991 X 20.000 mm…
• Page 29
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft: 153.6 X 154.4 mm Assembly width “A” 64.75 X 65.25 mm Crank width “B” Runout limit “C” 0.035 mm 0.160 X 0.272 mm Big end side clearance “D” 0.5 mm 0.8 X 1.0 mm Small end free play “F”…
• Page 30
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Valve seat size (V.S) Starter jet 1 (G.S.1) Starter jet 2 (G.S.2) Throttle valve size (Th. V) #130 15.8 X 16.8 mm Fuel level (F.L) 1,050 X 1,250 r/min Engine idle speed 36.0 X 38.7 kPa (270 X 290 mmHg) Intake vacuum Fuel pump: Type…
• Page 31
  SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Camshaft cap Flange bolt Cylinder head Bolt Cylinder head cover Bolt Coolant drain bolt (cylinder body) Bolt Spark plug — Connecting rod Rotor Flange bolt 13.0…
• Page 32
  SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Stator coil Screw Starter motor Flange bolt Thermo switch — Thermo switch housing — PT1/8 Crankcase tightening sequence: 2-10…

• Page 33: Chassis

  SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Angular bearing Front suspension: Front fork travel 149 mm Fork spring free length 505 mm 500 mm Spring rate (K1) 6.4 N/mm (0.64 kg/mm) 0 X 149 mm Stroke (K1) Optional spring…

• Page 34
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual Disc outside diameter thickness 4 mm Disc deflection limit 0.2 mm Pad thickness inner 5.5 mm 0.5 mm Pad thickness outer 5.5 mm 0.5 mm Master cylinder inside diameter 15.8 mm Caliper cylinder inside diameter 33.96 + 30.23 mm…
• Page 35
  SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Remarks size size mSkg Upper bracket and inner tube Upper bracket and steering stem 10.8 Steering stem and ring nut See “NOTE” Inner tube and under bracket Horn bracket and brake hose holder Brake hose holder and under bracket Front brake hose union bolt Cowling stay and frame…
• Page 36
  SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Remarks size size mSkg Caliper bracket and swingarm Brake disc and wheel hub (front and rear) Driven sprocket and rear hub Bleed screw and brake caliper Rear brake hose union bolt Front wheel axle pinch bolt Brake hose joint and brake hose Chain puller and locknut…

• Page 37: Electrical

  SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) 10_ at 1,150 r/min Advancer type Electrical type T.C.I.: 192 X 288 Ω at 20_C/Blue/Yellow – Pickup coil resistance/color Green/White T.C.I. unit model/manufacturer TNDF33/NIPPONDENSO Ignition coil: Model/manufacturer J0300/NIPPONDENSO Minimum spark gap…

• Page 38
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Horn: Type Plane type Quantity Model/manufacturer YF-12/NIKKO Maximum amperage 2.5 A Flasher relay: Type Semi transistor type Model/manufacturer FE246BH/NIPPONDENSO Self cancelling device 75 X 95 cycle/min Flasher frequency Wattage 21 W 2 + 3.4 W Starting circuit cut off relay: Model/manufacturer G8R-30Y-F/OMRON…

• Page 39: General Torque Specifications

  SPEC GENERAL TORQUE SPECIFICATIONS 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 included in the applicable sec- tions of this book. To avoid warpage, tighten multi- fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached.

• Page 40: Lubrication Point And Grade Of Lubricant

  SPEC LUBRICATION POINT AND GRADE OF LUBRICANT LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE Lubrication point Lubricant type Oil seal lips O-ring Bearing Crankshaft (big end) Piston surface Piston pin Cylinder Piston ring, oil ring Connecting rod bolt Crankshaft journal Balancer (bearing/shaft) Camshaft, camshaft cap Valve stem (IN/EX)

• Page 41: Chassis

  SPEC LUBRICATION POINT AND GRADE OF LUBRICANT CHASSIS Lubrication point Lubricant type Steering bearing and bearing race (upper / lower) Front wheel oil seal (right / left) Rear wheel oil seal Clutch hub oil seal Clutch hub fitting area Rear brake pedal shaft Sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever bolt, sliding surface…

• Page 42: Lubrication Diagrams

  SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil pump (for pumping oil to the oil tank) Oil pump (for lubricating the engine parts) Oil strainer Oil filter Drain bolt Oil tank 2-20…

• Page 43
  SPEC LUBRICATION DIAGRAMS Front balancer Oil strainer Oil pump Relief valve Oil pump (for pumping oil to the oil tank) Oil pump (for lubricating the engine parts) 2-21…
• Page 44
  SPEC LUBRICATION DIAGRAMS Camshaft Rear balancer Main axle Drive axle Drain bolt Front balancer 2-22…
• Page 45
  SPEC LUBRICATION DIAGRAMS Cylinder head Rear balancer Crankshaft Drain bolt 2-23…
• Page 46
  SPEC LUBRICATION DIAGRAMS Main axle Drive axle 2-24…

• Page 47: Cable Routing

  SPEC CABLE ROUTING CABLE ROUTING Throttle cable Meter light lead Right handlebar switch lead Thermo switch lead Brake hose Fan motor lead Main switch lead Ignition coil (left) lead Clutch cable Ignition coil (right) lead Left handlebar switch lead Horn lead A Fasten the right handlebar switch lead with a plastic band.

• Page 48
  SPEC CABLE ROUTING D Fasten the horn lead with a plastic band. J Fasten the wire harness, right handlebar switch lead, E 60 mm meter light lead and headlight lead with a plastic band. F Fasten the brake hose with plastic bands. K To the throttle position sensor.
• Page 49
  SPEC CABLE ROUTING Front flasher light (left) lead Neutral switch lead Main switch lead A.C. magneto lead Starter cable Air filter case breather hose Left handlebar switch lead Carburetor heater hose Spark plug lead Speedometer cable Carburetor breather hose Brake hose Fuel hose Wire harness Vacuum hose (#2)
• Page 50
  SPEC CABLE ROUTING A Fasten the left handlebar switch lead and main switch E Fasten the sidestand switch lead, neutral switch lead lead with a plastic clamp. and A.C. magneto lead with a plastic clamp. B To the air filter case. F Fasten the sidestand switch lead and air filter case C Fasten the coolant reservoir hose, A.C.
• Page 51
  SPEC CABLE ROUTING Starter motor lead Coolant reservoir breather hose Fuel tank breather hose Carburetor breather hose Spark plug lead Rear brake switch lead Right handlebar switch lead Battery positive lead Clutch cable Battery negative lead Brake hose Throttle cable A Pass the battery positive lead and battery negative lead through the Headlight lead guide.
• Page 52
  SPEC CABLE ROUTING D Pass the carburetor breather hoses and vacuum J Pass the coolant reservoir hose over the throttle hose (#1) through the guide. cables. E Pass the vacuum hose (#1) through the guide. K Fasten the wire harness, right handlebar switch lead, F Fasten the coolant reservoir hose with a plastic meter light lead and headlight lead with a plastic band.
• Page 53
  SPEC CABLE ROUTING O Pass the fuel tank breather hose through the hole of S Fasten the wire harness with plastic clamps. the frame bracket. T To the engine. P Pass the coolant reservoir breather hose and fuel U Fasten the coolant reservoir breather hose with a tank breather hose through the guide.
• Page 54
  SPEC CARBLE ROUTING Headlight lead Coolant reservoir hose B Fasten the wire harness and cool- Wire harness Vacuum hose (#2) ant reservoir hose with a plastic Meter light lead Fuel hose clamp. Throttle stop screw cable Carburetor breather hose C Pass the starter relay lead through Vacuum hose (#1) Cylinder head breather hose the guide.
• Page 55
  SPEC CABLE ROUTING D Fasten the taillight lead with a plastic band to the tail- M Fasten the meter light lead and headlight lead with light bracket. plastic clamps. E 50 mm N Fasten the meter light lead, headlight lead and front F Fasten the carburetor breather hoses with a plastic flasher light lead connector with a plastic clamp.
• Page 56
  SPEC…
• Page 57
  INSP…
• Page 58
  INSP CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ……….PERIODIC MAINTENANCE/LUBRICATION INTERVALS .
• Page 59
  INSP TIRE INSPECTION ……….3-47 WHEEL INSPECTION .

• Page 60: Chapter 3. Periodic Inspection And Adjustment

  S Correct if necessary. S Check operation. Sidestand* S Repair if necessary. S Check operation. Sidestand switch* S Replace if necessary. : If is recommended that these items be serviced by a Yamaha dealer. : Lithium soap base grease. : Molybdenum disulfide grease.

• Page 61
  INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS 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 the fluid as required. 2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3.

• Page 62: Cowlings, Seat, Tail Cover And Fuel Tank

  INSP COWLINGS, SEAT, TAIL COVER AND FUEL TANK COWLINGS, SEAT, TAIL COVER AND FUEL TANK COWLINGS Order Job name/Part name Q’ty Remarks Cowlings removal Remove the parts in the order below. Side cowling (left and right) Meter panel Damper Wind shield Inner panel Front flasher light lead Disconnect…

• Page 63: Seat, Tail Cover And Fuel Tank

  INSP COWLINGS, SEAT, TAIL COVER AND FUEL TANK SEAT, TAIL COVER AND FUEL TANK 16 Nm (1.6 mSkg) Order Job name/Part name Q’ty Remarks Seat, tail cover and fuel tank removal Remove the parts in the order below. Side cowling Refer to “COWLINGS”.

• Page 64: Air Filter Case

  INSP AIR FILTER CASE AIR FILTER CASE AIR FILTER CASE Order Job name/Part name Q’ty Remarks Air filter case removal Remove the parts in the order below. Side cowling, seat, side cover and fuel Refer to “COWLINGS, SEAT, TAIL tank COVER AND FUEL TANK”.

• Page 65: Engine

  INSP VALVE CLEARANCE ADJUSTMENT ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: S The valve clearance should be adjusted when the engine is cool to touch. S The piston must be at Top Dead Center (T.D.C.) on compression stroke to check or adjust the valve clearance.

• Page 66
  INSP VALVE CLEARANCE ADJUSTMENT 5. Disconnect: S Thermo unit lead 1 S Thermo switch lead 2 S Ground lead 3 S Thermostatic valve housing 4 6. Remove: S Spark plug caps S Spark plugs S Cylinder head cover 7. Remove: S Timing plug 1 S Straight plug 2 S O-ring…
• Page 67
  INSP VALVE CLEARANCE ADJUSTMENT S Measure the valve clearance using a feeler gauge 2 . NOTE: S Record the measured reading if the clearance is incorrect. S Rotate the crankshaft 270_ counterclockwise and check the clearance of piston #2. NOTE: Make sure that the camshaft lobes are opposite each other when the piston is at TDC on the com- pression stroke.
• Page 68
  INSP VALVE CLEARANCE ADJUSTMENT S Remove the valve lifters 1 and the pads 2 . NOTE: S Place a rag in the timing chain space to prevent pads from falling into the crankcase. S Identify each valve lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place.
• Page 69
  INSP VALVE CLEARANCE ADJUSTMENT S Locate the rounded-off value and the mea- sured valve clearance in the chart “PAD SELECTION TABLE”. The field where these two coordinates intersect shows the new pad number to use. NOTE: Use the new pad number only as a guide when verifying the valve clearance adjustment.

• Page 70: Valve Clearance Adjustment

  INSP VALVE CLEARANCE ADJUSTMENT INTAKE INSTALLED PAD NUMBER MEASURED 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 CLEARANCE 0.00 X 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.05 X 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.10 X 0.14…

• Page 71: Valve Clearance Adjustment

  INSP VALVE CLEARANCE ADJUSTMENT S Recheck the valve clearance. S If the clearance is still incorrect, repeat all the clearance adjustment steps until the specified clearance is obtained. 10. Install: S All removed parts NOTE: Install all removed parts in reversed order of their removal.

• Page 72: Carburetor Synchronization

  INSP CARBURETOR SYNCHRONIZATION CARBURETOR SYNCHRONIZATION NOTE: Valve clearance and idling speed should be ad- justed properly before synchronizing the carbure- tors. 1. Place the motorcycle on a level surface. NOTE: Place the motorcycle on its centerstand if a cen- terstand is equipped. If not, place a suitable stand under the motorcycle.

• Page 73
  INSP CARBURETOR SYNCHRONIZATION 7. Adjust: S Carburetor synchronization Adjustment steps: S Synchronize carburetor #1 to carburetor #2 by turning synchronizing screw 1 until both gauges read the same. S Race the engine for less than a second, two or three times and check the synchronization again.

• Page 74: Idling Speed Adjustment

  INSP IDLING SPEED ADJUSTMENT IDLING SPEED ADJUSTMENT NOTE: The carburetor synchronization should be ad- justed properly before adjusting the idling speed. 1. Start the engine and let it warm up for several minutes. 2. Attach: S Engine tachometer 1 (to the #1 spark plug lead). Engine tachometer: 90890-03113 3.

• Page 75: Throttle Cable Adjustment

  IDLING SPEED ADJUSTMENT/ INSP THROTTLE CABLE ADJUSTMENT S Turn the throttle stop screw 2 in or out until specified idling speed is obtained. Turnning in: Idling speed is increased. Turnning out: Idling speed is decreased. 6. Adjust: S Throttle cable free play Refer to “THROTTLE CABLE FREE PLAY AD- JUSTMENT”.

• Page 76
  INSP THROTTLE CABLE ADJUSTMENT 3. Adjust: S Throttle cable free play Adjustment steps: First step: S Loosen the locknut 1 S Turn the adjuster 2 in or out until the specified free play is obtained. Turnning in: Free play is increased. Turnning out: Free play is decreased.

• Page 77: Spark Plug Inspection

  INSP SPARK PLUG INSPECTION SPARK PLUG INSPECTION 1. Remove: S Spark plug caps S Spark plugs CAUTION: Before completely removing the spark plug, use compressed air to clean the cylinder head cover areas to prevent dirt from falling into the engine.

• Page 78: Ignition Timing Check

  INSP IGNITION TIMING CHECK IGNITION TIMING CHECK NOTE: Carburetor synchronization, engine idle speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: S Timing plug 1 2. Attach: S Timing light S Engine tachometer (to the #1 spark plug lead) Timing light: 90890-03141…

• Page 79: Compression Pressure Measurement

  INSP COMPRESSION PRESSURE MEASUREMENT COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in performance loss. 1. Check: S Valve clearance Out of specification ! Adjust. Refer to “VALVE CLEARANCE ADJUST- MENT”. 2. Start the engine and let it warm up for several minutes.

• Page 80
  INSP COMPRESSION PRESSURE MEASUREMENT Compression pressure (With oil applied into cylinder) Reading Diagnosis Worn or damaged Higher than pistons /piston without oil rings ! Repair Defective ring(s), valves, cylinder Same as without oil head gasket or pis- ton is possible ! Repair Compression pressure (at sea level): Standard:…

• Page 81: Engine Oil Level Inspection

  INSP ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION NOTE: Position the motorcycle straight up when inspect- ing the oil level. 1. Place the motorcycle on a level surface. NOTE: S After idling the engine for 15 minutes, be sure the motorcycle is vertical, then check that the oil lev- el is between the maximum and minimum marks.

• Page 82: Engine Oil Replacement

  INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the drain bolt. 3. Remove: S Oil filler plug 1 4. Remove: S Drain bolt (with gasket) 1 S Oil filter drain bolt (with gasket) 2 Drain the crankcase and oil tank of its oil.

• Page 83
  INSP ENGINE OIL REPLACEMENT 7. Fill: S Crankcase CAUTION: The engine should be filled with oil in two steps. First fill the engine with 3.2 liters of oil. Then start the engine and race it five or six times. Stop the engine and fill it with oil to the specified level.

• Page 84: Clutch Adjustment

  INSP CLUTCH ADJUSTMENT/ AIR FILTER CLEANING CLUTCH ADJUSTMENT 1. Check: S Clutch cable free play a Out of specification ! Adjust. Free play: 10 X 15 mm At clutch lever end 2. Adjust: S Clutch cable free play Adjustment steps: S Loosen the locknut(s) 1 .

• Page 85: Carburetor Joint Inspection

  AIR FILTER CLEANING/ INSP CARBURETOR JOINT INSPECTION 3. Inspect: S Air filter element Damage ! Replace. 4. Clean: S Air filter element Blow off dust from the outer surface of the ele- ment with compressed air. 5. Install: S Air filter element S Air filter case cover NOTE: Make sure the element is properly seated in the fil-…

• Page 86: Fuel Line Inspection

  FUEL LINE INSPECTION/ INSP BREATHER HOSE INSPECTION FUEL LINE INSPECTION 1. Remove: S Side cowling S Seat S Side cover S Fuel tank Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. 2. Inspect: S Vacuum hoses 1 S Fuel hoses 2 Cracks /Damage ! Replace.

• Page 87: Exhaust System Inspection

  EXHAUST SYSTEM INSPECTION/ INSP COOLANT LEVEL INSPECTION EXHAUST SYSTEM INSPECTION 1. Inspect: S Exhaust pipes S Mufflers Cracks /Damage ! Replace. S Gaskets Exhaust gas leaks ! Replace. 2. Check: S Exhaust pipe nut 1 20 Nm (2.0 mSkg) S Exhaust pipe bolt 2 24 Nm (2.4 mSkg) S Muffler bolt 3 24 Nm (2.4 mSkg)

• Page 88: Coolant Replacement

  COOLANT LEVEL INSPECTION/ INSP COOLANT REPLACEMENT CAUTION: Hard water or salt water is harmful to the en- gine parts; use boiled or distilled water if you can’t get soft water. COOLANT REPLACEMENT 1. Remove: S Side cowling (right) S Seat Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”.

• Page 89
  INSP COOLANT REPLACEMENT 5. Install: S Gaskets S Drain bolt 1 10 Nm (1.0 mSkg) S Cylinder drain bolt 10 Nm (1.0 mSkg) 6. Connect: S Coolant reservoir hose 7. Fill: S Cooling system (radiator and engine) (to specified level a ) Recommended coolant: High quality ethylene glycol anti-freeze containing corrosion…
• Page 90
  INSP COOLANT REPLACEMENT CAUTION: S Hard water or salt water is harmful to the en- gine parts. Use boiled or distilled water if you can’t get soft water. S Do not use water containing impurities or oil. S Take care that no coolant splashes onto painted surfaces.

• Page 91: Cooling System Inspection

  COOLANT REPLACEMENT/ INSP COOLING SYSTEM INSPECTION COOLING SYSTEM INSPECTION 1. Inspect: S Radiator 1 S Hose 2 2 S Hose 3 3 Cracks /Damage ! Replace. Refer to “RADIATOR” in CHAPTER 5. 3-32…

• Page 92: Chassis

  INSP FRONT BRAKE ADJUSTMENT CHASSIS FRONT BRAKE ADJUSTMENT 1. Adjust: S Brake lever position (distance a from handle grip to front brake le- ver) Adjustment steps: S Turn the adjuster 1 while pushing the front brake lever forward until the desired lever posi- tion is obtained.

• Page 93: Rear Brake Adjustmet

  INSP REAR BRAKE ADJUSTMENT REAR BRAKE ADJUSTMENT 1. Check: S Brake pedal height a Out of specification ! Adjust. Brake pedal height: 29 mm Below top of footrest. 2. Adjust: S Brake pedal height Adjustment steps: S Loosen the locknut 1 . S Turn the adjuster 2 in or out until the specified pedal height is obtained.

• Page 94: Brake Fluid Level Inspection

  INSP BRAKE FLUID LEVEL INSPECTION BRAKE FLUID LEVEL INSPECTION NOTE: Position the motorcycle straight up when inspect- ing the fluid level. 1. Place the motorcycle on a level surface. NOTE: Place the motorcycle on its centerstand if a cen- terstand is equipped. If not, place a suitable stand under the motorcycle.

• Page 95: Brake Pad Inspection

  BRAKE PAD INSPECTION/ INSP BRAKE LIGHT SWITCH ADJUSTMENT BRAKE PAD INSPECTION 1. Activate the brake lever or brake pedal. 2. Inspect: S Brake pad Wear indicator 1 almost contacting the brake disc ! Replace brake pad as a set. Refer to “FRONT AND REAR BRAKE” in CHAPTER 7.

• Page 96: Brake Hose Inspection

  BRAKE HOSE INSPECTION/ INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE HOSE INSPECTION 1. Inspect: S Brake hoses 1 S Brake pipe 2 Cracks /Wear/Damage ! Replace. WARNING The brake pipe must not be disassembled. Do not loosen the bolts 3 . 2.

• Page 97: Shift Pedal Adjustment

  AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP SHIFT PEDAL ADJUSTMENT d. Place the other end of the hose into a contain- e. Slowly apply the brake lever or pedal several times. f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position.

• Page 98: Drive Chain Slack Adjustment

  SHIFT PEDAL ADJUSTMENT/ INSP DRIVE CHAIN SLACK ADJUSTMENT 2. Adjust: S Change pedal position Adjustment steps: S Remove the drive sprocket cover 1 . S Loosen both locknuts 2 . S Turn the shift pedal link 3 in or out to obtain the correct pedal position.

• Page 99
  INSP DRIVE CHAIN SLACK ADJUSTMENT 2. Check: S Drive chain slack a Out of specification ! Adjust. Drive chain slack: 40 X 50 mm 3. Loosen: S Caliper bracket bolt 1 S Axle nut 2 4. Adjust: S Drive chain slack Adjustment steps: S Loosen both locknuts 3 .

• Page 100: Drive Chain Lubrication

  DRIVE CHAIN LUBRICATION/ INSP STEERING HEAD INSPECTION DRIVE CHAIN LUBRICATION The chain consists of many parts that work with each other. If the chain is not maintained properly, it will wear out rapidly. Therefore, form the habit of periodically servicing the chain.

• Page 101
  INSP STEERING HEAD INSPECTION 4. Remove: S Starter cable holder 1 S Cable guide 2 S Handlebar holder (upper) 3 (with plugs) S Handlebar 4 5. Loosen: S Upper bracket pinch bolts 1 6. Remove: S Handle crown nut 2 S Upper bracket 3 7.

• Page 102: Front Fork Inspection

  STEERING HEAD INSPECTION/ INSP FRONT FORK INSPECTION S Check the steering head by turning it lock to lock. If it binds, remove the steering stem as- sembly and inspect the steering bearings. Refer to “STEERING HEAD” in CHAPTER 7. S Install the rubber washer 3 . S Install the ring nut (upper) 2 .

• Page 103: Front Fork Adjustment

  FRONT FORK INSPECTION/ INSP FRONT FORK ADJUSTMENT 2. Check: S Inner tube 1 Scratches /Bent/Damage ! Replace. S Oil seal Excessive oil leakage ! Replace. 3. Hold the motorcycle in an upright position and apply the front brake. 4. Check: S Operation Pump the front fork up and down for several times.

• Page 104: Rear Shock Absorber Adjustment

  FRONT FORK ADJUSTMENT/ INSP REAR SHOCK ABSORBER ADJUSTMENT Damping force 1. Adjust: S Damping force Turn the adjuster 1 in or out. Turnning Damping force is increased. Turnning Damping force is decreased. Adjuster position: Standard: 4 clicks out Minimum: 5 clicks out Maximum: 0 clicks out *: From the fully turned-in position.

• Page 105
  INSP REAR SHOCK ABSORBER ADJUSTMENT 2. Adjust: S Spring preload Fine adjustment (bottom) Adjustment steps: S Loosen the locknut 1 . S Turn the adjuster 2 in or out. Turnning Spring preload is increased. Turnning Spring preload is decreased. Measurement length c : Standard: 61 mm Minimum: 59 mm Maximum: 63 mm…
• Page 106
  INSP TIRE INSPECTION TIRE INSPECTION 1. Measure: S Tire pressure Out of specification ! Adjust. WARNING S Tire inflation pressure should only be checked and adjusted when the tire tempera- ture equals the ambient air temperature. Tire inflation pressure and suspension must be adjusted according to the total weight of the cargo, rider, passenger and accessories (fairing, saddlebags, etc.
• Page 107
  WARNING After extensive tests, the tires mentioned be- low have been approved by Yamaha Motor Co. Ltd. for this model. No guarantee for handling characteristics can be given if a tire combina- tions other than the approved is used on this motorcycle.
• Page 108
  TIRE INSPECTION/WHEEL INSPECTION/ INSP CABLE INSPECTION AND LUBRICATION NOTE: For tires with a “DRIVE” mark 1 : S Install the wheel with the “DRIVE” mark pointing in direction in which the wheel will rotate. WARNING After mounting a tire, ride conservatively for a while to give the tire time to seat itself properly in the rim.
• Page 109
  LEVER AND PEDAL LUBRICATION/SIDESTAND INSP LUBRICATION/REAR SUSPENSION LUBRICATION LEVER AND PEDAL LUBRICATION Lubricate levers and pedals at their pivoting points. Recommended lubricant: Engine oil SIDESTAND LUBRICATION Lubricate the sidestand at pivoting points. Recommended lubricant: Engine oil REAR SUSPENSION LUBRICATION Lubricate the rear suspension at pivoting points. Recommended lubricant: Molybdenum disulfide grease 3-50…
• Page 110
  INSP BATTERY ELECTRICAL BATTERY 7 Nm (0.7 mSkg) 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) 7 Nm (0.7 mSkg) 8 Nm (0.8 mSkg) Order Job name/Part name Q’ty Remarks Battery removal Remove the parts in the order below. Remove the parts in the order below. Seat Refer to “COWLINGS, SEAT, TAIL COVER Refer to “COWLINGS, SEAT, TAIL COVER…
• Page 111
  INSP REMOVAL REMOVAL WARNING Immediately after removing the battery leads, securely cover the terminals with the covers 1 to prevent the battery leads from being shorted. 1. Remove: S Seat Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. 2. Remove: S Negative terminal cover 1 S Positive terminal cover 2 WARNING…
• Page 112
  INSP INSPECTION INSPECTION NOTE: Since the MF battery is a sealed type battery, it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery. Therefore the charge of the battery has to be checked by measuring the voltage at the bat- tery terminals.
• Page 113
  INSP INSPECTION 1. Check: S Battery condition Volt meter Battery condition checking steps: S Connect a digital voltmeter to the battery termi- nals. Tester (+) lead ! battery (+) terminal Tester (–) lead ! battery (–) terminal NOTE: The charge state of an MF battery can be checked Relationship between the open-circuit voltage 13.0 and the charging time at 20_C…
• Page 114
  INSP INSPECTION S Before removing the clips from the battery terminals, be sure to turn off the charger’s power switch. S The open-circuit voltage variation for the MF battery after charging is shown below. As shown in the figure, the open circuit voltage stabilizes about 30 minutes after charging has been completed.
• Page 115
  INSP INSPECTION Charging method using a variable-current (voltage) type charger NOTE: Measure the open-circuit Voltage should be measured 30 min- Charger utes after the machine is stopped. voltage prior to charging. AMP meter NOTE: Set the charging voltage at 16 X 17 V. Connect a charger and AMP (If the setting is lower, charging will be meter to the battery and start…
• Page 116
  INSP INSPECTION Charging method using a constant-voltage type charger NOTE: Measure the open-circuit Voltage should be measured 30 min- voltage prior to charging. utes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging. Make sure that the current is higher than the standard charging current written…
• Page 117
  INSP INSPECTION/INSTALLATION/FUSE INSPECTION 2. Inspect: S Battery terminal Dirty ! Clean with a wire brush. Poor connection ! Correct. NOTE: After cleaning the terminals, grease them lightly. INSTALLATION 1. Install: S Battery assembly 1 NOTE: S During installation, be sure the projection a on the battery box aligns with the grommet on the frame.
• Page 118
  INSP FUEL INSPECTION 2. Inspect: S Fuses 1 Inspection steps: S Connect the pocket tester to the fuse and check it for continuity. NOTE: Set the tester selector to “Ω 1” Pocket tester: 90890-03112 S If the tester indicates , replace the fuse. 3.
• Page 119
  HEADLIGHT BEAM ADJUSTMENT/ INSP HEADLIGHT BULB REPLACEMENT EB305021 HEADLIGHT BEAM ADJUSTMENT 1. Adjust: S Headlight beam (vertically) Turn the adjuster 1 in or out. Headlight beam is Turnning in: lowered. Turnning out: Headlight beam is raised. 2. Adjust: S Headlight beam (horizontally) Turn the adjuster 2 in or out.
• Page 120
  INSP HEADLIGHT BULB REPLACEMENT 5. Install: S Bulb Secure the new bulb with the bulb holder. CAUTION: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the transpar- ency of the glass, life of the bulb, and luminous flux will be adversely affected.
• Page 121
  INSP…
• Page 123
  CHAPTER 4. ENGINE OVERHAUL ENGINE ASSEMBLY ……….LEADS .
• Page 124
  A.C. MAGNETO AND STARTER WHEEL GEAR ….. 4-37 STATOR COIL ……….4-37 A.C.

• Page 125: Engine Assembly

  ENGINE ASSEMBLY ENGINE OVERHAUL ENGINE ASSEMBLY LEADS 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Leads disconnect Disconnect the parts in the order below. Side cowling, seat, side cover and fuel Refer to “COWLINGS, SEAT, TAIL COV- tank. ER AND FUEL TANK”…

• Page 126: Drive Sprocket And Exhaust Pipe/Muffler

  ENGINE ASSEMBLY DRIVE SPROCKET AND EXHAUST PIPE/MUFFLER 12 Nm (1.2 mSkg) 70 Nm (7.0 mSkg) 24 Nm (2.4 mSkg) 5 Nm (0.5 mSkg) 24 Nm (2.4 mSkg) 20 Nm (2.0 mSkg) 20 Nm (2.0 mSkg) Order Job name/Part name Q’ty Remarks Drive sprocket and exhaust Remove the parts in the order below.

• Page 127: Engine Assembly

  ENGINE ASSEMBLY ENGINE ASSEMBLY 10 Nm (1.0 mSkg) 89 Nm (8.9 mSkg) 60 Nm (6.0 mSkg) 30 Nm (3.0 mSkg) 30 Nm (3.0 mSkg) 60 Nm (6.0 mSkg) 30 Nm (3.0 mSkg) 64 Nm (6.4 mSkg) Order Job name/Part name Q’ty Remarks Engine removal…

• Page 128
  ENGINE ASSEMBLY 10 Nm (1.0 mSkg) 89 Nm (8.9 mSkg) 60 Nm (6.0 mSkg) 30 Nm (3.0 mSkg) 30 Nm (3.0 mSkg) 60 Nm (6.0 mSkg) 30 Nm (3.0 mSkg) 64 Nm (6.4 mSkg) Order Job name/Part name Q’ty Remarks Engine stay (left) Engine bracket (lower) For installation, reverse the removal…

• Page 129: Installation

  ENGINE ASSEMBLY INSTALLATION 1. Install: S Bolt 1 X 6 NOTE: Do not fully tighten. 2. Tighten: S Tighten the bolts in the order below. 1 Bolt 30 Nm (3.0 mSkg) 2 Bolt 30 Nm (3.0 mSkg) 3 Bolt 64 Nm (6.4 mSkg) 4 Bolt 89 Nm (8.9 mSkg) 5 Bolt…

• Page 130: Camshaft

  CAMSHAFT CAMSHAFT CYLINDER HEAD COVER 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Cylinder head cover removal Remove the parts in the order below. Side cowling, seat, side cover and fuel Refer to “COWLINGS, SEAT, TAIL tank COVER AND FUEL TANK” in CHAPTER 3. Air filter case Refer to “AIR FILTER CASE”…

• Page 131: Camshaft

  CAMSHAFT CAMSHAFT 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 18 Nm (1.8 mSkg) 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) 20 Nm (2.0 mSkg) Order Job name/Part name Q’ty Remarks Camshaft removal Remove the parts in the order below. Spark plug Plug/O-ring Timing chain guide (upper)

• Page 132: Removal

  CAMSHAFT REMOVAL 1. Remove: S Timing plug 1 S Straight plug 2 2. Align: S “T” mark (with stationary pointer) NOTE: S Turn the crankshaft counterclockwise and align the “T” mark a with the stationary pointer b when #1 piston is at TDC on compression stroke. S The #1 piston is in compression stroke TDC when the cam lobes are turned away from each other.

• Page 133: Inspection

  CAMSHAFT 8. Remove: S Timing chain guide (exhaust) S Camshaft cap 1 NOTE: Remove the camshaft cap bolts in a crisscross pattern, working from the inside to the outside. CAUTION: The bolts (camshaft caps) must be removed evenly to prevent damage to the cylinder head, camshafts or camshaft caps.

• Page 134
  CAMSHAFT 4. Measure: S Camshaft-to-cap clearance Out of specification ! Measure bearing diam- eter (camshaft) Camshaft-to-cap clearance: 0.020 X 0.054 mm Measurement steps: S Install the camshaft onto the cylinder head. S Position a strip of Plastigauge 1 onto the camshaft.

• Page 135: Installation

  CAMSHAFT INSTALLATION 1. Install: S Exhaust camshaft 1 S Intake camshaft 2 (with camshaft sprocket temporarily tighten) S Dowel pins 3 NOTE: Install the camshaft with the punch mark a facing upward. 2. Install: S Camshaft caps 10 Nm (1.0 mSkg) NOTE: S Install the camshaft cap with the arrow mark a embossed facing timing chain of the engine.

• Page 136
  CAMSHAFT CAUTION: Do not turn the crankshaft during the cam- shaft installation. Damage or improper valve timing will result. S Make sure that marks d and e are aligned after the crankshaft is rotated twice and the piston is at TDC.

• Page 137: Cylinder Head

  CYLINDER HEAD CYLINDER HEAD 40 Nm (4.0 mSkg) 21 Nm (2.1 mSkg) 10 Nm (1.0 mSkg) 60 Nm (6.0 mSkg) 10 Nm (1.0 mSkg) 60 Nm (6,0 mSkg) Order Job name/Part name Q’ty Remarks Cylinder head removal Remove the parts in the order below. Exhaust pipe Refer to “ENGINE ASSEMBLY”.

• Page 138: Inspection

  CYLINDER HEAD INSPECTION 1. Eliminate: S Carbon deposit (from combustion chamber) Use rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: S Spark plug threads S Valve seat 2. Inspect: S Cylinder head Scratches /Damage ! Replace. 3.

• Page 139: Valve And Valve Spring

  VALVE AND VALVE SPRING VALVE AND VALVE SPRING Order Job name/Part name Q’ty Remarks Valve and valve spring removal Remove the parts in the order below. Cylinder head cover Refer to “CYLINDER HEAD COVER”. Cylinder head Refer to “CYLINDER HEAD”. Valve lifter Adjusting pad Valve cotter…

• Page 140: Removal

  VALVE AND VALE SPRING REMOVAL 1. Remove: S Valve lifters 1 S Pads 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: S Valve sealing Leakage at valve seat ! Inspect the valve face, valve seat and the valve seat width.

• Page 141: Inspection

  VALVE AND VALVE SPRING INSPECTION 1. Measure: S Stem-to-guide clearance Stem-to-guide clearance = Valve guide inside diameter a – Valve stem diameter b Out of specification ! Replace valve guide. Stem-to-guide clearance: Intake: 0.010 X 0.037 mm <Limit>: 0.08 mm Exhaust: 0.025 X 0.052 mm <Limit>: 0.10 mm…

• Page 142
  VALVE AND VALVE SPRING 3. Eliminate: S Carbon deposit (from valve face) 4. Inspect: S Valve face Pitting/Wear ! Reface the face. S Valve stem end Mushroom shape or diameter larger than rest of stem ! Replace. 5. Measure: S Margin thickness a Out of specification ! Replace.
• Page 143
  VALVE AND VALVE SPRING Measurement steps: S Apply the Mechanic’s blueing dye (Dykem) b to the valve face. S Install the valve into the cylinder head. S Press the valve through the valve guide and onto the valve seat to make a clear pattern. S Measure the valve seat width.
• Page 144
  VALVE AND VALVE SPRING NOTE: To obtain the best lapping result, lightly tap the valve seat while rotating the valve back and forth between your hand. S Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: Be sure to clean off all compound from the valve face and valve seat after every lapping operation.

• Page 145: Installation

  VALVE AND VALVE SPRING 13. Measure: S Spring tilt a Out of specification ! Replace. Spring tilt limit: 2.5_/1.7 mm INSTALLATION 1. Install: S Stem seal S Valve S Spring seat S Valve spring S Valve retainer (into cylinder head) NOTE: S Make sure that each valve is installed in its origi- nal place, also referring to the embossed mark…

• Page 146
  VALVE AND VALVE SPRING 2. Install: S Valve cotters 1 NOTE: Install the valve cotters while compressing the valve spring with the valve spring compressor. Valve spring compressor 2 : 90890-04019 Attachment 3 : 90890-04108 3. Secure the valve cotters 1 onto the valve stem by tapping lightly with a piece of wood.

• Page 147: Cylinder And Piston

  CYLINDER AND PISTON CYLINDER AND PISTON 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Cylinder and piston removal Remove the parts in the order below. Cylinder head Refer to “CYLINDER HEAD”. Joint O-ring O-ring Dowel pin Cylinder Cylinder gasket O-ring Refer to “REMOVAL”, and Circlip…

• Page 148: Removal

  CYLINDER AND PISTON REMOVAL 1. Remove: S Piston circlips 1 S Piston pins 2 S Pistons 3 NOTE: S Before removing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase cavity. S Put identification marks on each piston head for reference during reinstallation.

• Page 149
  CYLINDER AND PISTON Cylinder bore “C” 89.500 X 89.505 mm Taper limit “T” 0.05 mm Out of round “R” 0.03 mm “C” = Maximum D “T” = (Maximum D , or D ) – (Maximum D or D “R” = (Maximum D or D –…
• Page 150
  CYLINDER AND PISTON 3. Measure: S Side clearance Out of specification ! Replace piston and rings as a set. NOTE: Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance. Side clearance: Top ring: 0.035 X 0.070 mm 2nd ring: 0.035 X 0.070 mm…

• Page 151: Installation

  CYLINDER AND PISTON 6. Inspect: S Piston pin Blue discoloration/Grooves ! Replace, then inspect lubrication system. 7. Measure: S Piston pin-to-piston clearance Measurement steps: S Measure the piston pin outside diameter a . If out of specification, replace the piston pin. Outside diameter (piston pin): 19.991 X 20.000 mm <Limit>: 19.975 mm…

• Page 152
  CYLINDER AND PISTON 2. Install: S Piston pins 1 S Pistons 2 S Piston circlips 3 NOTE: S Apply engine oil to the piston pins. S Be sure that the arrow mark a on the piston points to the exhaust side of the engine. S Before installing the piston, cover the crankcase with a clean rag to prevent the piston from falling into the crankcase.

• Page 153: Clutch

  CLUTCH CLUTCH CRANKCASE COVER (RIGHT) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Crankcase cover (right) removal Remove the parts in the order below. Engine oil Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Clutch cable Crankcase cover (right) NOTE: Loosen the bolts in a crisscross pattern.

• Page 154: Clutch

  CLUTCH CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job name/Part name Q’ty Remarks Clutch removal Remove the parts in the order below. Clutch spring Pressure plate Plain washer/Bearing Pull rod Friction plate Clutch plate Refer to “REMOVAL”, and Clutch boss nut “INSTALLATION”.

• Page 155: Removal

  CLUTCH REMOVAL 1. Straighten the lock washer tab. 2. Remove: S Clutch boss nut 1 S Lock washer 2 S Clutch boss 3 NOTE: Loosen the clutch boss nut 1 while holding the clutch boss 3 with the universal clutch holder. Universal clutch holder: 90890-04086 3.

• Page 156: Installation

  CLUTCH 4. Inspect: S Dogs (on the clutch housing) Pitting/Wear/Damage ! Deburr or replace. S Clutch housing bearing Wear/Damage ! Replace clutch housing. NOTE: Pitting on the clutch housing dogs will cause errat- ic operation. S Clutch boss splines Pitting/Wear/Damage Replace clutch boss.

• Page 157
  CLUTCH 4. Install: S Pressure plate NOTE: Align the punched mark a on the clutch boss with the punched mark b on the pressure plate. 5. Install: S Clutch springs 1 S Clutch spring bolts 2 8 Nm (0.8 mSkg) NOTE: Tighten the clutch spring bolts in stage, using a crisscross pattern.

• Page 158: Crankcase Cover (Left)

  CRANKCASE COVER (LEFT) CRANKCASE COVER (LEFT) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 5 Nm (0.5 mSkg) Order Job name/Part name Q’ty Remarks Crankcase cover (left) removal Remove the parts in the order below. Engine oil Refer to “ENGINE OIL REPLACE- MENT”…

• Page 159: Shift Shaft

  SHIFT SHAFT SHIFT SHAFT 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) Order Job name/Part name Q’ty Remarks Shift shaft removal Remove the parts in the order below. Clutch Refer to “CLUTCH”. Shift arm Refer to “CRANKCASE COVER (LEFT)”. Shift shaft Circlip Plain washer Torsion spring…

• Page 160: Inspection

  SHIFT SHAFT INSPECTION 1. Inspect: S Stopper lever 1 Roller turns roughly ! Replace. Bends/Damage ! Replace. 2. Inspect: S Torsion spring (shift shaft) 1 S Torsion spring (stopper lever) 2 Wear/Damage ! Replace. 3. Inspect: S Shift shaft 1 S Shift pawls 2 Bends/Wear/Damage ! Replace.

• Page 161: A.c. Magneto And Starter Wheel Gear

  A.C. MAGNETO AND STARTER WHEEL GEAR A.C. MAGNETO AND STARTER WHEEL GEAR STATOR COIL 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Stator coil removal Remove the parts in the order below. Engine oil Refer to “ENGINE OIL REPLACE- MENT”…

• Page 162
  A.C. MAGNETO AND STARTER WHEEL GEAR A.C. MAGNETO AND STARTER WHEEL GEAR 130 Nm (13.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks A.C. magneto and starter wheel Remove the parts in the order below. gear removal Rotor Shaft Refer to “REMOVAL”…

• Page 163: Removal

  A.C. MAGNETO AND STARTER WHEEL GEAR REMOVAL 1. Remove: S Bolt (rotor) 1 S Washer 2 NOTE: S Loosen the bolt (rotor) 1 while holding the mag- neto with the sheave holder 3 . S Do not allow the sheave holder 3 to touch the projection on the rotor.

• Page 164: Installation

  A.C. MAGNETO AND STARTER WHEEL GEAR 2. Inspect: S Starter wheel gear 1 (contacting surfaces) Pitting/Wear/Damage ! Replace. INSTALLATION 1. Install: S Starter wheel gear 1 S Woodruff key 2 2. Install: S Plate washer S Rotor 1 S Washer NOTE: S Clean the tapered portions of the crankshaft and rotor.

• Page 165: Oil Pump

  OIL PUMP OIL PUMP OIL PUMP COVER AND OIL PUMP DRIVEN GEARS 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Oil pump cover and oil pump driven Remove the parts in the order below. gear removal Engine oil Refer to “ENGINE OIL REPLACE-…

• Page 166: Oil Pump

  OIL PUMP OIL PUMP 6 Nm (0.6 mSkg) 6 Nm (0.6 mSkg) Order Job name/Part name Q’ty Remarks Oil pump removal Remove the parts in the order below. Oil pump assembly 1 (For pumping oil to the oil tank) Gasket Dowel pin Oil pump assembly 2 (For lubricating the engine parts)

• Page 167: Inspection

  OIL PUMP INSPECTION 1. Inspect: S Oil pump driven gears Wear/Cracks /Damage ! Replace. 2. Measure: S Tip clearance a (between the inner rotor 1 and the outer rotor S Side clearance b (between the outer rotor 2 and the pump housing 3 ) (between the inner rotor 1 /outer rotor 2 and the pump housing 3 )

• Page 168: Oil Hose

  OIL TANK OIL TANK OIL HOSE 21 Nm (2.1 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Oil hose removal Remove the parts in the order below. Engine oil Refer to “ENGINE OIL REPLACE- MENT”…

• Page 169
  OIL TANK OIL TANK 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Oil tank removal Remove the parts in the order below. Engine oil Refer to “ENGINE OIL REPLACE- MENT” in CHAPTER 3. Engine Refer to “ENGINE ASSEMBLY”.

• Page 170: Oil Pan

  OIL PAN OIL PAN OIL PAN 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Oil pan removal Remove the parts in the order below. Engine oil Refer to “ENGINE OIL REPLACE- MENT”…

• Page 171: Balancer

  OIL PAN BALANCER 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Balancer weight removal Remove the parts in the order below. Engine oil Refer to “ENGINE OIL REPLACE- MENT” in CHAPTER 3. Engine Refer to “ENGINE ASSEMBLY”.

• Page 172: Installation

  OIL PAN 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Rear balancer weight Front balancer holder/Dowel pin Refer to “REMOVAL” and “INSTALLATION”. Front balancer shaft/O-ring Front balancer weight For installation, reverse the removal procedure.

• Page 173
  OIL PAN REMOVAL 1. Remove: S Plate 1 2. Remove: S Rear balancer holder 1 S Dowel pins 3. Remove: S Rear balancer shaft 1 S Rear balancer weight 2 4. Remove: S Front balancer holder 1 S Dowel pins 5.
• Page 174
  OIL PAN INSTALLATION 1. Install: S Front balancer weight 1 S Front balancer shaft 2 S O-ring 3 S Plate (balancer shaft) 12 Nm (1.2 mSkg) Installation steps: S Turn the crankshaft until the keyway a is aligned with the embossed mark b on the crankcase.
• Page 175
  OIL PAN Installing steps: S Turn the crankshaft until the keyway a is aligned with embossed mark b on the crank- case. S While holding the crankshaft, install the balancer weight and align the mark c on the rear balanc- er gear with the embossed mark d on the crank- case.

• Page 176: Crankshaft

  CRANKSHAFT CRANKSHAFT CRANKSHAFT ASSEMBLY 12 Nm (1.2 mSkg) (M6) 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) 40 Nm (4.0 mSkg) Order Job name/Part name Q’ty Remarks Crankshaft removal Remove the parts in the order below. Balancer weight Refer to “BALANCER”. Water pump Refer to “WATER PUMP”…

• Page 177: Connecting Rod

  CRANKSHAFT CONNECTING ROD 48 Nm (4.8 mSkg) Order Job name/Part name Q’ty Remarks Connecting rod removal Remove the parts in the order below. Connecting rod bolt Refer to “REMOVAL”, and Connecting rod “INSTALLATION”. Connecting rod cap Connecting rod bearing For installation, reverse the removal procedure.

• Page 178: Removal

  CRANKSHAFT REMOVAL 1. Remove: S Cover plate 1 2. Remove: S Upper crankcase S Lower crankcase S Dowel pins NOTE: S Loosen the bolts 1/4 turn each and remove them after all are loosened. S Remove the bolts starting with the highest num- bered one.

• Page 179: Inspection

  CRANKSHAFT 4. Remove: S Main journal bearings 1 NOTE: Identify each plain bearing position very carefully so that it can be reinstalled in its original place. 5. Remove: S Pin 1 S Timing chain guide (intake) 2 6. Remove: S Connecting rod cap 1 S Connecting rod 2 S Connecting rod bearing 3 NOTE:…

• Page 180
  CRANKSHAFT 3. Measure: S Oil clearance (main journal) Out of specification ! Replace bearing. Oil clearance: 0.020 X 0.038 mm <Limit>: 0.1 mm Measurement steps: CAUTION: Do not interchange the bearings and connect- ing rod. They must be installed in their original positions, or the correct oil clearance may not be obtained causing engine damage.
• Page 181
  CRANKSHAFT S Tighten the bolt to specification in the tighten- ing sequence cast on the crankcase. 1 X 6 (M10): 40 Nm (4.0 mSkg) (M8) 24 Nm (2.4 mSkg) (M6) 12 Nm (1.2 mSkg) Upper crankcase Lower crankcase NOTE: S Lubricate the threads of bolts 1 X 6 with mo- lybdenum disulfide motor oil.
• Page 182
  CRANKSHAFT S Install the upper half of the bearing into the con- necting rod and lower half of the bearing into the connecting rod cap. S Put a piece of Plastigauge a on the crank pin. S Assemble the connecting rod halves. NOTE: S Do not move the connecting rod or crankshaft until the oil clearance measurement has been…
• Page 183
  CRANKSHAFT 5. Select: S Main journal bearing (J S Connecting rod bearing (P Selection of bearings: Example 1: Main journal bearing S If “J ” on the crankcase is “6” and “2” on the crankweb, then the bearing size for “J ”…

• Page 184: Installation

  CRANKSHAFT INSTALLATION 1. Apply: S Molybdenum disulfide grease (onto threads of bolts and nut seats) S Engine oil (onto crank pins and inner surfaces of connect- ing rod bearings) 2. Install: S Connecting rod bearings 1 S Connecting rods 2 S Connecting rod caps 3 (onto crank pins) NOTE:…

• Page 185
  7. Apply: S Engine oil (onto inner surfaces of main journal bearings) S Sealant (onto crankcase mating surfaces) Yamaha bond No. 1215: 90890-85505 NOTE: DO NOT ALLOW any sealant to come in contact with the oil gallery or crankshaft bearings.
• Page 186
  CRANKSHAFT 10. Install: S Lower crankcase 1 (onto upper crankcase 2 ) Place the lower crankcase assembly onto the upper crankcase assembly. CAUTION: Before tightening the crankcase bolts, check the following point: S Be sure the gears shift correctly when the shift cam is turned by hand.

• Page 187: Transmission, Shift Cam And Shift Fork

  TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK 12 Nm (1.2 mSkg) Order Job name/Part name Q’ty Remarks Transmission, shift cam and shift Remove the parts in the order below. fork removal Lower crankcase Refer to “CRANKSHAFT”. Drive axle assembly/Oil seal Circlip Shift fork guide bar 2…

• Page 188: Removal

  TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL 1. Remove: S Drive axle assembly 1 2. Remove: S Shift fork guide bars 1 S Shift fork “R” 2 S Shift fork “L” 3 S Shift fork “C” 4 S Shift cam 5 3.

• Page 189: Inspection

  TRANSMISSION, SHIFT CAM AND SHIFT FORK INSPECTION 1. Inspect: S Shift fork cam follower 1 S Shift fork pawl 2 Scoring/Bends/Wear/Damage ! Replace. 2. Inspect: S Guide bar Roll the guide bar on a flat surface. Bends ! Replace. WARNING Do not attempt to straighten a bent guide bar.

• Page 190: Installation

  TRANSMISSION, SHIFT CAM AND SHIFT FORK 6. Inspect: S Gear teeth Blue discoloration/Pitting/Wear ! Replace. S Mated dogs Rounded edges/Cracks /Missing portions ! Replace. 7. Check: S Proper gear engagement (each gear) 116.6 X 116.68 mm (with its counterpart) Incorrect ! Reassemble. S Gear movement Roughness ! Replace.

• Page 191
  TRANSMISSION,SHIFT CAM AND SHIFT FORK 3. Install: S Shift cam 1 S Shift fork “C” 2 S Shift fork “L” 3 S Shift fork “R” 4 S Shift for guide bars 5 NOTE: S Install the shift forks with the embossed mark to the right and in sequence (R, C, L) beginning from the right.
• Page 193
  COOL…
• Page 194
  COOL CHAPTER 5. COOLING SYSTEM RADIATOR …………INSPECTION .
• Page 195
  COOL…

• Page 196: Radiator

  COOL RADIATOR COOLING SYSTEM RADIATOR 5 Nm (0.5 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Radiator removal Remove the parts in the order below. Coolant Refer to “COOLANT REPLACEMENT” in CHAPTER 3. Side cowling, seat, side cover and Refer to “COWLINGS, SEAT, TAIL COVER fuel tank…

• Page 197: Inspection

  COOL RADIATOR INSPECTION 1. Inspect: S Radiator core 1 Obstruction ! Blow out with compressed air through rear of the radiator. Flattened fin ! Repair/Replace. 2. Inspect: S Fan 2 S Cracks /Damage ! Replace. 3. Inspect: S Radiator hoses Crancks /Damage ! Replace.

• Page 198: Installation

  COOL RADIATOR INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1. Install: S Radiator assembly 7 Nm (0.7 mSkg) 2. Fill: S Cooling system Refer to “COOLANT REPLACEMENT” in CHAPTER 3. 3. Inspect: S Cooling system Decrease of pressure (leaks) ! Repair as re- quired.

• Page 199: Thermostatic Valve

  COOL THERMOSTATIC VALVE THERMOSTATIC VALVE THERMOSTATIC VALVE ASSEMBLY 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Thermostatic valve assembly Remove the parts in the order below. removal Coolant Refer to “COOLANT REPLACEMENT” in CHAPTER 3. Side cowling, seat, side cover and Refer to “COWLINGS, SEAT, TAIL COVER fuel tank AND FUEL TANK”…

• Page 200: Thermostatic Valve

  COOL THERMOSTATIC VALVE THERMOSTATIC VALVE 28 Nm (2.8 mSkg) 15 Nm (1.5 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Thermostatic valve housing disas- Remove the parts in the order below. sembly Thermo switch Thermo unit Ground lead Thermostatic valve cover Refer to “ASSEMBLY”.

• Page 201: Inspection

  COOL THERMOSTATIC VALVE INSPECTION 1. Inspect: S Thermostatic valve 1 Valve does not open at 80 X 84_C ! Replace. Inspection steps: S Suspend thermostatic valve in a vessel. S Place reliable thermometer in a water. S Observe thermometer, while stirring water con- tinually.

• Page 202: Water Pump

  COOL WATER PUMP WATER PUMP WATER PUMP 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Water pump removal Remove the parts in the order below. Coolant Refer to “COOLANT REPLACEMENT” in CHAPTER 3. Coolant hose 3 Water pump cover O-ring Water pump housing…

• Page 203: Installation

  COOL WATER PUMP INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. NOTE: S It is not necessary to remove and inspect the wa- ter pump if the coolant is not unusually low or if it has no engine oil mixed in it. S Always replace the entire water pump.

• Page 204
  CARB…
• Page 205
  CARB CHAPTER 6. CARBURETION CARBURETOR ……….CARBURETOR ASSEMBLY .
• Page 206
  CARB…
• Page 207
  CARB CARBURETOR CARBURETION CARBURETOR CARBURETOR ASSEMBLY Order Job name/Part name Q’ty Remarks Carburetor assembly removal Remove the parts in the order below. Side cowling, seat, side cover and Refer to ”COWLINGS, SEAT, TAIL fuel tank COVER AND FUEL TANK” in CHAPTER 3. Refer to ”AIR FILTER CASE”…
• Page 208
  CARB CARBURETOR CARBURETOR Order Job name/Part name Q’ty Remarks Carburetor disassembly Disassemble the parts in the order below. Carburetor heater hose Float chamber Needle valve Float Starter jet Main jet Refer to ”INSTALLATION”. Pilot jet Jet housing Jet needle Throttle valve…
• Page 209
  CARB CARBURETOR Order Job name/Part name Q’ty Remarks Needle jet Pilot air jet 1 Main air jet 2 Diaphragm Starter plunger Pilot screw For assembly, reverse the disassembly procedure.
• Page 210
  CARB CARBURETOR ASSEMBLY CAUTION: S Before reassembling, wash all parts in clean petroleum based solvent. S Always use a new gasket. 1. Install: S Main jet 1 S Starter jet 2 S Pilot jet 3 2. Install: S Valve seat NOTE: Make sure that projection a on the valve seat is aligned with the slot b on the carburetor body.
• Page 211
  CARB CARBURETOR FUEL LEVEL ADJUSTMENT 1. Measure: S Fuel level a Fuel level: 15.8 X 16.8 mm Below the MIKUNI mark Out of specification ! Adjust. NOTE: Adjust the float level by slightly bending the float tang 1 . Fuel level measurement and adjustment steps: S Place the motorcycle on a level surface.
• Page 212
  CARB CARBURETOR 1. Adjust: S TPS (throttle position sensor) position Adjustment steps: S Turn the main switch to ”ON”. S Disconnect the TPS (throttle position sensor) coupler. S Reconnect the TPS (throttle position sensor) coupler. NOTE: When the above procedure is commenced, the machine switches to TPS (throttle position sen- sor) adjustment mode.
• Page 213
  CARB CARBURETOR 2. Inspect: S TPS (throttle position sensor) Inspection steps: S Disconnect the TPS (throttle position sensor) coupler. S Remove the TPS (throttle position sensor) from carburetor. S Connect the pocket tester (Ω 1k) to the TPS (throttle position sensor) couplers. Tester (+) lead ! Blue terminal 1 Tester (–) lead ! Black/Blue terminal 2 S Check the TPS (throttle position sensor) resis-…
• Page 214
  CARB…
• Page 215
  CHAS…
• Page 216
  CHAS CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISCS ……. INSPECTION .
• Page 217
  CHAS REAR SHOCK ABSORBER AND RELAY ARM ….. . 7-50 HANDLING NOTES ……… . . 7-51 NOTES ON DISPOSAL .

• Page 218: Chapter 7. Chassis

  CHAS FRONT WHEEL AND BRAKE DISCS CHASSIS FRONT WHEEL AND BRAKE DISCS 58 Nm (5.8 mSkg) 19 Nm (1.9 mSkg) 40 Nm (4.0 mSkg) 20 Nm (2.0 mSkg) Order Job name/Part name Q’ty Remarks Front wheel and brake disc removal Remove the parts in the order below.

• Page 219
  CHAS FRONT WHEEL AND BRAKE DISCS Order Job name/Part name Q’ty Remarks Front wheel disassembly Disassemble the parts in order below. Oil seal Clutch retainer Meter clutch Oil seal Refer to “ASSEMBLY”. Bearing Spacer Bearing For assembly, reverse the disassembly procedure.

• Page 220: Inspection

  CHAS FRONT WHEEL AND BRAKE DISCS INSPECTION 1. Inspect: S Front wheel axle. Roll it on a flat surface. Bends ! Replace. WARNING Do not attempt to straighten a bent axle. 2. Measure: S Wheel runout S Over the specified limit ! Replace. Rim runout limits: Radial a : 1 mm Lateral b : 0.5 mm…

• Page 221
  CHAS FRONT WHEEL AND BRAKE DISCS NOTE: Use a socket 3 that matches the outside diame- ter of the race of the bearing and oil seal. CAUTION: Do not strike the center race 4 or balls 5 of the bearing. Contact should be made only with the outer race 6 .

• Page 222: Assembly

  CHAS FRONT WHEEL AND BRAKE DISCS ASSEMBLY Reverse the “DISASSEMBLY” procedure. Note the following points. 1. Lubricate: S Bearings S Oil seals (lips) Recommended lubricant: Lithium soap base grease INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1. Lubricate: S Front wheel axle S Drive /Driven gear (speedometer) Recommended lubricant:…

• Page 223: Static Wheel Balance Adjustment

  CHAS FRONT WHEEL AND BRAKE DISCS STATIC WHEEL BALANCE ADJUSTMENT NOTE: S After replacing the tire and/or rim, wheel balance should be adjusted. S Adjust the wheel balance with brake disk installed. 1. Remove: S Balancing weight 2. Set the wheel on a suitable stand. 3.

• Page 224
  CHAS FRONT WHEEL AND BRAKE DISCS S Turn the wheel so that the heavy spot is 90_ up. S Check that the heavy spot is at rest there. If not, try another weight until the wheel is bal- anced. 5. Check: S Wheel balance Checking steps: S Turn the wheel so that is comes to each point as…

• Page 225: Rear Wheel, Brake Disc And Driven Sprocket

  CHAS REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET REAR WHEEL 107 Nm (10.7 mSkg) 35 Nm (3.5 mSkg) 40 Nm (4.0 mSkg) 16 Nm (1.6 mSkg) Order Job name/Part name Q’ty Remarks Rear wheel removal Remove the parts in the order below.

• Page 226: Brake Disc And Driven Sprocket

  CHAS REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET BRAKE DISC AND DRIVEN SPROCKET 60 Nm (6.0 mSkg) 20 Nm (2.0 mSkg) Order Job name/Part name Q’ty Remarks Brake disc and driven sprocket Remove the parts in the order below. removal Collar (left/right) Brake disc Driven sprocket…

• Page 227
  CHAS REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET Order Job name/Part name Q’ty Remarks Rear wheel disassembly Disassembly the parts in the order below. Oil seal Bearing Collar Bearing For assembly, reverse the disassembly procedure. 7-10…

• Page 228: Inspection

  CHAS REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET INSPECTION 1. Inspect: S Rear wheel axle Refer to “FRONT WHEEL AND BRAKE DISC”. 2. Measure: S Wheel runout Refer to “FRONT WHEEL AND BRAKE DISC”. 3. Install: S Wheel bearings S Oil seals S Collars Refer to “FRONT WHEEL AND BRAKE DISC”.

• Page 229: Static Wheel Balance Adjustment

  CHAS REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET 6. Inspect: S Driven sprocket More than 1/4 teeth a wear ! Replace sprocket. Bent teeth ! Replace sprocket. Correct Roller Sprocket Driven sprocket replacement steps: S Remove the self locknuts and driven sprocket. S Clean the hub, especially on the surfaces in con- tact with the sprocket, using a clean cloth.

• Page 230: Front And Rear Brake

  CHAS FRONT AND REAR BRAKE FRONT AND REAR BRAKE FRONT BRAKE PAD 6 Nm (0.6 mSkg) 40 Nm (4.0 mSkg) Order Job name/Part name Q’ty Remarks Front brake pad removal Remove the parts in the order below. Cable guide Pad cover Retaining clip Refer to “BRAKE PAD REPLACE- Retaining pin…

• Page 231: Rear Brake Pad

  CHAS FRONT AND REAR BRAKE REAR BRAKE PAD 40 Nm (4.0 mSkg) 6 Nm (0.6 mSkg) Order Job name/Part name Q’ty Remarks Rear brake pad removal Remove the parts in the order below. Pad cover Retaining clip Retaining pin Pad spring Brake pad Pad shim (left/right) Bleed screw…

• Page 232: Brake Pad Replacement

  CHAS FRONT AND REAR BRAKE CAUTION: Disc brake components rarely require disas- sembly. DO NOT: S Disassemble components unless absolutely necessary. S Use solvents on internal brake components. S Use contaminated brake fluid for cleaning. Use only clean brake fluid. S Allow brake fluid to come in contact with the eyes, otherwise eye injury may occur.

• Page 233
  CHAS FRONT AND REAR BRAKE 2. Install: S Pad shims (onto brake pads) S Brake pads S Pad spring Installation steps: S Connect a suitable hose 1 tightly to the caliper bleed screw 2 . Put the other end of this hose into an open container.
• Page 234
  CHAS FRONT AND REAR BRAKE S Replace the pads as a set if either is found to be worn to the wear limit a . Wear limit a : 0.5 mm 2. Install: S Pad shims (onto brake pads) S Brake pads S Pad spring Installation steps: S Connect a suitable hose 1 tightly to the caliper…

• Page 235: Front Brake Master Cylinder

  CHAS FRONT AND REAR BRAKE FRONT BRAKE MASTER CYLINDER 9 Nm (0.9 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Front brake master cylinder removal Remove the parts in the order below. Brake fluid Drain Brake lever Front brake switch lead coupler Disconnect Front brake switch…

• Page 236
  CHAS FRONT AND REAR BRAKE Order Job name/Part name Q’ty Remarks Front brake master cylinder disas- Disassemble the parts in the order below. sembly Adjuster Spring Plate Boot Circlip Master cylinder kit Master cylinder body For assembly, reverse the disassembly procedure.

• Page 237: Rear Brake Master Cylinder

  CHAS FRONT AND REAR BRAKE REAR BRAKE MASTER CYLINDER 7 Nm (0.7 mSkg) 30 Nm (3.0 mSkg) 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Rear brake master cylinder removal Remove the parts in the order below. Brake fluid Drain Union bolt Copper washer/Brake hose…

• Page 238
  CHAS FRONT AND REAR BRAKE Order Job name/Part name Q’ty Remarks Rear brake master cylinder discon- Disconnect the parts in the order below. nection Boot Circlip Master cylinder kit Master cylinder body For assembly, reverse the disconnection procedure. 7-21…

• Page 239: Master Cylinder Inspection

  CHAS FRONT AND REAR BRAKE MASTER CYLINDER INSPECTION 1. Inspect: S Master cylinder 1 Wear/Scratches ! Replace the master cylin- der assembly. S Master cylinder body 2 Cracks /Damage ! Replace. S Oil delivery passage (master cylinder body) Blow out with compressed air. Front Rear 2.

• Page 240
  CHAS FRONT AND REAR BRAKE Front brake 1. Install: S Master cylinder 1 S Master cylinder bracket 2 9 Nm (0.9 mSkg) CAUTION: S Align the end of the holder with the punch mark a on the handlebar. S Tighten first the upper bolt, then the lower bolt.
• Page 241
  CHAS FRONT AND REAR BRAKE WARNING S Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake perfor- mance. S Refill with the same type of brake fluid: mix- ing fluids may result in a harmful chemical reaction and lead to poor performance.
• Page 242
  CHAS FRONT AND REAR BRAKE 2. Install: S Clevis pin 1 S Washer S Cotter pin 3. Fill: S Brake reservoir Refer to “MASTER CYLINDER ASSEMBLY – Front brake”. 4. Inspect: S Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION”…

• Page 243: Front Brake Caliper

  CHAS FRONT AND REAR BRAKE FRONT BRAKE CALIPER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job name/Part name Q’ty Remarks Front brake caliper removal Remove the parts in the order below. Brake fluid Drain Cable guide Union bolt Copper washer…

• Page 244
  CHAS FRONT AND REAR BRAKE 6 Nm (0.6 mSkg) Order Job name/Part name Q’ty Remarks Front brake caliper disassembly Disassemble the parts in the order below. Pad cover Retaining clip Retaining pin Pad spring Refer to “CALIPER DISASSEMBLY” Brake pad and “CALIPER ASSEMBLY”.

• Page 245: Rear Brake Caliper

  CHAS FRONT AND REAR BRAKE REAR BRAKE CALIPER 40 Nm (4.0 mSkg) 14 Nm (1.4 mSkg) 40 Nm (4.0 mSkg) Order Job name/Part name Q’ty Remarks Rear brake caliper removal Remove the parts in the order below. Brake fluid Drain Brake hose Brake hose joint Refer to “CALIPER INSTALLATION”.

• Page 246
  CHAS FRONT AND REAR BRAKE 6 Nm (0.6 mSkg) Order Job name/Part name Q’ty Remarks Rear brake caliper disassembly Disassemble the parts in the order below. Pad cover Retaining clip Retaining pin Pad spring Refer to “CALIPER DISASSEMBLY” Brake pad and “CALIPER ASSEMBLY”.

• Page 247: Caliper Disassembly

  CHAS FRONT AND REAR BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling the front brake caliper or rear brake caliper, drain the brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: S Pistons S Piston seals 1 Removal steps: S Using a wood piece 2 , lock the right side piston.

• Page 248: Caliper Inspection And Repair

  CHAS FRONT AND REAR BRAKE CALIPER INSPECTION AND REPAIR Recommended brake component replacement schedule: Brake pads As required Piston seal, Every two years Every two years dust seal Brake hoses Every two years Replace only when brakes are Brake fluid disassembled.

• Page 249: Caliper Installation

  CHAS FRONT AND REAR BRAKE CALIPER INSTALLATION 1. Install: S Front brake S Brake caliper 1 (temporarily) S Copper washers S Brake hose 2 S Union bolt 3 30 Nm (3.0 mSkg) CAUTION: When installing the brake hose on the caliper 1 , take care that the pipe touches the projec- tion a on the brake caliper.

• Page 250: Front Fork

  CHAS FRONT FORK FRONT FORK 23 Nm (2.3 mSkg) 24 Nm (2.4 mSkg) 30 Nm (3.0 mSkg) 9 Nm (0.9 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Front fork removal Remove the parts in the order below. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.

• Page 251
  CHAS FRONT FORK 24 Nm (2.4 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Front fork disassembly Disassemble the parts in the order below. Cap bolt Drain the fork oil O-ring Washer Fork spring Dust seal Refer to “DISASSEMBLY” and Retaining clip “ASSEMBLY”.
• Page 252
  CHAS FRONT FORK 24 Nm (2.4 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Inner tube/Piston metal Oil lock piece Refer to “DISASSEMBLY” and Damper rod/Damper rod spring “ASSEMBLY”. Slide metal Outer tube For assembly, reverse the disassembly procedure.

• Page 253: Disassembly

  CHAS FRONT FORK DISASSEMBLY NOTE: S Do not reuse the front fork protector that was re- moved from the outer tube. S When installing a new front fork protector, be sure it is not twisted and will not come off easily. 1.

• Page 254: Inspection

  CHAS FRONT FORK INSPECTION 1. Inspect: S Inner fork tube 1 S Outer fork tube 2 Scratches /Bends/Damage ! Replace. WARNING Do not attempt to straighten a bent inner fork tube as this may dangerously weaken the tube. 2. Measure: S Fork spring free length a Over specified limit ! Replace.

• Page 255
  CHAS FRONT FORK 2. Lubricate: S Inner fork tube (outer surface) Recommended lubricant: Fork oil 10W or equivalent 3. Install: S Piston metal 1 S Damper rod 2 S Oil lock piece 3 4. Tighten: S Damper bolt 1 30 Nm (3.0 mSkg) NOTE: Tighten the damper rod bolt while holding the damper rod with the T-handle and holder.
• Page 256
  CHAS FRONT FORK NOTE: Before installing the oil seal, apply the lithium soap base grease onto the oil seal lips. CAUTION: Be sure that the oil seal numbered side face upward. 7. Install: S Dust seal 1 Use the fork seal driver weight. Fork seal driver weight: 90890-01367 8.
• Page 257
  CHAS FRONT FORK INSTALLATION 1. Install: S Front fork(s) Temporarily tighten the pinch bolts. CAUTION: Make sure that the inner tube end is flush with the top of the upper bracket. 2. Tighten: S Pinch bolts (lower bracket) 1 30 Nm (3.0 mSkg) S Cap bolts 2 24 Nm (2.4 mSkg) S Pinch bolts (upper bracket) 3…

• Page 258: Handlebar

  CHAS HANDLEBAR HANDLEBAR 23 Nm (2.3 mSkg) 9 Nm (0.9 mSkg) 26 Nm (2.6 mSkg) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order below. Band Clutch cable Clutch switch lead coupler Disconnect Clutch switch Left handlebar switch Clutch lever Grip end…

• Page 259
  CHAS HANDLEBAR 23 Nm (2.3 mSkg) 9 Nm (0.9 mSkg) 26 Nm (2.6 mSkg) Order Job name/Part name Q’ty Remarks Right handlebar switch Throttle cable housing cover Refer to “INSTALLATION”. Throttle cable housing Throttle cable Throttle grip Plug Handlebar holder (upper) Handlebar grip (left) Clutch lever holder Refer to “INSTALLATION”.

• Page 260: Inspection

  CHAS HANDLEBAR INSPECTION 1. Inspect: S Handlebar Bends/Crancks /Damage ! Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handle- bar. Handlebar grip (left) replacement steps: S Remove the handlebar grip. S Apply a light coat of an adhesive for rubber on the handlebar end.

• Page 261
  CHAS HANDLEBAR 2. Install: S Throttle grip 1 S Throttle cable housing 2 S Throttle cables 3 S Throttle cable housing cover WARNING Align the projection a on the throttle cable housing with the hole b on the handlebar. 3. Install: S Right handlebar switch 1 NOTE: Align the projection a on the handlebar switch…
• Page 262
  CHAS HANDLEBAR 6. Install: S Left handlebar switch 1 NOTE: Align the projection a on the handlebar switch with the hole b on the handlebar. 7. Adjust: S Clutch cable free play Refer to “CLUTCH ADJUSTMENT” in CHAP- TER 3. 8.

• Page 263: Steering Head

  CHAS STEERING HEAD STEERING HEAD LOWER BRACKET 108 Nm (10.8 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) 48 Nm (4.8 mSkg) 2 nd 16 Nm (1.6 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Lower bracket removal Remove the parts in the order below.

• Page 264
  CHAS STEERING HEAD 108 Nm (10.8 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) 48 Nm (4.8 mSkg) 16 Nm (1.6 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Plate seal Ring nut (lower) Plate washer Lower bracket Refer to “REMOVAL”…

• Page 265: Removal

  CHAS STEERING HEAD REMOVAL 1. Remove: S Ring nut (lower) 1 Use the ring nut wrench 2 . Ring nut wrench: 90890-01403 WARNING Support the lower bracket so that it may not fall down. INSPECTION 1. Wash the bearing and bearing races with a sol- vent.

• Page 266: Installation

  CHAS STEERING HEAD INSTALLATION 1. Tighten: S Ring nuts (lower and upper) Tightening steps: S Tighten the ring nut (lower) 1 using the ring nut wrench 2 . Ring nut: 48 Nm (4.8 mSkg) NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle.

• Page 267: Rear Shock Absorber

  CHAS REAR SHOCK ABSORBER REAR SHOCK ABSORBER 64 Nm (6.4 mSkg) 64 Nm (6.4 mSkg) Order Job name/Part name Q’ty Remarks Rear shock absorber removal Remove the parts in the order below. Seat Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK” in CHAP- TER 3.

• Page 268
  CHAS REAR SHOCK ABSORBER HANDLING NOTES WARNING This shock absorber contains highly com- pressed nitrogen gas. Rear and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling.

• Page 269: Swingarm And Drive Chain

  CHAS SWINGARM AND DRIVE CHAIN SWINGARM AND DRIVE CHAIN 7 Nm (0.7 mSkg) 90 Nm (9.0 mSkg) 35 Nm (3.5 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Swingarm and drive chain removal Remove the parts in the order below. Rear wheel Refer to “REAR WHEEL, BRAKE DISC AND DRIVE SPROCKET”.

• Page 270
  CHAS SWINGARM AND DRIVE CHAIN 7 Nm (0.7 mSkg) 90 Nm (9.0 mSkg) 35 Nm (3.5 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Swingarm Drive chain Chain protector Collar Thrust cover Bush Bearing For installation, reverse the removal procedure.
• Page 271
  CHAS SWINGARM AND DRIVE CHAIN INSPECTION 1. Measure: S 10 link length (drive chain) a Out of specification ! Replace drive chain. 10 link length limit: 159 mm NOTE: S For measurement make the chain tense by fin- ger. S 10 link length is a measurement between the in- sides of the 1 and rollers as shown.
• Page 272
  CHAS SWINGARM AND DRIVE CHAIN 4. Lubricate: S Drive chain Drive chain lubricant: SAE 30 X 50W motor oil or chain lubricants suitable for “O-ring” chains 5. Inspect: S Drive chain stiffness Stiff ! Clean and lubricate or replace. 6. Check: S Swingarm free play Inspection steps: S Check the tightening torque of the pivot shaft…
• Page 273
  CHAS…
• Page 274
  – ELEC…
• Page 275
  ELEC CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS ……..SWITCH INSPECTION .
• Page 276
  ELEC…

• Page 277: Electrical Components

  ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS Ignitor unit Fuse box Starting circuit cut-off relay Battery Rectifier / regulator Rear brake switch Main switch Sidestand switch Thermo switch Neutral switch Thermo unit Ignition coil Flasher relay Horn Starter relay…

• Page 278: Switch Inspection

  ELEC SWITCH INSPECTION SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for con- tinuity. If the continuity is faulty as any point, re- place the switch. Pocket tester: 90890-03112 NOTE: S Set the pocket tester to “0” before starting the test.

• Page 279: Switch Continuity Inspection

  ELEC SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Refer to “SWITCH INSPECTION” and check for continuity between lead terminals. Poor connection, no continuity ! Correct or replace. * The coupler locations are circled. Rear brake switch Fuse Engine stop switch Start switch Front brake switch Main switch Clutch switch…

• Page 280: Ignition System

  ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM…

• Page 281: Troubleshooting

  ELEC IGNITION SYSTEM TROUBLESHOOTING IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE (NO SPARK OR INTERMITTENT SPARK) Procedure Check: 1. Fuse (main and ignition) 8. Main switch 2. Battery 9. Engine stop switch 3. Spark plug 10. Neutral switch 4. Ignition spark gap 11.

• Page 282
  ELEC IGNITION SYSTEM 3. Spark plug Standard spark plug: DPR8EA-9/X24EPR-U9 S Check the spark plug condition. NGK /NIPPONDENSO S Check the spark plug type. S Check the spark plug gap. Refer to “SPARK PLUG INSPECTION” in CHAPTER 3. Spark plug gap: INCORRECT 0.8 X 0.9 mm CORRECT…
• Page 283
  ELEC IGNITION SYSTEM OUT OF SPECIFICATION S Check the spark plug cap for specified resis- tance. Spark plug cap resistance: 10 kΩ at 20_C Replace spark plug cap. MEETS SPECIFICATION Tester (+) lead ! Red/Black terminal 6. Ignition coil resistance Tester (–) lead ! Orange (Gray) terminal S Disconnect the ignition coil connector from the wire harness.
• Page 284
  ELEC IGNITION SYSTEM 7. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester (Ω 100) to the pickup coil terminal. Tester (+) lead ! Green/White terminal Tester (–) lead ! Blue/Yellow terminal S Check the pickup coil for specified resistance.
• Page 285
  ELEC IGNITION SYSTEM 12. Wiring connection S Check the entire ignition system for connec- tions. POOR CONNECTION Refer to “CIRCUIT DIAGRAM”. CORRECT Correct. Replace ignitor unit.

• Page 286: Electric Starting System

  ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8-10…

• Page 287: Starting Circuit Operation

  ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the “ENGINE STOP” switch and the main switch are both closed, the starter motor can operate only if: The transmission is in neutral (the neutral switch is closed).

• Page 288: Troubleshooting

  ELEC ELECTRIC STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. Procedure Check: 1. Fuse (main and ignition) 8. Neutral switch 2. Battery 9. Sidestand switch 3. Starter motor 10. Clutch switch 4. Starting circuit cut-off relay 11. Start switch 5. Starter relay 12.

• Page 289
  ELEC ELECTRIC STARTING SYSTEM WARNING This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the 3. Starter motor vicinity. S Remove the starter motor from the engine. S Check the starter motor. DOES NOT MOVE Refer to “INSPECTION AND REPAIR”.
• Page 290
  ELEC ELECTRIC STARTING SYSTEM 5. Starter relay S Disconnect the relay unit coupler from the wire harness. S Connect the pocket tester (Ω 1) and battery (12 V) to the relay unit coupler terminals. Battery (+) terminal ! Red/White terminal Battery (–) terminal ! Blue/White terminal NO CONTINUITY…
• Page 291
  ELEC ELECTRIC STARTING SYSTEM 10. Clutch switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace clutch switch. 11. Start switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace handlebar switch (right). 12. Wiring connection. S Check the entire starting system for connec- tions.

• Page 292: Starter Motor

  ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in the order below. Exhaust pipe and muffler assembly Refer to “ENGINE ASSEMBLY” in CHAP- TER 4.

• Page 293
  ELEC ELECTRIC STARTING SYSTEM Inspection and repair 1. Inspect: S Commutator Dirty ! Clean it with #600 grit sandpaper. 2. Measure: S Commutator diameter a Out of specification ! Replace starter motor. Commutator wear limit: 27 mm 3. Measure: S Mica undercut b Out of specification ! Scrape the mica to prop- er value using a hacksaw blade can be ground to fit.
• Page 294
  ELEC ELECTRIC STARTING SYSTEM 5. Measure: S Brush length a Out of specification ! Replace. Brush length limit: 5 mm 6. Measure: S Brush spring force Fatigue/Out of specification ! Replace as a set. Brush spring force: 570 X 920 g 7.
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  ELEC ELECTRIC STARTING SYSTEM 3. Install: S Gasket 1 S Yoke 2 S Washer kit 3 S Gasket 4 S Front bracket 5 S O-ring 6 NOTE: Align the match marks a on the yoke with the match marks b on the brackets. 8-19…

• Page 296: Charging System

  ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 8-20…

• Page 297: Troubleshooting

  ELEC CHARGING SYSTEM TROUBLESHOOTING THE BATTERY IS NOT CHARGED. Procedure Check: 1. Fuse (main) 4. Stator coil resistance 2. Battery 5. Wiring connection 3. Charging voltage (entire charging system) NOTE: S Remove the following parts before troubleshoot- Engine tachometer: ing. 90890-03113 1) Seat Pocket tester:…

• Page 298
  ELEC CHARGING SYSTEM 3. Charging voltage S Connect the engine tachometer to spark plug lead #1. S Connect the pocket tester (DC 20 V) to the bat- tery. Tester (+) lead ! Battery (+) lead Tester (–) lead ! Battery (–) lead S Start the engine, accelerate to about, 5,000 r/min then check the measured voltage.
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  ELEC CHARGING SYSTEM 5. Wiring connection S Check the entire starting system for connec- tions. POOR CONNECTION Refer to “CIRCUIT DIAGRAM”. CORRECT Correct. Replace rectifier/regulator. 8-23…

• Page 300: Lighting System

  ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 8-24…

• Page 301: Troubleshooting

  ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT, AUXILIARY LIGHT AND/OR METER LIGHT DO NOT COME ON. Procedure Check: 1. Fuse (main and head) 5. Pass switch 2. Battery 6. Wiring connection 3. Main switch (entire lighting system) 4.

• Page 302
  ELEC LIGHTING SYSTEM 4. Lights switch/Dimmer switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Lights switch/Dimmer switch are faulty, replace handlebar switch (left). 5. Diode S Remove the diode from the wire harness. S Check for continuity as follows: Terminal – terminal Tester (+) lead ! Terminal Continuity Tester (–) lead ! Terminal…

• Page 303: Lighting System Check

  ELEC LIGHTING SYSTEM LIGHTING SYSTEM CHECK 1. Headlight and high beam indicator light does not come on. 1. Voltage Headlight: Tester (+) lead ! Yellow or Green lead. S Connect the pocket tester (DC 20 V) to the Tester (–) lead ! Black lead.

• Page 304
  ELEC LIGHTING SYSTEM 2. Meter light does not come on. 1. Voltage S Connect the pocket tester (20 V) to the bulb socket coupler. Tester (+) lead ! Blue terminal Tester (–) lead ! Black terminal S Turn the main switch to “ON”. S Turn the lights switch to “ON”…
• Page 305
  ELEC LIGHTING SYSTEM 4. Auxiliary light does not come on. 1. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. Tester (+) lead ! Blue/Red lead Tester (–) lead ! Black lead S Turn the main switch to “ON”. S Turn the light switch to “ON”…
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  ELEC LIGHTING SYSTEM 8-30…

• Page 307: Signal System

  ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 8-31…

• Page 308
  ELEC SIGNAL SYSTEM Main switch Horn Battery Turn switch Fuse (main) Flasher relay Starting circuit cut-off relay Tail / brake light Neutral switch Headlight fuse Tachometer Rear brake switch Neutral indicator light Signal system fuse Turn indicator light Front brake switch Rear flasher light Front flasher light Horn switch…

• Page 309: Troubleshooting

  ELEC SIGNAL SYSTEM TROUBLESHOOTING S FLASHER LIGHTS, BRAKE LIGHT AND/OR INDICATOR LIGHTS DO NOT COME ON. S HORN DOES NOT SOUND. Procedure Check: 1. Fuse (main, head and signal) 2. Battery 3. Main switch 4. Wiring connection (entire signal system) NOTE: S Remove the following parts before troubleshoot- Pocket tester:…

• Page 310: Signal System Check

  ELEC SIGNAL SYSTEM 3. Main switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace main switch. 4. Wiring connection S Check the entire signal system for connec- tions. POOR CONNECTION Refer to “WIRING DIAGRAM”. CORRECT Correct. Check condition of each circuit for signal sys- tem.

• Page 311
  ELEC SIGNAL SYSTEM 3. Voltage S Connect the pocket tester (DC 20 V) to the horn at the “Black” terminal. Tester (+) lead ! Black lead Tester (–) lead ! Frame ground S Turn the main switch to “ON”. S Push the horn switch. S Check for voltage (0 V) on the “Black”…
• Page 312
  ELEC SIGNAL SYSTEM S Turn the main switch to “ON”. S Turn brake lever is pulled in or brake pedal is stepped down. OUT OF SPECIFICATION S Check for voltage (12 V) on the “Yellow” lead at the bulb socket connector. MEETS Wiring circuit from main switch to bulb socket SPECIFICATION…
• Page 313
  ELEC SIGNAL SYSTEM 3. Voltage S Connect the pocket tester (DC 20 V) to the flasher relay lead. Tester (+) lead ! Brown/White terminal Tester (–) lead ! Frame ground S Turn the main switch to “ON”. S Check for voltage (12 V) on the “Brown/White” OUT OF SPECIFICATION lead at the flasher relay terminal.
• Page 314
  ELEC SIGNAL SYSTEM 4. Neutral indicator light does not come on. 1. Neutral switch NO CONTINUITY Refer to “SWITCH INSPECTION”. CONTINUITY Replace neutral switch. 2. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket coupler. Tester (+) lead ! Brown terminal Tester (–) lead ! Sky blue terminal S Turn the main switch to “ON”.

• Page 315: Cooling System

  ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 8-39…

• Page 316: Troubleshooting

  ELEC COOLING SYSTEM TROUBLESHOOTING S FAN MOTOR DOES NOT MOVE. S WATER TEMPERATURE METER DOES NOT MOVE, WHEN ENGINE IS WARM. Procedure Check: 1. Fuse (main, signal and fan) 6. Thermo unit 2. Battery 7. Water temperature 3. Main switch 8.

• Page 317
  ELEC COOLING SYSTEM 3. Main switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Main switch is faulty, replace it. 4. Fan motors S Disconnect the fan motor couplers. S Connect the battery (12 V) as shown. Battery (+) lead ! Blue lead Battery (–) lead ! Black lead DOES NOT MOVES S Check the fan motors for operation.
• Page 318
  ELEC COOLING SYSTEM WARNING 5. Thermo switch S Handle the thermo switch with special care. S Remove the thermo switch from the radiator. S Never subject it to strong shock or allow it to be S Connect the pocket tester (Ω 1) to the ther- dropped.
• Page 319
  ELEC COOLING SYSTEM 6. Thermo unit S Remove the thermo unit from the radiator. S Connect the pocket tester (Ω 10) to the ther- mo unit S Immerse the thermo unit in the water S Measure the resistance. Thermo unit resistance: 80_C: 47 X 53 Ω…

• Page 320: Tps (Throttle Position Sensor) Self Diagnosis

  ELEC TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS Revolution ( 10 r / min) Tachometer display Engine speed time (seconds) CIRCUIT DIAGRAM If the needle of the tachometer shows the follow- ing pattern while the engine is running, the throttle position sensor circuit is broken, shorted, or the TPS (throttle position sensor) is locked.

• Page 321
  ELEC TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS TROUBLESHOOTING IF THE TACHOMETER’S TPS (THROTTLE POSITION SENSOR) SELF-DIAGNOSIS OPERATES. Procedure Check: 1. TPS (throttle position sensor) 2. Wire harness NOTE: Use the following special tool(s) in this trouble- Pocket tester: shooting. 90890-03112 1.
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  ELEC…
• Page 323
  TRBL SHTG…
• Page 324
  TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/HARD STARTING ……FUEL SYSTEM ……….ELECTRICAL SYSTEM .
• Page 325
  TRBL SHTG…

• Page 326: Starting Failure/Hard Starting

  TRBL STARTING FAILURE/HARD STARTING SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. If should be helpful, howev- er, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.

• Page 327: Compression System

  TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH SPEED PERFORMANCE SHTG COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston rings S Loose spark plug S Improperly installed piston ring S Loose cylinder head or cylinder S Worn, fatigued or broken piston ring S Broken cylinder head gasket S Seized piston ring S Worn, damaged or seized cylinder…

• Page 328: Faulty Gear Shifting

  FAULTY GEAR SHIFTING/ TRBL CLUTCH SLIPPING/DRAGGING SHTG FAULTY GEAR SHIFTING HARD SHIFTING Refer to “Clutch dragging.” SHIFT PEDAL DOES NOT MOVE Shift shaft Transmission S Improperly adjusted shift rod S Seized transmission gear S Bent shift shaft S Jammed impurities S Incorrectly assembled transmission Shift cam, shift fork S Groove jammed with impurities…

• Page 329: Overheating

  TRBL OVERHEATING/FAULTY BRAKE/ FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION SHTG OVERHEATING OVERHEATING Ignition system Compression system S Improper spark plug gap S Heavy carbon build-up S Improper spark plug heat range Engine oil S Faulty ignitor unit S Incorrect oil level S Improper oil viscosity Fuel system S Improper carburetor main jet (improper setting)

• Page 330: Instable Handling

  INSTABLE HANDLING/ TRBL FAULTY LIGHTING AND SIGNAL SYSTEM SHTG INSTABLE HANDLING INSTABLE HANDLING Handlebar Front forks S Improperly installed or bent S Uneven oil levels on both sides S Uneven spring tension (uneven damping force Steering S Improperly installed handlebar crown adjuster position) S Bent steering stem S Broken spring…

• Page 331: Flasher Keeps On

  TRBL FAULTY LIGHTING AND SIGNAL SYSTEM SHTG FLASHER KEEPS ON HORN IS INOPERATIVE S Faulty flasher relay S Faulty battery S Bulb burnt out S Faulty fuse S Faulty main and/or horn switch S Improperly adjusted horn FLASHER WINKS QUICKER S Faulty horn S Improper bulb S Broken wire harness…

• Page 332
  TDM850 ’96 WIRING DIAGRAM 1 A.C. magneto / pickup coil 2 Rectifier / regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Starting circuit cut-off relay 9 Gear position switch Sidestand switch T.P.S. (throttle position sensor) Ignitor unit Ignition coil Spark plug…