YAMAHA KJ900S(6)* SERVICE MANUAL AKM-28197-20NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to put an entire mechanic's education into ‘one manual, so it is assumed that persons using this book ta perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be for- warded to all Authorized Yamaha dealers and will, where applicable, appear in future edi- tions of this manual. PARTICULARY IMPORTANT INFORMATION This material is distinguished by the following notation. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR a SAFETY IS INVOLVED! FREED —Fellvre to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or @ person inspecting or repairing the motorcycle, A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. ANOTE provides key information to make procedures easier or clearer.HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated sym- bots") Asttitle @: This is a chapter with its symbol on the upper right of each page. 2nd title @: This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.) 3rd title @: This is a final title. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particularly important procedure © is placed between a line of asterisks “* "with each procedure preceded by “@*. IMPORTANT FEATURES * Data and a special tool are framed in a box preceded by a relevant symbol ©. An encircled numeral © indicates a part name, and an encircled alphabetical letter data or an alignment mark @, the others being indicated by an alphabetical letter in a box * A condition of a faulty component will precede an arrow symbol and the course of action required the symbol @. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identi- fying correct disassembly and assembly procedures.ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols © to © are designed as thumb tabs to indicate the chapter's num- berand content. @ General information @ Specifications © Periodic inspection and adjustment @Engine © Cooling system @ Carburetion OChassis @ Electrical @ Troubleshooting Illustrated symbols @ to @ are used to identify the specifications appearing in the text. @ Filling fluid @ Lubricant ® Special too! @ Tightening @ Wear limit, clearance © Engine speed @OQVA Illustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point. © Apply engine oil @ Apply gear oi ® Apply molybdenum disulfide oil @ Apply wheel bearing grease @ Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease @ Apply lacking agent (LOCTITE) @ Use new oneINDEX GENERAL INFORMATION l SPECIFICATIONS PERIODIC INSPECTION AND QqQ ADJUSTMENT INSP ENGINE OVERHAUL or CARBURETION e ; FH HASSI CHASSIS eins IG ELECTRICAL ELEC 9 TROUBLESHOOTING a we SHTG B®CONTENTS CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . VEHICLE IDENTIFICATION NUMBER (For E, AUS and NZ). FRAME SERIAL NUMBER (Except for E, AUS and NZ) ENGINE SERIAL NUMBER...... . IMPORTANT INFORMATION PREPARATION FOR REMOVAL, ALL REPLACEMENT PARTS.. GASKETS, OIL SEALS, AND O-RING! LOCK WASHERS/PLATES AND COTTER PINS. BEARINGS AND OIL SEALS... CIRCLIPS.. SPECIAL TOOLS FOR TUNE UP ... FOR ENGINE SERVICE. FOR CHASSIS SERVICE FOR ELECTRICAL COMPONENT! ‘CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS .. MAINTENANCE SPECIFICATION: ENGINE.. CHASSIS. ELECTRICAL... EXCLUSIVE SPECIFICATION HOW TO USE THE CONVERSION TABLE. GENERAL TORQUE SPECIFICATIONS . LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE .. CHASSIS ..LUBRICATION DIAGRAMS .. CABLE ROUTING CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION.. a PERIODIC MAINTENANCE/LUBRICATION INTERVALS .... SIDE COVER, FUEL TANK AND COWLING. REMOVAL, INSTALLATION ... ENGINE... VALVE CLEARANCE ADJUSTMENT CARBURETOR SYNCHRONIZATION IDLING SPEED ADJUSTMENT. THROTTLE CABLE ADJUSTMENT SPARK PLUG INSPECTION... IGNITION TIMING CHECK COMPRESSION PRESSURE ENGINE OIL LEVEL INSPECTION .. ENGINE OIL REPLACEMENT CLUTCH ADJUSTMENT. AIR FILTER CLEANING FUEL LINE INSPECTION CHASSIS. FRONT BRAKE LEVER POS! REAR BRAKE ADJUSTMENT. BRAKE FLUID LEVEL INSPECTION BRAKE PAD INSPECTION .. BRAKE LIGHT SWITCH ADJUSTMEN’ BRAKE HOSE INSPECTION AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)... FINAL GEAR OIL LEVEL INSPECTION... FINAL GEAR OIL REPLACEMENT. STEERING HEAD INSPECTION. FRONT FORK INSPECTION REAR SHOCK ABSORBER ADJUSTMENT..TIRE INSPECTION WHEEL INSPECTION CABLE INSPECTION AND LUBRICATION. LEVER AND PEDAL LUBRICATION ‘SIDESTAND LUBRICATION CENTERSTAND LUBRICATION .. REAR SUSPENSION LUBRICATION. ELECTRICAL .... BATTERY INSPECTION FUSE INSPECTION HEADLIGHT BEAM ADJUSTMENT .. HEADLIGHT BULB REPLACEMEN’ DIGITAL CLOCK ADJUSTMENT. CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL. FUEL TANK AND COWLINGS. ENGINE OLL.. BATTERY LEADS AIR FILTER CASE A.LS (AIR INDUCTION SYSTEM! CARBURETOR HOSES AND LEADS .. CLUTCH CABLE ‘SHIFT PEDAL. STARTER MOTOR.. A.C. GENERATOR EXHAUST PIPE. OIL COOLER DRIVE SHAFT RUBBER BOOT ENGINE REMOVAL... ENGINE DISASSEMBLY... CYLINDER HEAD COVER, CAMSHAFT AND CYLINDER HEAD. CYLINDER AND PISTON . PICKUP COIL .. CLUTCH ‘OIL PAN AND OIL PUMP. CRANKCASE DISASSEMBLY. ‘SHIFT FORK AND SHIFT CAM. TRANSMISSION .....CRANKSHAFT AND STARTER CLUTCH VALVE ‘CONNECTING ROD. OIL PUMP... INSPECTION AND REPAIR..... CYLINDER HEAD. WALVE AND VALVE GUIDE . VALVE SEAT. VALVE SPRING VALVE LIFTER. CAMSHAFT ... TIMING CHAIN, SPROCKET AND CHAIN GUIDE TIMING CHAIN TENSIONER CYLINDER AND PISTON... PISTON RING PISTON PIN .. CRANKSHAFT AND CONNECTING ROD. OIL PUMP, PRIMARY DRIVE. STARTER DRIVES CLUTCH .. TRANSMISSION AND SHIFTE! ‘SHIFT SHAFT AND STOPPER LEVER OIL-JET NOZZLE. RELIEF VALVE, OIL PIPE AND STRAINER. GIL COOLER CRANKCASE . e BEARING AND OIL SEAL CIRCLIP AND WASHER MIDDLE GEAR SERVICI REMOVAL. DISASSEMBLY... INSPECTION... REASSEMBLY INSTALLATION .. GEAR LASH MEASUREMENT . GEAR LASH ADJUSTMENT... : MIDDLE DRIVE GEAR AND DRIVEN GEAR POSITIONING ENGINE ASSEMBLY AND ADJUSTMENT OIL PUMP. CONNECTING ROD VALVE... CRANKSHAFT AND STARTER CLUTCH. ‘TRANSMISSION SHIFT FORK AND SHIFT CAM...CRANKCASE ASSEMBLY. MIDDLE GEAR SHAFT. SHIFT SHAFT.. OIL PAN AND OIL PUMP CLUTCH AND PICKUP COIL. PISTON AND CYLINDER CYLINDER HEAD AND CAMSHAFT... TIMING CHAIN TENSIONER CYLINDER HEAD COVER. ENGINE REMOUNTING.. CHAPTER 5. CARBURETION (CARBURETOR... REMOVAL. DISASSEMBLY... INSPECTION ASSEMBLY. INSTALLATION FUEL LEVEL ADJUSTMENT. TPS (THROTTLE POSITION SENSOR) ADJUSTMENT AND INSPECTION A.LS. (AIR INDUCTION SYSTEM) AIR INJECTION AIR CUT VALVE. ALLS. (AIR INDUCTION SYSTEM) DIAGRAMS, ALS. (AIR INDUCTION SYSTEM) INSPECTION .. ALLS. (AIR INDUCTION SYSTEM) ADJUSTMENT.. ‘CHAPTER 6. CHASSIS INSTALLATION STATIC WHEEL BALANCE ADJUSTMEN’ REAR WHEEL .. REMOVAL... INSPECTIOT INSTALLATION STATIC WHEEL BALANCE ADJUSTMENT...FRONT AND REAR BRAKE. BRAKE PAD REPLACEMEN” CALIPER DISASSEMBLY .. MASTER CYLINDER DISASSEMBLY. INSPECTION AND REPAIR . CALIPER ASSEMBLY MASTER CYLINDER ASSEMBLY... FRONT FORK. REMOVAL.. DISASSEMBLY. INSPECTION ASSEMBLY INSTALLATION STEERING HEAD AND HANDLEBAR REMOVAL. INSPECTION INSTALLATION REAR SHOCK ABSORBER AND SWINGARM. HANDLING NOTES NOTES ON DISPOSA! REMOVAL. INSPECTION, INSTALLATION ‘SHAFT DRIVE... TROUBLESHOOTING REMOVAL. FINAL DRIVE GEAR CASE DRIVE SHAFT INSTALLATION CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS... CHECKING OF CONNECTIONS. IGNITION SYSTEM. CIRCUIT DIAGRAM TROUBLESHOOTINGELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM. STARTING CIRCUIT OPERATION TROUBLESHOOTING STARTER MOTOR. CHARGING SYSTEM... CIRCUIT DIAGRAM... TROUBLESHOOTING LIGHTING SYSTEM .. CIRCUIT DIAGRAM... TROUBLESHOOTING .. LIGHTING SYSTEM CHECK SIGNAL SYSTEM. CIRCUIT DIAGRAM... TROUBLESHOOTIN SIGNAL SYSTEM CHECK FUEL PUMP SYSTEM.. CIRCUIT DIAGRAM... FUEL PUMP CIRCUI TROUBLESHOOTING FUEL PUMP TEST... CARBURETOR HEATER SYSTEM. 7-89 CIRCUIT DIAGRAM TROUBLESHOOTING TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS. CIRCUIT DIAGRAM TROUBLESHOOTING CHAPTER 8. TROUBLESHOOTING STARTING FAILURE/HARD STARTING. FUEL SYSTEM.. ELECTRICAL SYSTEM COMPRESSION SYSTEM .. Roos POOR IDLE SPEED PERFORMANCE... POOR IDLE SPEED PERFORMANCE.POOR MEDIUM AND HIGH SPEED PERFORMANCE .. POOR MEDIUM AND HIGH SPEED PERFORMANCE FAULTY GEAR SHIFTING. HARD SHIFTING... : SHIFT PEDAL DOES NOT MOVE JUMP-OUT GEAR CLUTCH SLIPPING/DRAGGING CLUTCH SLIPPING, CLUTCH DRAGGING OVERHEATING OVERHEA’ FAULTY BRAKE .. POOR BRAKING EFFECT. FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION. OIL LEAKAGE .. MALFUNCTION.. INSTABLE HANDLING.. INSTABLE HANDLING. FAULTY LIGHTING AND SIGNAL SYSTEM. HEADLIGHT DARK BULB BURNT OUT. FLASHER DOES NOT LIGHT. FLASHER WINKS SLOWER.. FLASHER KEEPS ON FLASHER WINKS QUICKER HORN IS INOPERATIVE.... XJ900S(G) '95 WIRING DIAGRAM “GEN MOTORCYCLE IDENTIFICATION | INFO 4 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER (For E, AUS and NZ} The vehicle identification number @ is stamped into the right side of the steering head. Starting serial number: JYASKMSO%SA023101 (E) JVA4PSTOXSA000101 (AUS, NZ) NOTE: The vehicle identification number is used to. identify your motorcycle and may be used to register your motorcycle with the licens- ing authority in your state. FRAME SERIAL NUMBER: (Except for E, AUS and NZ) The frame serial number @ is stamped into the right side of the steering head. ‘Starting serial number: 4KM-000101 4PR-000101 (CH, A) NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. ENGINE SERIAL NUMBER The engine serial number @ is stamped into crankcase. Starting serial number: 4KM-000101 4KM-023101 (E) 4PR-000101 (CH, A} 4PS-000101 (AUS, NZ) NOTE: # The first three digits of these numbers are for model identification; the remaining digits are the unit production number. © Designs and specifications are subject to change without notice.IMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR REMOVAL 1.Remove all dirt, mud dust, and foreign material before removal and disassembly. 2.Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3.When disassembling the machine keep mated parts together. This includes gears, sylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced. 4,During the machine disassembly, clean all parts and place them in trays in the ‘order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5.Keep away from fire. ALL REPLACEMENT PARTS 1.Use only genuine Yamaha parts for all replacements. Use oil and/or grease rec- ‘ommended by Yamaha for assembly and adjustment. Other brands may be similar jn function and appearance, but inferior in quality. GASKETS, OIL SEALS, AND O-RINGS 1.All gaskets, seals and O-rings should be replaced when an engine is overhauled. All gaskets surfaces, oil seal lips and O- rings must be cleaned. 2.Properly oil all mating parts and bearing during reassembly. Apply grease to the il seal lips.IMPORTANT INFORMATION een LOCK WASHERS/PLATES AND COTTER PINS 1.All lock washers/plates © 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. BEARINGS AND OIL SEALS install the bearing(s) and oil seal(s) with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seals), apply a light coating of light- weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. @ Oil seat — CAUTION: © Do not use compressed air to spin the bear- ings dry. This causes damage to the bear- ing surfaces. PSs © Bearing CIRCLIPS 1.Alll circlips should be inspected carefully before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlips @, make sure that the sharp edged corner @ is positioned opposite to the thrust @ it receives. See the sectional view. @ Shattseas 100 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and asse bly. 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 provided. FOR TUNE UP Inductive timing light 2 P/N. 90890-03141 LE LS ges a This tool is necessary for checking ignition timing. ‘Vacuum gauge P/N. 90890-03094 Adapter P/N. 90890-03060 This gauge is needed for carburetor synchro- nization. Refer to the list provided to avoid errors when placing an order. inductive tachometer P/N. 90890-03113 Compression gauge P/N. 90890-03081 Adapter P/N. 90890-04082 This gauge is used to measure the engine compression, Fuel level gauge PIN. 90890-01312 This gauge is used to measure the fuel the float chamber. vel in Carburetor angle driver P/N, 90890-03158 This tool is used to adjust the pilot screw. This tool is used to measure the exhaust gas.SPECIAL TOOLS Eel oe FOR ENGINE SERVICE Piston pin puller P/N. 90890-01304 Tappet adjusting toot PIN. 90890-04125 ‘This tool is necessary to replace valve adjust- ing pads. 3 Universal clutch holder PIN. 90890-04086 This tool is used to hold the clutch when removing or installing the clutch boss locknut. Valve spring compressor P/N. 90890-04019 £ This tool is needed to remove and install the valve assemblies. Valve guide remover (6.0 mm) P/N. 90890-04064 ea This tool is used to remave the valve guides. Valve guide reamer (6.0 mm} P/N. 90890-04066 This tool is used to rebore the new valve guide. ‘Attachment P/N. 90890-01243 This tool is needed to remove and install the| valve assemblies. Valve guide installer (6.0 mm) P/N. 90890-04065 S This tool is needed to install the valve guides: properly. Valve seat cutter P/N. YM-91043-C This tool is used to adjust the valve clearance.SPECIAL TOOLS YAMAHA Bond No. 1215 P/N. 90890-85505, ko wt This sealant (Bond) is used for crankcase mat- ing surfaces, ete. 1 Damper spring compressor P/N. 90890-04090 dl This tool is needed to disassemble and reas- semble the middle gear damper. Universal joint holder P/N. 90890-04062 é This tool is used when disassembling/assam- bling the U-joint and adjusting gear lash. P/N. 90890-04080 Middle gear backlash tool j This tool is needed when measuring gear lash. 14 Piston ring compressor PIN, 90890-04008 This tool is used to compress piston rings when installing the cylinder. Oil filter wrench P/N. 90890-01426 This tool is used to remove and install the oil filter. Thandie P/N. 90890-01326 A S This tool is used to loosen and tighten the front fork damper rod holding bolt. Piston base PIN. 90890-01067 ~ Use four pieces of these to hold the pistons during cylinder installation. FOR CHASSIS SERVICE Front fork cylinder complete holder (27 mm) PIN, 90890-01388 ‘This tool is used ta loosen and tighten the front fork damper rod holding bolt.3 4 Fork seal driver attachment (941) PIN. 90890-01381 Fork seal driver weight P/N. 90890-01367 This tool is used when installing the fork seal. Ring nut wrench Final gear backlash band P/N. 90890-01403 P/N. 90890-01230 This tool is used to loosen and tighten the steering ring nut. This tool is needed when measuring gear lash. Middle and final gear holding tool Final drive shaft bearing retainer wrench PIN. 90890-01229 P/N. 90890-04050 This tool is used to remove and install the| ‘This tool is used when measuring gear lash. bearing retainer. FOR ELECTRICAL COMPONENTS ‘This instrument is necessary for checking the| ignition system components. Pocket tester PIN, 90890-03112 This instrument is invaluable for checking the electrical system.GENERAL SPECIFICATIONS |[SPEG SPECIFICATIONS GENERAL SPECIFICATIONS Model XJ9005 Model code: aKMT Engine starting number: “4KIM-000107 Frame starting number: ‘4KIM-000101 Dimensions: Overall length 2,230 mm Overall width 735 mm Overall height 1,300 mm Seat height 795 mm Wheelbase 1,505 mm, Minimum ground clearance 130mm Minimum turning radius 3,000 mm Basic weight: With oil and full fuel tank 265 kg Engi Engine type Cylinder arrangement Displacement Bore x stroke ‘Compression ratio Compression pressure (STD) Starting system Air-cooled 4-stroke, DOHC Forward-inclined parallel 4-cylinder 892m? 68.5 x 60.5 mm 10:1 1,200 kPa (12 kg/emn?, 12 bar) at 330 r/min Electric starter Lubrication system: Wet sump ‘Oil type or grade: Engine oil SAE20W40 type SE motor oil Final gear oil: SAES0API "GL.4" Hypoid Gear Oil ‘Oil capacity: ~ Engine oil Periodic oil change 3.2L With oil filter replacement 34L Total amount 4aL Final gear case oil Total amount O2L ‘Air filter: Dry type element Fuel: Type Regular unleaded gasoline Fuel tank capacity Fuel reserve amount 24L BLGENERAL SPECIFICATIONS [sPec| Carburetor: Type / quantity BDSR34/4 Manufacturer MIKUNI Spark plug: Type DPRSEA-9/X24EPR-U9 Manufacturer NGK/NIPPONDENSO Spark plug gap 0.8 ~ 0.9 mm Clutch type: Wet, multiple-dise Transmission: Primary reduction system Primary reduetion ratio Secondary reduction system Secondary reduction ratio Transmission type Spur gear 97/58 (1.672) Shaft drive 46/38X 19/18X32/11 (3.717) Constant mesh 5-speed Operation Left foot operation Gear ratio Ist 35/16 (2.188) 2nd 30/20 (1.500) 3rd 30/26 (1.154) 4th 28/30 (0.933) 5th 26/32 (0.813) ‘Chassis: Frame type Double cradle Caster angle ar Trail 121mm Tire: Type Size front rear Manufacturer front rear Type front rear Tire pressure (cold tire): Maximum load-except motorcycle Loading condition AX Tubeless. 120/T0-17 58V 180/70-17 69V METZLER/BRIDGESTONE/DUNLOP METZLER/BRIDGESTONE/DUNLOP ME33/G601/K505F MES5A/G602/K505 205 kg 0~ 90 kg front 225 kPa (2.25 kg/cm?, 2.25 bar) rear 250 kPa (2.5 kg/em?, 2.5 bar) Loading condition B* 90 ~ 205 kg front 250 kPa (2.5 kg/em?, 2.5 bar) rear 290 kPa (2.9 kg/em’, 2.9 bar) Brakes Front brake type Dual disc brake operation | Right hand operation Rear brake type Single disc brake operation. Right foot operationModel GENERAL SPECIFICATIONS [sPec| ‘Suspension: Front suspension Rear suspension Telescopic fork Swingarm (link suspension) ‘Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight type: Bulb wattage x quantity: Headlight Auxiliary light Tail / brake light Flasher light Licence light Meter light Indicator light NEUTRAL TURN OIL LEVEL HIGH BEAM FUEL Coil spring / Oil damper Coil-gas spring / Oil damper 140mm 110 mm T.C.l. (digital) AC. generator YTX14-BS. 12V 12 AH Quartz bulb (halogen) 12 V60 W/ 55 W 12V4Wx1 T2V5W/21Wx2 12V21Wx4 12V5Wx2 12V3.4Wx4 12V3.4Wx1 12V3.4Wx2 12V3.4Wx1 12V3.4Wx1 12V3.4Wx1MAINTENANCE SPECIFICATIONS [srec] v=] MAINTENANCE SPECIFICATIONS ENGINE Model ‘XJ900S Cylinder head: Warp limit OlShey O rant 0.03 mm, Cylinder: Bore size 68.49 ~ 68.54 mm. Taper limit 0.05 mm. Out of round limit 0.01 mm. Camshaft: Drive method Chain drive (center) Cam cap inside diameter Camshatt outside diameter Shaft-to-cap clearance Cam dimensions >— Intake on “Be ocr Exhaust "AT “Br “cr Camshaft runout limit 25.000 ~ 25.021 mm 24.967 ~ 24.980 mm 0.020 ~ 0.054 mm 36.75 ~ 36.85 mm 27.975 ~ 28.075 mm 8.75 ~ 8.85 mm 36.75 ~ 36.85 mm 27.975 ~ 28.075 mm 8.75 ~ 8.85 mm 0.03 mm,MAINTENANCE SPECIFICATIONS Model Cam chain: Cam chain type / No. of links Cam chain adjustment method Vaive, vaive seat, valve guid Valve clearance (cold) Valve dimensions: XJ900S" SILENT-CHAIN/150 Autom: 0.11 ~ 0.15 mm. 0.16 ~ 0.20 mm ye ae Head Dia “A" head diameter “B" face width “C" seat width “D" margin thickness ‘Stem outside diameter Guide inside diameter Stem-to-guide clearance Stem runout limit rn Valve seat width Seat Width Margin Thickness 33.9 ~ 34.1 mm 27.9 ~ 28.1 mm 2.3mm. 2.3mm. 0.9~ 1.1mm 0.9~ 1.1mm 1mm Imm 5.975 ~ 5.990 mm. 5.960 ~ 5.975 mm 6.000 ~ 6.012 mm. 6.000 ~ 6,012 mm 0.010 ~ 0.037 mm 0.025 ~ 0.052 mm 0.01 mm Valve spring: Inner spring Free length Set length (valve closed) Compressed pressure (installed) 37.4mm, 37.4mm 31.8mm 31.8mm 6.35 ~ 7.45 kg 6.35 ~ 7.45 kgMAINTENANCE SPECIFICATIONS SPEC Tilt limit (top view) Piston: Direction of winding 2571.6mm 2.5/1.6 mm Clockwise {top view) IN EX Clockwise Outer spring Free length IN 39.85 mm EX 39.85 mm Set length (valve closed) IN 23.8 mm EX 33.8 mm Compressed pressure (installed) IN 12.1 ~ 14.1kg ex 12.1 ~ 14.1kg Tilt limit IN 2.57.7 mm 2571.7 mm Ze Direction of winding Counterclockwise IN Ex Counterclockwise C) Piston to cylinder clearance 0.03 ~ 0.05 mm. <0.1 mm>MAINTENANCE SPECIFICATIONS Model xJ9005) Piston size “D” Measuring point “H” Oversize Piston off-set Piston off-set direction Piston pin bare inside diameter Piston pin outside diameter Piston rings: Top ring: Co [et Type Dimensions (B x T) End gap (installed) Side clearance (installed) 2nd ring: Type Dimensions (B x T) End gap (installed) Side clearance Oil ring: Dimensions (B x T) End gap (installed) Connecting rod: Oil clearance. 68.45 ~ 68.50 mm 5.5mm 69 mm. 69.5 mm 0.5 mm IN side 16.002 ~ 16.013 mm 15.990 ~ 16.000 min Barrel 12%25 mm 0.10 ~ 0.25 mm 0.025 ~ 0.080 mm Taper 1.2x3.1mm 0.30 ~ 0.45 mm 0.02 ~ 0.06 mm 25x2.8mm 0.2 ~ 0.7 mm 0.026 ~ 0.055 mm.MAINTENANCE SPECIFICATIONS Model J900S lal ‘x B Assembly width “B” 340.8 ~ 342.0 mm Runout limit "C” 0.03 mm Big end side clearance “D” 0.160 ~ 0.262 mm Big end radial clearance “E” 0.016 ~ 0.040 mm Journal oil clearance 0.020 ~ 0.052 mm Color code (corresponding size) @ Blue @ Black @ Brown @ Green © Yellow Clutch: Friction plate thickness. 29~3.1mm Quantity 8 Friction plate wear limit 28mm Clutch plate thickness 1.9~2.1mm Quantity 7 Warp limi 0.05 mm Clutch spring free length 51.8 mm Quantity 6 Minimum length 50mm Clutch release method Outer pull, rack & pi Transmission: Main axle deflection limit 0.08 mm Drive axle deflection limit 0.08 mm Shifter: Shifter type Guide bar Carburetor: |. D. mark 4KM 00 Main jet (Md) #100 Main air jot (MAJ) | #72.5 Jet needle WN) SDT3-2 Needle jet (NJ) oz Pilot air jet (PAJ1) | #120 Pilot outlet (P.0) 1.0 Pilot jet (PJ) #125 Bypass 1 (BPA) | 09 Bypass 2 (BP2) |o8 Bypass 3 (‘BP3) | 09 Pilot screw (PS) 1-1/2 Valve seat size ws) 15MAINTENANCE SPECIFICATIONS —— eee Model XJ900S Starter jet #30 Throttle valve size (Th) #125 Fuel level (FEL) 6~7mm Engine idle speed 950 ~ 1,050 r/min Intake vacuum 30.3 ~ 32.9 kPa (230 ~ 250 mmHg) Lubrication system: Oil filter type Oil pump type Tip clearance Side clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure (hot) Shaft drive: Paper type Trochoid type 0.03 ~ 0.09 mm 0.03 ~ 0.08 mm 120 ~ 160 kPa (1.2 ~ 1.6 kg/cm, 1.2 ~ 1.6 bar? 540 ~ 660 kPa (5.4 ~ 6.6 kg/cm, 5.4 ~ 6.6 bar) 80 kPa (0.8 kg/cm’, 0.8 bar) at 1,000 r/min xX! MB bolt: 24 Nm (2.4m + kg) 4: MG bolt: 12 Nm (1.2 m= kg) Middle gear backlash 0.1 ~0.2mm Final gear backlash 0.1 ~ 0.2 mm Crankcase tightening sequence: Crankcase (upper) Crankease (lower) x9, iis aS | pele SONI Ker WN es IL ¥ Fr raf FO . 1 n it 6 @ ~MAINTENANCE SPECIFICATIONS Model Lubrication chart: = Pressure food > Splashed Generator EX camshaft IN. camshaft [stat Middle gear Transmission [Piston, Cylinder Connecting rod bearing Crankshaft bearings} (wntMAINTENANCE SPECIFICATIONS IsPec| Tightening torques Tightening Part to be tightened Part name torque mkg Camshaft cap Bolt 10 Cylinder head (cam chain) Stud bolt 05 Cylinder head (exhaust pipe) ‘Stud bolt 8 18 Oil gallery bolt — og ‘Spark plug _ 18 Cylinder head Nut 32 Cylinder head cover 10 Cylinder (cam chain) 08 Cylinder 20 Cylinder head 10 Connecting rod 37 ‘Cam sprocket 24 Guide stopper or Chain guide (intake) 20 Oil pump sprocket 12 Oil pump 12 Oil filter housing 50 Oil detivery pipe 32 Drain bolt 43 Oil level switch 10 Oil filter Ww Carburetor joint 12 Air filter case 10 Exhaust pipe 290 Muffler and stay 25 Exhaust pipe blind plug (CO test) o7 Exhaust pipe and stay 25 Exhaust pipe and muffler 20 Reed vaive bracket and cowling stay 10 Pipe 2, 3. and cowling stay o7 Air cut valve and cowling stay o7 Crankease 20 Crankcase 24 Crankease 12 Bearing holder 25 Oil baffle plate og Oil baffle plate os Shift shaft lever cover 12 Drive axle bearing housing 12 Clutch cover 12 Besgr ws BSRNVvV ana an@esesnansusrsseoeasggesMAINTENANCE SPECIFICATIONS IsPEc Partto be tightened Tightening torque Nm [mkg Clutch cable stay Generator bearing housing Plate stopper HY-VO chain guide [Clutch spring Clutch boss Middle drive pinion gear Yoke joint Middle driven bearing housing Shift pedal adjuster Shift arm Shift cam bearing holder Self locking nut Final gear bearing housing Final gear bearing housing Final gear oil filler bolt Final gear oil drain plug Final drive bearing retainer Final gear case Final gear case Final gear case and swingarm AC. generator AC. generator Pickup coil base Timing plate ‘Starter motor ‘Starter motor and crankcase Neutral switch 12 12 10 10 Use lock 10 | 10 | washer 10 os 70 Use lock washer gy, [Use lock washer 90 25 10 10 10 u 23 23 23 23 n 18 09 42 25 25 08 45 07 12 20 Bold No. 1215}MAINTENANCE SPECIFICATIONS |SPEC; CHASSIS Model XJ900S Steering system: Steering bearing type Ball bearing Front suspension: Front fork travel 140 mm Fork spring free length 505 mm Spring free length Fitting length Spring rate (KAD 5.0 N/mm (0.5 kg/mm) (K2) 9.0 N/mm (0.9 kg/mm) Stroke (Kn) 0~ 80mm (K2) 80 ~ 140 mm Optional spring No Oil capacity 444.cm? Oil level 133 mm Oil grade Fork oil 5 W or equivalent Rear suspension: - Shock absorber travel 50 mm 177mm 161.5 mm (157.5 ~ 165.5 mm} Spring rate (Ka) 155.0 Nimm (15.5 kg/mm) ‘Stroke (K1) 0~50mm Optional spring No ‘Swingarm: Free play limit end 1mm side imm Front wheel: Type Cast whee! Rim size 17 X MT3.00 Rim material Aluminum Rim runout limit radial §=— | 1mm lateral 0.5mm Rear wheel: Type Cast whee! Rim size 17 X MT4.00 Rim material Aluminum Rim runout limit radial = | 1mm lateral 0.5mm Front disc brake: Type Dual Disc outside diameter x thickness 320 x 4mm Disc deflection limit 0.15 mm Pad thickness inner 6.1mm <0.8 mm> Pad thickness outer 6.1mm -13MAINTENANCE SPECIFICATIONS |SPEC; Limits =0.8 mms ae Master cylinder inside diameter 15.87 mm Caliper cylinder inside diameter 30.2 mm Caliper cylinder inside diameter 33.3 mm. Brake fluid type DOT #4 Rear disc brake: Type Single Dise outside diameter x thickness 267 x5 mm Disc deflection limit 0.15 mm Pad thickness inner 5.5mm <0.5 mm> Pad thickness outer | 5.5mm <0.5 mm> _ ae Ee . ry Master cylinder inside diameter 14mm Caliper cylinder inside diameter 42.85 mm Brake fluid type DOT #4 Brake lever & brake pedal: Brake lever free play (at lever pivat) omm Brake pedal position 30 mm Brake pedal free play Omm Clutch lever free play (at lever end) 10 ~ 15mm. Throttle cable free play 3~5mmMAINTENANCE SPECIFICATIONS |SPEC Tightening torques Tightening Part to be tightened Thread size torque Remarks Nm | mkg Chassis: _ i Handle crown and inner tube M8 1.25 30 | 30 Handle crown and steering stem M14 x 1.25 110 1.0 Handle crown and handlebar (upper) M8x 1.25, 23 | 23 Steering stem and ring nut M25 x 1.0 18 18 ‘See “NOTE” Front master cylinder and cap 4x07 2 | 02 Front master cylinder and bracket M6 x 1.0 9 09 Front brake hose and union bolt mi0x125 | 30 | 30 Cowling and cowling stay Mb x 08 07 | 007 Cowling and frame MSx08 07 0.07 Cowling and windscreen M5 x 08 07 | 007 Cowling and inner panel M5 x08 4a | of Cowling and headlight M6x 1.0 7 | o7 Cowling stay and frame MBx 1.25 16 | 16 M6x 1.0 7 o7 Cowling stay and meter M6x 1.0 7 o7 Cowling stay and front flasher light mi2xi2 | 13 | 13 Meter and meter cable Mi2x 10 3 | 03 Brake hose holder and front fork M6x 1.0 7 o7 Engine mount (front-upper/lower) miox12 | 48 | 48 (rear-upperflower) miox125 | 48 | 48 Down tube and frame M10x 1.25 89 89 Engine stay (front) and frame M8x 1.25 30 | 30 Engine stay (rear) and frame MBx 1.25 30 | 30 Pivot shaft (left) and frame m22x15 | 100 | 100 Pivot shaft (right) and frame 22x15 7 | o7 Pivot shaft (right) and locknut m22x15 | 100 | 100 Relay arm and frame Miox1.25 | 48 | 48 Relay arm and connecting rod Mi2x125 | 48 | 48 Connecting rod and rear arm Mi2x1.25 | 48 | 48 Rear shock absorber and frame Miox125 | 40 | 40 Rear shock absorber and relay arm Miox12 | 48 | 48 Fuel cock and fuel tank M6x 1.0 7 | o7 Fuel sender and fuel tank Mx 08 4 | o4 Rear fender and frame M6x 1.0 7 | o7 Taillight M6x 1.0 7 | o7 Rear fender cover and side cover Mx 0.8 4 | 04 Side cover and frame MBx 0.8 4 | o# Rear fender stay and frame M6x 1.0 10MAINTENANCE SPECIFICATIONS Tightening Part to be tightened Thread size foraue Nm | mkg o7 04 03 03 07 30 30 30 30 30 08 56 59 105 35 35 20 06 06 03 19 16 22 09 16 30 Rear brake reservoir tank and rear fender Mex 70 Rear flasher light and rear fender Mi2x 1.25 Reflector bracket and rear fender Max 07 Rear fender and flap Max 07 Battery cover and frame Mex 1.0 Footrest bracket and frame MBx 1.25 Rear footrest and frame MBX 1.25 Rear master cylinder and bracket M8 x 1.25 Brake hose and union bolt M10% 1.25 Shift pedal MB x 1.25 Brake pedal and brake shaft Mex 1.0 Mainstand bolt and nut M10x 1.25 Front wheel axle M14x 15 Rear wheel axle and nut MI6x 15 Front brake caliper and front fork M10x 1.25 Rear brake caliper and caliper bracket M10x 1.25 Disc brake and hub (front/rear) M6x 10 Front brake caliper and bleed screw M7x 10 Rear brake caliper and bleed screw MB x 1.25 Speedometer cable and gear unit Mi2x 1.0 Front wheel axle pinch bolt Max 1.25 Rear wheel axlé pinch bolt MBx 1.25 Front brake caliper retaining bolt MBx 1.25 Front fender and front fork M6 x 1.0 Rear brake hose and hose joint M10x 1.0 Rear brake caliper and hose joint M10x 1.0 CRSETSCOORRSRSSOSSSSBrwoan 8a NOTE: 1 First, tighten the ring nut approximately 52 Nm (5.2 m = kg) by using the torque wrench, then loosen the ring nut one turn. 2.Retighten the ring nut to specification.MAINTENANCE SPECIFICATIONS |SPEC ELECTRICAL Voltage: TV Ignition system: Ignition timing (B.T.D.C.) 5° at 1,000 r/min Advanced timing (B.T.D.C.) 40° at 5,000 r/min Advancer type Electrical type ‘Throttle open (%b Engine speed (x 10? rimin) Tae ickup coil resistance / color 446 ~ 545 Q at 20'C/ White/Red - White/Green T.C.I. unit model / manufacturer J4T051/MITSUBISHI Ignition coil: Model / manufacturer J0312,J0313/NIPPONDENSO Minimum spark gap 6mm Primary winding resistance 1.87 ~ 2.53 Qat 20°C Secondary winding resistance 12 ~ 18k at 20'C ‘Spark plug cap: Type Resin type Resistance 10 ka Charging system: Type AG. generator Model / manufacturer B3G/NIPPONDENSO Nominal output 14 V 33 A at 5,000 r/minMAINTENANCE SPECIFICATIONS [sPec| e a 2 g é 2 3 4 5 Engine spoed (x 10? rimin) Rotor coil resistance 2.76 ~ 3.05 Qat 20°C Stator coil resistance 0.19 ~ 0.21 Qat 20°C Brush overall length 13.7 mm. <4.7 mm> Spring force 520 ~ 5809 Voltage regulator: Type Semi-conductor, field control type Model / manufacturer B3G/NIPPONDENSO No load regulated voltage 14.2 ~ 14.8V Rectifier: Model / manufacturer 83G/NIPPONDENSO Withstand voltage 200 V Battery: Specific gravity 1.320 Electric starter system: Type Constant mesh type Starter motor: Model / manufacturer DB4DT/NIPPONDENSO Output 0.6 kW Armature coil resistance 0.013 ~ 0.015 Oat 20°C Brush overall length 12mm cLimit> <8.5mm> Spring force 650 ~ 9509 Commutator diameter 28mm Wear limit> <27 mm> Mica undercut 0.6 mm ‘Starter switch: Model / manufacturer MSBF/JIDECO Amperage rating 100A Coil winding resistance 4.18 ~ 4.62 Q at 20°CMAINTENANCE sPEciFicaTions |SPEC Model XJ900S) Horn: Type Quantity Model / manufacturer Maximum amperage Flasher relay: Type Model / manufacturer Self cancelling device Flasher frequency Wattage Oil level switch: Model / manufacturer Plane type 1 YF-12/NIKKO 254A Full transistor type FE246BH/NIPPONDENSO No 75 ~ 95 cycle/min 21Wx24+3.4W AHT/NIPPONDENSO Fuel gauge: Model / manufacturer Sender unit resistance full empty Starting circuit cut off relay: AKM/NIPPONDENSO 4~ 10 Qat20°C 90 ~ 100 © at 20°C Model / manufacturer 3EN/OMRON Coil winding resistance 202.5 ~ 247.5 Qat 20°C Diode Yes Circuit breaker: Type Fuse Amperage for individual circuit MAIN 30Ax1 HEAD 1BAx1 SIGNAL 20Ax1 IGNITION 1OAx1 cLocK 1OAx1 Reserve 20AXx1 Reserve 1OAx1 -19EXCLUSIVE SPECIFICATION EXCLUSIVE SPECIFICATION The following specifications are exclusive for the below listed countries, For specifications other than below, please refer to the General and maintenance specifica- tions. For Spain Model code: 4KM2 Engine starting number: 4KM-023101 Vehicle identification number: JYA4KMS0-*SA023101 For Switzerland, Austria Model code: PRT Engine starting number: 4PR-000101 Frame starting number: 4PR-000101 Carburetor: LD. mark 4PROO Ignition system: ‘Advancer type Ignition timing (8.7.0.0) Throttle opom (9) Engine speed ( 10° min) TCs T.C.l. unit model/manufacturer J4T052/MITSUBISHI For Australia Model code: aPS1 Engine starting number: 4PS-000101 Vehicle identification number: JYA4PSTO#SA000 101 Unleaded fuel onlyHOW TO USE THE CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS HOW TO USE THE CONVERSION TABLE All specification data in this manual is listed in Sl and METRIC UNITS. Use this table to convert METRIC unit data to IMP unit data. GENERAL TORQUE ‘SPECIFICATIONS This chart specifies torque for standard fas- ‘teners with standard |.S.O. pitch threads. Torque specifications for special compo- nents or assemblies are included in the applicable sections of this baok. To avoid Fx warpage, tighten multi-fastener assemblies METRIC = MULTIPLIER (MP in a crisscross fashion, in progressive “tmm x 0.03937 = *#in stages, until full torque is reached. Unless 2mm x 0.03937 = 0.08in otherwise specified, torque specifications call for clean, dry threads. Components CONVERSION TABLE should be at room temperature. METRIC TO IMP Known | Multiplier | Result mig [7233 | ib ea mag [26.794 [init _— emekg, 0.0723 ft-lb T emkg [0.8679 [init I come IK 2205 ib Weight 0.03527 ‘oe foe [mph osz1 | mi ‘ 3251 [ft Distance ane 03037 Jin 0.09837 [in 0.03527 | oz (IMP lig.) General torque Volume! 0.06702 Jewin A 8 specifications Capacity 0.8789 ‘qt (IMP lig.) (Nut) (Bolt) 0.2199 | gal (IMP liad Nm [mea | komm (55997 | Ib/in Tomm | 6mm 6 6 | /kg/emn? 14.2234 psi {Ibyin?) [Centigrade | 95(*C)+32 | Fahrenheit (°F) 42mm | &mm 15 15 4mm | 10mm | 30 30 17mm 42mm s 55 19mm | 14mm 85 85 22mm 16mm 130 13.0 “24LUBRICATION POINT AND GRADE OF LUBRICANT LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE $ g Oil seal lips O-ring Bearing Piston surface Piston pin Crankshaft pin Crankshaft journal/big end Connecting rod bolt/nut Connecting rod small end Middle drive shaft (drive damper cam/driven damper cam) Middle drive gear Middle driven gear Camshaft cam loba/journal Valve stem (IN, EX) Valve stem end (IN, EX) Valve lifter Oil pump rotor (inner/outen), housing Oil strainer assembly Idle gear surface Starter idle gear Starter idle gear shaft Starter clutch (outer/rotler) Crankcase cover (pull rod hole) Primary drive gear/damper Transmission gear (wheel/pinion) Axle (main/drive) Pull rod (bearing/washer) Shiftcam Shift fork/guide bar Shift shaft assembly 2-22 Add gids Padidlsdldadaldidididd @adidiadgieLUBRICATION POINT AND GRADE OF LUBRICANT CHASSIS Lubrication Point Steering bearing (upper/lower) Front wheel oil seal (right/left) Rear wheel oil seal Clutch hub oil seal Clutch hub fitting area Rear brake pedal shaft Shift pedal Center stand sliding surface Side stand sliding surface Tube guide (throttle grip) inner surface Clutch cable end (lever side) Brake lever bolt, sliding surface Clutch lever bolt, sliding surface Rear footrest pivot Rear shock absorber (upper) Rear shock absorber (lower - oil seal) Connecting rod bearing (on the swingarm) Swingarm pivot bearing Swingarm pivot oil seal Relay arm bearing (inner) Final drive gear/ring gear Drive shaft (final gear side) Drive shaft (middle gear side) SHOUGSGIGSSGSSS 20050888LUBRICATION DIAGRAMS |SPEC LUBRICATION DIAGRAMS Camshaft (intake) © Main axle shaft (exhaust) @ Starter clutch @ Crankshaft er @® Oil pump © Shift guide barLUBRICATION DIAGRAMS @ Oil nozzle @ Starter clutch @ Main axle © Drive axle © Shift guide barLUBRICATION DIAGRAMSLUBRICATION DIAGRAMS |SPEC| U=* Q hit guide bar @ Drive axle @Main axle @ Middle drive shaftCABLE ROUTING @ Meter assembly coupler [A] Clamp the meter lead to the cowling stay. @ Band @ Flasher lead @Hom © Thermo switch © Headlight coupler @ Cowling stay Clamp the horn lead to the inner fork tube 60 mm from the handle crown. [G)Pass the left and right flasher leads through the cowling stay guide wire. {5} Clamp the horn lead to the inner fork tube 20 mm from the under bracket, [E]When connecting the horn lead, make sure that the lead points down- wards from the connector so that water cannot get inside when it rains. [E] Clamp the brake hoses to the inner fork tube. [5]Clamp the wire harness to the cowling stay.CABLE ROUTING @ Fuse box [Clamp the fuel sender wire harness to the side cover stay. @ignitor unit Clamp the high tension cord, #4, to the upper part, and the #2 cord to @ Fuel sender lead the lower part at the marked position. @ Clutch cable lamp the high tension cords and clutch cable and sensing hose. @Clamp Clamp the high tension cords, #1, #2, #3 and #4 to the clamp on the ©Band frame at the marked positions accordingly. @Clip @ Rear brake switch lead[Clamp the brake hoses to the inner tube. IE] Clamp the brake hoses to the guide wire. GlAtter connecting the left and right flasher leads, clamp them to the cowling stay. Con- nect the thermo switch lead to the plug with white tape affixed to it. (Clamp the auxiliary light lead and wire har- ness to the cowling stay. (Clamp the flasher lead and thermo switch lead to the cowling stay. CABLE ROUTING ‘osition the spark plug cap so that itis facing inwards. [K]Pass the drain hoses for the tank and the drain hose for the air filter case through the clamp. [Pass the battery © lead under the cross pipe and reais it to the side of the battery © ter- minal [Clamp the rear brake switch lead to the back stay. +30@ Handlebar switch (left) @ Main switch coupler @ High tension cord (#1) G@High tension cord (#2) @ High tension cord (#4) © Sidestand switch lead @ Oil level switch lead © Speed meter cable © Starter motor lead [Bl Clamp the wire harness to the cowling Clamp the left handlebar switch lead to the inner tube. [)Clamp the left handlebar switch lead, the main switch lead and the starter cable to the tension [Clamp the wire harness at the point where the white tape is affixed to it. [E]Clamp the high tension cords (#1 and #2). [E) Clip both ends of the fuel h [Clamp the wire harness inside the seat rail. [Point the clamp end so that itis facing downwards. (1) Pass the flasher lead inside the protruding tab on the r iamp the wire harness and the fuel pump lead. P pump lead behind the wire harness. [EiPass the wire harness and the fuel pump lead through the guide wire on the stay lock. Position the fuel pump lead behind the wire harness. [E) Pass the starter motor lead under the cross pipe, then clamp it to the cross pipe. Pass the starter motor lead inside the tab an the rear fender and then inside the bracket an the rear shock absorberPass the side stand switch lead through the inner part of the rear arm. (8) Clamp the side stand switch lead and the oil level switch lead with the engine clamp. {Pull the oil level switch lead backwards slightly so that itis not slack. [B+Pass the throttle position sensor lead inside the high tension cords (#1 and #2). Either one of the high tension cords (#1) and (#2) can be uppermost. +Pass the cord (#4) outside the fuel hose and breather hose. +Pass the cord (#1) outside the fuel hose, breather hose and throttle position sensor lead. CABLE ROUTING [] Clamp the high tension cord, #4, to the upper art at the marked position, and the high ten- sion cord #2 to the lower part. [B Position the spark plug cap so that it is facing inwards. [S]Clamp the left handlebar switch lead, main ‘switch lead, starter cable and throttle cables. [Pass the speedometer cable to the left of the headlight and pass it through the guide wire which secures the cowling stay guide wire, brake hose holder, fender bracket guide wire and caliper. Clamp the part of the wire harness which has white tape affixed to it onto the cowling stay. When installing the cowling, make sure that the speedometer cable is not pinched between the headlight and the cowling.@ Front flasher light (right) lead © Auxiliary light lead @ Thermo switch lead @ Oil level switch lead @ Side stand switch lead © Fuel sender lead @ Battery © lead © Battery @ lead © Main fus @ lanitor @ Fuse box @ Flasher relay Throttle position sensor lead CABLE ROUTING |SPEC [lThe wire harness must be uppermost, followed by the clutch wire, with the throttle wire underneath, Clamp the AC generator lead, fuel hose and air filter case drain hose. Pass the wire harness through the guide on the reer fender, then pass it around to the left side of the motorcycle. [BI Pass the rear flasher leads underneath the point where the tail light is installed. [Pass the left and right rear flasher leads through the guide hole in the rear fender. [1 Connect the leads and clamp them to the frame at the guide hole,[Clamp the wire harness to the rear fender at the tab. [HIPass the coupler for the wire harness outside the rear fender. [Pass the seat lock wire outside the rear fender. Pass the wire harness underneath the point where the rear fender and fuel filter are installed, then pass it above the frame and the bracket of the rear shack absorber. Pass the starter motor lead under the wire harness and fuel hose. {Clamp the portion of the wire harness marked with white tape. -asten the ground terminal and the ignition coil together. Clamp the wire hamess, main switch lead and starter cable. (0) Clamp the handlebar switch lead to the han- dlebar. BTo carburetor.INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if fallowed, will ensure more reli- able vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehi- cles that are being prepared for sale. All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE/LUBRICATION INTERVALS unit: kn BREAKIN a rem REMARKS Son | S000 er | _2.0000r Smenths | _32monthe Vave Check valve cloaronce. Adjust W necessary EVERY 24,000 [Spark pluoe Checkcondition. Clean or replace t necessay. | __O. 6 Oo fier ‘loan. Replace H necessery O © ‘Check iele speadleynehronizaionitanar opera Carburetort tion ° ° O° Adlust ¥ necessary. Tie Check vel hose for cracks or damage, el Bee Replace if necessary |. © Engine Toplaco (Warm engine bafov draining) o o o Engine ol fiker™ Raplaeo. oO o ‘hock oi eval iakage Final coer alt Roplace every 24000 of 24 months. fahisee: o ° ‘heck operator ieakage (soo NOTED Brakes Correct if necessary. ° ° cacy heck operation. Adjuat Wf naconsay o oO ‘Cheek rer arm assembly for loosonoes Rear arm pivot? Correct if necessary. ° Modertaly repack ovary 24,000 or 24 rnoaths.*6* Tear ausponsion link piv- | Check operation. Apply groase ight every o os 214000 or 24 month" Check balancahdemagaranout. sheets Replace if necessary. o ° ; heck bearings assembly for loosenasaidomeoe. Wheel baacingy Replace if damaged. ° ° ‘heck bearings assembly for looseness stoning bearings? | Covroctf nocaseary. ° ° Moderately repack every 24,000 oF 24 manths.** Fron forks® ‘Check operationdoil leakage. Repair necessary o oO Fear shack sbsorber* _| Check aperatian/oilleakege. Repair necessary. oO oO 5 ~~] Gheckal chassis fitings and factors stint resenets Correct if necessary. oO o ° eras atanet ane: ration, Repair i nocessor Corea heck operation. Rep necanary. oO ° O [Seteetna toe Chock operation ler or replace necessary. o o o ‘+: itis recommended that these items be serviced by a Yamaha dealer. +; Medium weight wheel bearing grease. (bearing type} +5: Molybdenum disulfide grease,PERIODIC MAINTENANCE/LUBRICATION INTERVALS NOTE: Brake fluid replacement: 1.When disassembling the master cylinder or caliper cylin mally check the brake fluid level and add the fluid as required. 2.0n the inner parts of the master cylinder and caliper cylinder, replace the oil seals every replace the brake fluid. Nor- ‘two years. 3.Replace the brake hoses every four years, or if cracked or damaged.SIDE COVER, FUEL TANK AND COWLING SIDE COVER, FUEL TANK AND COWLING REMOVAL 1.Remove: « Seat 2.Remove: e Tail cover @ 3.Remove: Grab bars (left and right) @ # Side covers (left and right) @ 4.Remove: * Bolt « Bolt® * Plate @ Damper rubber © 5.Turn the fuel cock © to “OFF”. 6.Disconnect: = Fuel sender coupler @ « Fuel hose @ PETG ighly flammable. Avoid spilling fuel on the hot engine.INSP SIDE COVER, FUEL TANK AND COWLING [Any 3. 4 NOTE; Place a rag under the fuel hose to avoid spilling fuel, 7.Remove: Fuel tank 8.Remove: « Screws «Windscreen © Rubber plugs «Inner cover @ 9.Remove: © Bolts 10.Disconnect: * Flasher light lead (front) 11.Remove: « Flasher light (front) @ 12.Disconneet: + Head light lead 18.Remove: +» CowlingSIDE COVER, FUEL TANK AND COWLING [se | INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.lnstall: + Fuel tank 2.Install: » Side covers B.lnstall: Seat NOTE: —______. Insert the lobes on the front of the seat into the bracket on the frame, then push down, the seat end. 3-5VALVE CLEARANCE ADJUSTMENT ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: — + The valve clearance should be adjusted ‘when the engine is cool to the touch. + The piston must be at Top Dead Center {T.D.C.) on compression stroke to check or adjust the valve clearance. 1.Remove: © Seat © Fuel tank » Cowling Refer to “SIDE COVER, FUEL TANK AND. COWLING”. 2.Disconnect: + Breather hose © Drain hose @ 3.Loosen: + Screws @ 4.Disconnect: + Hose (air filter case - air cut valve) © (from air filter case) 5.Remove: * Air filter case @VALVE CLEARANCE ADJUSTMENT eee 6.Disconnect: « Throttle cables © « Starter choke cable @ 7 Disconnect: « Carburetor heater coupler © « Fuel hose @ « TPS (throttle position sensor) coupler @ 8.Loosen: « Screws (carburetor - joint) @ 9.Remove: « Carburetor assembly 10.Remove: + Oil cooler Refer to “ENGINE REMOVAL” in CHAP- TER 4. When removing the union bolt ©, be sure to secure the hexagonal part @ to stop it ‘turning. 11.Remove: « Spark plug caps © 12.Remove: « Air cut valves © « Reed valves @ «Pipes @ «Hose @ 13.Remove: Cylinder head cover ®VALVE CLEARANCE ADJUSTMENT ee eae eee 14.Remove: ‘« Timing plate cover © 15.Check: « Valve clearance Out of specification > Adjust. Valve clearance (cold): Intake valve: 0.11 ~ 0.15 mm Exhaust valve: 0.16 ~ 0.20 mm FORE HOE CEPI EERE ERE EELEL EEE Checking steps: @Turn the crankshaft counterclockwise with a wrench. @Align the TDC mark @ with the align mark ® when #1 piston is at TDC on compres- sion stroke. NOTE: TDC on compression stroke can be found when the cam lobes are opposite each other as shown, Measure the valve clearance using a feeler gauge ©. NOTE: + Record the measured reading if the clear- anee is incorrect. + Measure the valve clearance in the follow- ing sequence. -_——oOoOmX______ Measuring sequence: #12 #2 #4 3 3-8180 VALVE CLEARANCE ADJUSTMENT [mus ¥ 360° 540° 720° Al Front Turn the crankshaft by the number of degrees indicated below counterclock- wise from #1 cylinder TOC. ‘Crankshaft counterclockwise turning angle Cylinder number ‘Combustion THO SEE me Re eae 16.Adjust: + Valve clearance SEER ORE CUNO ENN EER ER EER EERE EEEE Adjustment steps: ‘@Position the valve lifter slots (intake and exhaust) opposite each other. @Attach the tappet adjusting tool ©. | se} ‘Tappet adjusting tool: \F_| P/N 90890-04125 NOTE: ‘Make sure the tool only contacts the lifter @, not the pad @. @Slowly turn the tappet adjusting tool so that the pads can be removed. @Remove the pads from the lifters. Use a small screwdriver and a pair of tweezers for removal. Note pad numbers. @Select the proper valve adjusting pad from the following chart.INTAKE VALVE CLEARANCE ADJUSTMENT INSP ADJ IQ) MEASURED INSTALLED PAD NUMBER CLEARANCE /260]305]270] 220] 5230 25 | 200 245] 255] na [260266 [770] 276] 280/286] 290) 2065[300]305] 0.00 ~ 0.05 210] 5 '230]235| 745] '260| 86 |260|265]70|775) 260]285|290| 95) 0.08 ~ 0.10 205 25] 235 '220| 725] [225] 730) 20 235240] 260] [256] 260|265]270)275|260| 285 290|295| 300) ae 276 205]210)2 15) [230)235[240]245 [260 (286) 260) 265 270]275]200 310 265 [270|276 260] 85290) [a05/310| 315 026 ~ 0.30 1215]220) [236 240 245] 250| 255] 260|205) Ei) [275 [200] 285/290] 295] [310]316]320 0.31 - 0.35. |20)205) [00 [245 260] 255] 260|265 270) 275| 20285] 290|295|300] 305/310) 315 [320 20) "0.36 0.40 |235]2301 25] [280|256| 260|265]770[ 275 [200 [285 [280] 295| 300/308) 310) 315) 220| ‘041 ~ 0.45 |230)735) [250] 285 [260] 265 [270275] 26 285) [280296] 300|305/970) 315[320) ‘0.46 - 0.50/25] 240] 260/265] 770|275| 780] 785) 200) (296 300|305/310|315| 320) O51~ 0.55 |2aa)245 0] [265] 70] 276| 280265 | 290) 95) '300| 906) 310|315 320] ‘056 0.60 |245]250 (265) '270|276|20| 85 [300] 205| 00 [305] 310[315|320, 0.61 = 0.65 1260/2665) [270] [275|280|285|220|295| 500) (305) 's10)315|320 (066 ~ 0.70 [265 276 [280| 28s 290285 300] 305 310) [915]320) (071 ~ 0.75 |260)265)270|275) [200] '290|296| 300] 305]310] [315] 320] (076 0.80_|265)270|275| 260) 5 [200] 205|300|305 210) O81 ~ 0.85 [25 270276) 720) 200) 1285| 500) 305|310]375| 320] ‘0.86 - 0.90 _|275|280| 285] 290) 5 [300] 305[t0[375]3201 (091 ~ 0.95 [280] 285] 290] 300 [308[310] 315/320] (0.96 ~ 1.00 |205|290) 295|300| 506, st0|3 1.01 ~ 1.05 |290 296] 300|305| et) 320] 3.06 1.10 [295]300/ 905) 319] a] 1.11.18 [300|305|310|375] (320 1315 [220 11e= 1.20} 1 305] 310 ~[s10}315) | 320] 318] (320 EXHAUST '315/320) VALVE CLEARANCE (cold): 0.11 ~ 0.15 mm Example: Installed is 250 Measured clearance is 0.23 mm Replace 250 pad with 260 pad Pad number: (example) Pad No. 250 = 2.50 mm Pad No. 260 = 2.60 mm Always install pad with number down, MEASURED TNSTALLED FAD NUMBER CLEARANCE [765] 205]210]275 223] [za 20205] 2 (260) 266 [270/278 [280/765 [300 0.00 ~ 0:05 205] 210 225/230) [245 260 255| 260) [268270] 275] 260)705| 0.06 = 0.10 [200205 210] 216 730/235 '260|255 260] 265|270|275| 200) 705] 290) 210] 235] (220) | 235] 240) [255260 265| 270] 275, 220] O:i1= 0.15) 205 0.16 ~ 0.20 a [279] 021-095 |208]310]215 220 [225] 245]250 '265|270]775]200)785 700) [a05] 310/316) 0.36 ~ 0.30 [210|315|220) 225] [230 250) 255| [27075] 280| 285290} '305]3%0 [275|280) 285|200) [s10]315| Hse Be 9 "0.35 ~ 0.40. |220) [200] '255/260]265)270) '280 285) 290|285|300|305|310/375| [2 ‘047 = 0.45 [225 [205270276 2a 200295003030 046 ~ 0.50 _|730 285|270)275 280 [280296] 300| 3051310) 375] a (051 ~ 0.85 [35] '270)275|780| 785) [285/900] 305|310)375}320) (056 ~ 0.60 [240] '275| 280 |285|299 | 300/306] 310]315|320} O61 0.65 [245] [290)795] [305]310) 315/320] (0.66 ~ 0.70_|260] [285290 [295| 300] 306] [310/316] 320) (0.71~ 0.75 jase [290] 296 [300] 306) 's10) [315] 320] (0.76 0.80 260) '205|300 305) 319] ig 20 081 ~ 085 (205) [300305 [320] 316) 320) 086 ~ 0:90 [308] 10/315] 320) 091-095 _|275| [310/315] 320 (0.96 - 1.00 [200] isi5) 7.01 1.08 [286 310) 315] "329 3.08 ~ 1.10. 200 [320] 111-115 [296 1.76 = 1.20 [300306] 421 = 125 1.26 1.30 131 = 138 1.38 = 7.40 '305]310 [310)315) i315[329) VALVE CLEARANCE (eold): 0.16 ~ 0.20mm Example: Installed is 250 Measured clearance is 0.32 mm Replace 250 pad with 265 pad Pad number: (example) Pad No. 250 = 2.50 mm Pad No. 265 = 2.65 mm Always install pad with number down. -10VALVE CLEARANCE ADJUSTMENT Pad range Pads are stepped in 0.05 mm incre- ments No. 200 ~ | 2.00 mm ~ No. 320 | 3.20mm NOTE: Thickness of each pad is marked on the pad face that contacts the valve lifter (not the cam). @Round off the hundredths digit of the original pad number to the nearest 0.05 mm increment. Hundredths digit Rounded value (NOT ROUNDED OFF) EXAMPLE: Original pad number = 248 (2.48 mm) Rounded off digit = 250 NOTE: Pads can only be selected in 0.05 mm incre- ments. @ Locate the previously installed pad num- ber on the chart. Locate the measured valve clearance on the chart. The point where these coordinates intersect is the new pad number. Nove: —___ Use the new pad number as a guide only if the number must be verified. @install the new pad with the numbered side down. @ Remove the adjusting toolVALVE CLEARANCE ADJUSTMENT ‘Recheck the valve clearance. @if the clearance is incorrect, repeat all of the clearance adjustment steps until the specified clearance is obtained. ‘7.Install: * All removed parts NOTE: Install all removed parts in reversed order of their removal. Note the following points. 18.Install: * Timing plate cover ‘Screw (timing plate cover): et 19.Install: + Cylinder head cover + Spark plugs Bolt (cylinder head cover): 10 Nm (1.0 m+ kg) 21 Spark plug: 18 Nm (1.8 m= kg) 20.Install: # Oil cooler When installing the union bolt, be sure to secure the hexagonal part to stop it turning. Nut (oil cooler - frame): 10 Nm (1.0 m- kg) Bolt (oil cooler - oil pipe): 32 Nm (3.2 m+ kg)CARBURETOR SYNCHRONIZATION INSE Q CARBURETOR SYNCHRONIZATION NOTE: —____ Valve clearance and idling speed should be adjusted properly before synchronizing the carburetors. 1.Place the motorcycle on a level surface. NOTE: —__ Place the motorcycle on its centerstand if a centerstand is equipped. If not, place @ suit- able stand under the motorcycle. 2.Remove: » Seat + Fuel tank Refer to “SIDE COVER, FUEL TANK AND COWLING”. 3.Attach: » Adapters «Vacuum gauge © « Inductive tachometer © (to #1 spark plug lead) Vacuum gauge: 90890-03094 Adapter: 90890-03060 Inductive tachometer: 90890-03113 4.Start the engine and let it warm up for several minutes. 5.Check: « Engine idling speed Out of specification — Adjust. Refer to “IDLING SPEED ADJUSTMENT”. 6.Adjust: » Carburetor synchronization Adjustment steps: @ Synchronize carburetor #1 to carburetor #2 by turning synchronizing screw © until both gauges read the same. Race the engine for less than a second, two or three times and check the synchro- nization again.CARBURETOR SYNCHRONIZATION Repeat the above steps to synchronize carburetor #4 to carburetor #3 by turning synchronizing screw @ until both gauges fead the same. Repeat the same steps to synchronize car- buretor #2 to carburetor #3 by turning synchronizing screw © until both gauges read the same. Vacuum pressure at idle speed: 30.3 ~ 32.9 kPa (230 ~ 250 mm Hg) NOTE: The difference between both carburetors should be 1.33 kPa (10 mm Hg) or less. —_——— oe SOCIOL EEE 7.Check: * Engine idling speed Out of specification + Adjust. 8.Stop the engine and detach the measur- ing equipment. 9.Adjust: * « Throttle cable free play. Refer to “THROTTLE CABLE ADJUST- MENT". 3~5mm At throttle grip flange 10.Install: * Fuel tank * Seat Refer to “SIDE COVER, FUEL TANK AND COWLING”.IDLING SPEED ADJUSTMENT ae 6 IDLING SPEED ADJUSTMENT NOTE: The carburetor synchronization should be adjusted properly before adjusting the idling speed. 1.Start the engine and let it warm up for several minutes. 2.Attach: « Inductive tachometer (to the #1 spark plug lead) GZ] Inductive tachometer: \7 | 90890-03113 3.Check: « Engine idling speed Out of specification > Adjust. Engine idling speed: 950 ~ 1,050 r/min 4.Adjust: # Engine idling speed Adjustment steps: eTurn the pilot screw ® until it is lightly seated. @Turn out the pilot screw for the specified number of turns. QZ] Carburetor angle driver: \F | 90890-03158 Pilot screw: 1-1/2 turns out ‘eTurn the throttle stop screw @ in or out until specified idling speed is obtained. Turning in —> Idling speed increased. Turning out ~ Idling speed decreased.IDLING SPEED ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT 5.Adjust: « Throttle cable free play Refer to “THROTTLE CABLE ADJUST- MENT”. Free play: 3~5mm At throttle grip flange THROTTLE CABLE ADJUSTMENT OTE a Engine idling speed and carburetor syn- chronization should be adjusted properly before adjusting the throttle cable free play. 1.Check: « Throttle cable free play @ Out of specification > Adjust. Free play: 3~5mm At throttle grip flange 2.Remove: « Seat Fuel tank Refer to “SIDE COVER, FUEL TANK AND COWLING”. e Air filter case Refer to “VALVE CLEARANCE ADJUST- MENT”. 3.Adjust: « Throttle cable free play REARA AREER ERSEAEEREEREREEESEEROEEE Adjustment steps: MOTE" When accelerating, throttle cable #1 @ is pulled and throttle cable #2 @ is pushed.INSP THROTTLE CABLE ADJUSTMENT | ang First step: @Loosen the locknut @ on thrattle cable #2. @ Tum the adjuster @ in or out until all stack is removed from throttle cable #2. Second step: @ Loosen the locknut © on throttle cable #1. eTurm the adjuster ® in or out until the specified free play is obtained. Turning in — Free Turning out — Free eTighten the locknuts. NOTE: If the free play can not be adjusted here, adjust it at the throttle grip side of the cable. Final step: ‘@Loosen the locknut @. @Turn the adjuster ® in or out until the specified free play is obtained. Turning in — Free play is increased. Turning out — Free play is decreased. Tighten the locknut. PRG After adjusting, turn the handlebar to the iht and left, making sure that the engine idling speed does not chi AUS U HOSE ere eens seer ee 4.install: * Air filter case Refer to “VALVE CLEARANCE ADJUST- MENT’. + Fuel tank «Seat Refer to “SIDE COVER, FUEL TANK AND COWLING”.SPARK PLUG INSPECTION Inst Q ‘SPARK PLUG INSPECTION 1.Remove: * Spark plug caps = Spark plugs Before completely removing the spark plug, use compressed air to clean the cylin- der head cover areas to prevent dirt from falling into the engine. 2inspect: « Spark plug type Incorrect + Replace. ‘Standard spark plug: DPR8EA-9 (NGK) X24EPR-U9 (NIPPONDENSO) 3.Inspect: Electrode © Wear/Damage ~ Replace. «Insulator @ Abnormal color -> Replace. Normal color is a medium-te-light tan color. 4.Clean: # Spark plug (with spark plug cleaner or wire brush) 5.Measure: © Spark plug gap @ Use a wire gauge. Out of specification -> Re-gap. AN Spark plug gap: 0.8 ~0.9mm G.install; Spark plug Qs | Spark plug: faite NOTE: ————_ Before installing a spark plug, clean the gasket surface and plug surface.IGNITION TIMING CHECK [use | IGNITION TIMING CHECK NoTe: —____ Carburetor synchronization, engine idle speed and throttle cable free play should be adjusted properly before checking the igni- tion timing. 1.Remove: « Timing plate cover ® + Inductive tachometer ® {to the #1 spark plug lead) Timing light: 90890-03141 Inductive tachometer: 90890-03113 3.Check: + Ignition timing Her rOrreernnerrne ene enenn anne ‘Checking steps: ‘eStart the engine and let it warm up for several minutes. Let the engine run at the specified speed. [es “tao 1000 eVisually check the align mark @ to ver is within the required firing range @ indi- cated on the timing plate. Incorrect firing range — Check timing plate and/or pickup assembly. FOR nn ER EREIGNITION TIMING CHECK/ COMPRESSION PRESSURE MEASUREMENT | ADJ 4.install: + Timing plate cover COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in performance loss. 1.Check: Valve clearance Out of specification -> Adjust. Refer to “VALVE CLEARANCE ADJUST- MENT’. 2.Start the engine and let it warm up for several minutes. 3.Stop the engine. 4.Remove: Spark plug caps + Spark plugs plug, use compressed air to clean the eylin- der head cover areas to prevent dirt from falling into the engine. S.Attach: + Compression gauge @ Compression gauge: 90890-03081 Adapter: 90890-04082INSP COMPRESSION PRESSURE MEASUREMENT | ADJ 6.Measure: Compression pressure Above the maximum pressure: Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: Squirt a few drops of oil into the affected cylinder and measure again. Refer to the table below. Compression pressure (with oil applied into cylinder) Reading —_| Diagnosis Higher than | Worn or damaged pistons without oil | — Repair Defective ring(s), valves, cylinder head gasket or piston is possible > Repai Same as without oil Compression pressure (at sea levell: Standard: 1,200 kPa (12 kg/em?, 12 bar} Minimum: 1,000 kPa (10 kg/em?, 10 bar) Maxirnu 1,400 kPa (14 kg/cm, 14 bar) Measurement steps: @Crank over the engine with the throttle wide-open until the reading on the com- pression gauge stabilizes. 4 WARNING Before cranking the engine, ground all spark plug leads to prevent sparking. @Repeat the previous steps for the other cylinders. NOTE: The difference of compression pressure between the highest and lowest cylinder compression readings should be 100 kPa (1 kg/cm?, tbar) or les: OOO eRe REE EEE EEE REE EEE ENECOMPRESSION PRESSURE MEASUREMENT/ ENGINE OIL LEVEL INSPECTION 7.Instal «Spark plugs * Spark plug caps ‘Spark plug: 18 Nm (1.8 m - kg) ENGINE OIL LEVEL INSPECTION RU Position the motorcycle straight up when inspecting the oil level. oe 1.Place the motorcycle on a level surface. Nove; Place the motorcycle on its centerstand ifa centerstand is equipped. If not, place a suit- able stand under the motorcycle, 2.Inspect: «Oil level Oil level should be between maximum @ and minimum © marks. il level low -» Add oil to proper level. Recommended oi SAE 20W40 type SE motor oil Nore; Recommended oil classification: API Ser- vice "SE", “SF" and “SG" type or equiva- lent (e.g. “SF-SE", “SF-SE-CC", “SF-SE- SD" ete.). Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. e Do not allow foreign material to enter the crankcase. 3-22ENGINE OIL LEVEL INSPECTION/ [INSP ENGINE OIL REPLACEMENT | ADJ 3.Start the engine and let it warm up for several minutes. 4,Stop the engine and inspect the oil level once again. NOTE: Wait a few minutes until the oil settles before inspecting the oil level. 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: « Oil filler plug * Drain bolt © Drain the crankcase of its oil. 4.If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. perreeerrerrerrrtirrrrrre tered Replacement steps: @Remove the oil filter @ using the oil filter wrench @). Oil filter wrench: 90890-01426 e@Apply engine oil to the O-ring @ of the new oil filter. NOTE: —___ Make sure the O-ring @ Is positioned cor- rectly,ENGINE OIL REPLACEMENT Tighten the wrench, Ny, | Oil filter: [Sa 17. Nm (1.7 m+ kg) ANE R nat ae eae eiee ate a I filter using the oil filter 5.install: ° Drain bolt RS | Drain bolt: ES 43 Nm (4.3 m- kg) NOTE: Check the gasket (drain plug). If damaged, replace it with a new one. Gill: « Crankcase Refer to “ENGINE OIL LEVEL INSPEC- TION”. Oil quantity: Total amount: 4aL Periodic oil change: 3.2L ‘With oil filter replacement: BAL Tinstall: « Oil filler plug 8.Warm up the engine for a few minutes, then stop the engine. G.inspect: « Engine (for oil leaks) * Oil level 10.Check: + Oil pressure Checking steps: @Slightly loosen the oil gallery bolt ©. ‘eStart the engine and keep it idling until oil starts to seep from the oil gallery bolt, If no oil comes out after one minute, turn the engine off so it will not seize.ENGINE OIL REPLACEMENT/CLUTCH ADJUSTMENT @Check oil passages, oil filter and oil pump. for damage or leakage. Refer to “INSPEC- TION AND REPAIR” in CHAPTER 4. eStart the engine after solving the prob- lem(s) and recheck the oil pressure. eTighten the oil gallery bolt to specifica- tion. Oil gallery bolt: Sia CLUTCH ADJUSTMENT 1.Check: # Clutch cable free play @ Out of specification —» Adjust. | Free play: 10~15mm At clutch lever end 2.Adjust: Clutch cable free play Adjustment steps: @ Loosen the locknut(s) ©. @Turn the adjuster(s) ® in or out until the specified free play is obtained ‘Turning in — Free play is increased. Turning out — Free play is decreased. @ Tighten the locknut(s). [A] Handlebar side Engine sideAIR FILTER CLEANING AIR FILTER CLEANING 1.Remove: + Seat « Fuel tank Refer to “SIDE COVER, FUEL TANK AND ‘COWLING". 2.Remove: « Airfilter case cover © 3.Remove: « Airfilter element Never operate the engine with the air filter element removed. Unfittered air will cause wear of engine parts and possible engine damage. Additionally, operation without the filter element will affect carbu- retor tuning with subsequent poor perfor- mance and possible engine overheating. 4.Inspect: ilter element Damage ~ Replace. 6.Clean: Air filter element Blow out the dust in the outer surface of the element with compressed air. 6.Install: * Air filter element ir filter case cover NOTE: When installing the element in its case, be sure its sealing surface matches the sealing surface of the case so there is no air leak. install: © Fuel tank = Seat Refer to “SIDE COVER, FUEL TANK AND COWLING".FUEL LINE INSPECTION FUEL LINE INSPECTION inspect: « Fuel hose ®FRONT BRAKE LEVER POSITION ADJUSTMENT/ REAR BRAKE ADJUSTMENT CHASSIS FRONT BRAKE LEVER POSITION ADJUSTMENT Adjust: © Brake lever position (distance @ from handle grip to front brake lever) FEMUR HO HGD HE IERIE HIE Adjustment steps: ‘@Push the brake lever forward. @Turn the adjuster @ in or out. Turning in — Distance is smaller. Turning out -> Distance is largest. @Align the mark @ on the adjuster with the mark @ on the lever. JRE OHO IHO BCR aE aE EC Een nme Make sure that the brake does not drag after adjusting it. A soft spongy feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle Is operated. Air in the system will cause greatly ished braking capacity and result in loss of control and an accident. Inspect and bleed the sys- tem if necessary. REAR BRAKE ADJUSTMENT 1.Cheok: « Brake pedal height @ Qut of specification —» Adjust. %€] Brake pedal height: 30mm Below top of footrestREAR BRAKE ADJUSTMENT 2.Adjust: « Brake pedal height See EeS te Lee N MERE RRR EERE EEE Adjustment steps: @ Loosen the locknut(s) ©. @Tur the adjusterts) @ in or out until the specified pedal height is obtained. Turning in — P Turning out — Ped: WARNING check the adjuster end through the hole The adjuster end 6) must be visible within this hole. Tighten the locknut ©. Make sure that the brake doi after adjusting it. not drag A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capa- bility and can resutt in loss of contro! and ‘an accident. Inspect and bleed the system if necessa 3.Adjust: ¢ Brake light switch Refer to “BRAKE LIGHT SWITCH ADJUSTMENT”.BRAKE FLUID LEVEL INSPECTION BRAKE FLUID LEVEL INSPECTION NOTE: Position the motorcycle straight up when inspecting the fluid level. 1.Place the motorcycle on a level surface. NOTE: — Place the motorcycle on its centerstand if a Genterstand is equipped. If nat, place a suit- able stand under the motoreycle. 2Inspect: + Fluid level Fluid level is under “LOWER” level line @ — Fill to proper level. Recommended fluid: DOT #4 Front brake (Rear brake NOTE: When inspecting the fluid level in the reser- voir on the handlebar, make sure the mas- ter cylinder top is horizontal. Brake fluid may corrode painted surfaces or plastic parts. Always clean up spilled fluid immediately. Use only the designated quality fui Otherwise, the rubber seals may deterio- rate causing leakage and poor brake per- formance. « Refill with the same type of fluid. Mixing fluids may result in a harmful chemical reaction leading to poor brake perfor- mance.BRAKE FLUID LEVEL INSPECTION/BRAKE PAD INSPECTION/BRAKE LIGHT SWITCH ADJUSTMENT | ang « Be careful that water does no enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and could cause vapor lock. BRAKE PAD INSPECTION ‘Activate the brake lever or brake pedal. 2.Inspect: « Brake pad (front) rake pad (rear) Wear indicator @ almost contacting the brake disc > Replace brake pad as a set. Refer to "FRONT AND REAR BRAKE” in CHAPTER 6. jFront (B) Rear BRAKE LIGHT SWITCH ADJUSTMENT NOTE: The brake light switch is operated by move- ment of the brake pedal. Proper adjustment is achieved when the brake light comes on just before the brake begins to take effect 1.Check: # Brake light operation timing Incorrect + Adjust.BRAKE LIGHT SWITCH ADJUSTMENT/ [INSP BRAKE HOSE INSPECTION | ADJ. 2.Adjust: Brake light operating timing JERR RE EE ER EEE EERE Adjustment steps: @Hold the main body @ of the switch with your hand so that it does not rotate, and turn the adjuster ® in or out until the operating timing is correct. BRAKE HOSE INSPECTION inspect: « Brake hoses Cracks/Wear/Damage -» Replace. 2.Check, + Brake hose clamp Loosen — Tighten. 3.Hold the motorcycle on upright position and apply the front or rear brake. 4.Check: © Brake hoses Activate the brake lever or pedal several times. Fluid leakage — Replace the hose. Refer to “FRONT AND REAR BRAKE’ CHAPTER 6. 3-32NSP. AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) | ADJ 3-33 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) Bleed the brake system if: « The system has been disassembled. A brake hose has been loosened or removed. The brake fluid has been very low. « The brake operation has been faulty. A loss of braking performance may occur if the brake system is not properly bled. ‘Bleed: ‘« Brake system Air bleeding steps: a.Add proper brake fluid to the reservoir. b.install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c.Connect a clear plastic hose @ tightly to the caliper bleed screw @. @ Front Rear d.Place the other end of the hose into a con- er. e.Slowly apply the brake lever or pedal sev- eral times. f.Pull the lever in or push down on the pedal. Hold the lever or pedal in position, g.Loosen the bleed screw and allow the lever or pedal to travel towards its limit. h.Tighten the bleed screw when the lever or pedal limit has been reached, then release the lever or pedal. i. Repeat steps (e) to (h) until all ai have disappeared from the fluid. j. Tighten the bleed screw. Bleed screw: | Nm (0.6 m - kg) ubblesAIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ FINAL GEAR OIL LEVEL INSPECTION NOTE: Hf bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared. k.Add brake fluid to proper level. Refer to “BRAKE FLUID LEVEL INSPEC- TION”. PN) Check the operation of the brake after bleeding the brake system. FINAL GEAR OIL LEVEL INSPECTION NO’ oo Position the motorcycle straight up when ‘specting the oil level 1.Place the motoreycle on a level surface. NOTE: Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suit- able stand under the engine. 2.Remove: « Oil filler bolt © B.inspect: # Oil level Oil level should be up to bottom brim © of hole. Oil level low — Add oil to proper level. Recommended oil: SAE 80 API "GL-4" Hypoid gear oil if desired, an SAE s0wsg0 hypoid gear oil may be used for all conditions. Ne “GL-4" isa quality and additive rating. “GL- 5” or “GL6" rated hypoid gear oils may also be used. 4.Install: Oil filler bolt yy | Oil filler bolt: 23 Nm (2.3 m+ kg) 3-34FINAL GEAR OIL REPLACEMENT/ STEERING HEAD INSPECTION FINAL GEAR OIL REPLACEMENT 1.Place an oil pan under the final gear case. 2.Remove: Oil filler bolt Drain plug Drain the final gear case of its oil. 3.install: « Drain plug \ Drain plug: 23 Nm (2,3 m- kg) % o NOTE: Check the gasket (drain plug). If damaged, replace it with a new one. 4.Fill: + Final gear case Oil quantity: o2ZL Refer to “FINAL GEAR OIL LEVEL INSPEC- TION". STEERING HEAD INSPECTION A WARNING Securely support the motorcycle so there is no danger of it falling over. 1.Place the motorcycle an a level place. 2.Elevate the front wheel by placing a suit- able stand under the exhaust pipe. 3.Check: 's Steering assembly bearings Grasp the bottom of the front forks and gently rock the fork assembly back and forth. Looseness ~» Adjust the steering head.STEERING HEAD INSPECTION | ADJ 4.Remove: + Handlebar 5.Loosen: « Pinch bolts © 6.Remove: e Nut ® » Upper bracket @ 7.Adjust: # Steering head Adjustment steps: @Remove the special washer @, ring nut @ (upper) and rubber washer ©. @ Loosen the ring nut (lower) ©. @ Tighten the ring nut (lower) using the ring nut wrench @. NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle. 32] Ring nut wrench: 7 | 90890-01403 Ring nut (lower): (initial tightening): 52.Nm (5.2 m-kg) Loosen the ring nut (lower) © completely, then retighten it to specification, PRG) Do not overtighten. Ring nut (lower: (final tightening): 18 Nm (1.8 m+kg)STEERING HEAD INSPECTION | ADJ @Check the steering head by turning it lock to lock. If it binds, remove the steering stem assembly and inspect the steering bearings. Refer to “STEERING HEAD AND HANDLE- BAR" in CHAPTER 6. © Install the rubber washer @. Install the ring nut (upper) @- Finger tighten the ring nut (upper) @, then align the slots of both ring nuts. If necessary, hold the ring nut (lower) and tighten the ring nut (upper) until their slots are aligned. @ install the lock washer ©. NOTE: Make sure the lock washer tabs sit correctly in the slots. FEED ODIO EEE Eee B.lnstall: » Upper bracket e Handlebar Nut: 110 Nm (1.0m = kg) Pinch bolt (upper bracket): 30 Nm (3.0 m+ kg) Pinch bolt {handlebar holder): 23 Nm (2.3 m= kg)FRONT FORK INSPECTION/ REAR SHOCK ABSORBER ADJUSTMENT FRONT FORK INSPECTION A WARNING Securely support the motorcycle so there is no danger of it falling over. 1Place the motorcycle on a level place. 2.Check: e Inner tube Scratches/Damage — Replace. « Oil seal Excessive oil leakage —> Replace. 3.Hold the motorcycle in an upright posi- tion and apply the front brake. 4.Check: » Operation Pump the front fork up and down for sev- eral times. Unsmooth operation — Repair. Refer to “FRONT FORK” in CHAPTER 6. REAR SHOCK ABSORBER ADJUSTMENT PONS Securely support the motoreyele so there is no danger of it falling over Spring preload Adjust: + Spring preload NOT Use the special wrench and extension bar included in the owner's too! kit to adjust.REAR SHOCK ABSORBER ADJUSTMENT/ TIRE INSPECTION FEU Adjustment steps: « Turn the adjuster @ in or out. ARE Turning lower number -> Spring preload is softer. Turning higher number — Spring preload is harder. ‘Adjuster position: ‘Standard: Minimum: Maximum: | CAUTION: Never turn the adjuster beyond the maxi- mum or minimum setting. JUROR HIS HEI HEE HEEEE GENET TIRE INSPECTION 1.Measure: « Tire pressure Out of specification + Adjust. . tion pressure should be check and adjusted when the temperature of the tire equals the ambient air tempera- ture. Tire inflation pressure must be adjusted according to total weight of cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this modell, and vehicle speed. Proper loading of your motorcycle is important for the handling, braking, and other performance and safety characteris tics of your motorcycle. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcycle, and dis- tribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires.TIRE INSPECTION NEVER OVERLOAD YOUR MOTORCYCLE Make sure the total weight of the cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury. Basic weight: With oil and full fuel tank Maximum 205 kg Front Rear 225 kPa_| 250kPa Ue to 90kS | (2 25kgHlem’, | 2.5 kat/em*, 225ber) || 25bar) 250 kPa 290 kPa 90 kg ~ Maxi- axl: | 12.5 kaflem?, | (2.9 koflem?, num oat 25bar) | 2.9bar) 250kPa | 290 kPa High speed oe (25 katlem?, |(2.9kat/em?, 2.5 bar) 29 bar) * Load is the total tof cargo, rider, pas senger, and accessories. 2.Inspect: « Tire surfaces Wear/Damage -> Replace. X4] Minimum tire tread depth: (front and rear}: 1.0mm @ Tread depth Q Side wall @ Wear indicator 3-40TIRE INSPECTION PGT ‘tire. When a tire tread begins to show lines, replace the tire immediately. «Do not use tubeless tires on a wheel designed for tube type tires only. Tire f ure and personal injury may result from sudden d : AlTire | Wheel Tube type wheel — Tube type tire only. Tubeless type wheel ~> Tube type or tubeless ti 41 « Be sure to install the correct tube when using tube type tires. After extensive tests, the tires mentioned below have been approved by Yamaha Motor Co., Ltd. for this model. No guaran- tee for handling characteristics can be given if a tire combinations. other than the approved is used on this motorcycle. The front and rear tires should always be of the (Gane) Manufacturer METZELER 120/70-17 58V BRIDGESTONE | 120/70-17 58V DUNLOP 120/70-17 58V REAR: ‘Manufacturer Size Type METZELER 150/70-17 69V | MES5A BRIDGESTONE | 150/70-17 69v| G602 DUNLOP 150/70-17 69V | _K505 After mounting a tire, ride conservatively for a while to fe the tire time to seat itself properly in the rim. Failure to do so could lead to an accident with possible injury to the rider or damage to the motor- cycle.WHEEL INSPECTION/ [INSP CABLE INSPECTION AND LUBRICATION | any | Qa 3.82 WHEEL INSPECTION 1.Inspect: * Wheels Damage/Bends — Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. 4 WARNING Never attempt to make wheel. Vy Fepairs to the CABLE INSPECTION AND LUBRICATION 4 WARNING Damaged cable sheaths may cause corro- sion and interfere with the cable move- ment. Replace damaged cables as soon as possible. ‘Inspect: « Cable sheath Damage — Replace. 2.Check: + Cable operation Unsmooth operation — Lubricate. RJ Recommended lubricant: Ss SAE 2040 motor oil 2 NOTE; Hold cable end up and pour a few drops of lubricant into the cable sheath.LEVER AND PEDAL LUBRICATION/SIDESTAND LUBRICATION/ CENTERSTAND LUBRICATION/REAR SUSPENSION LUBRICATION 3-43 LEVER AND PEDAL LUBRICATION Lubricate levers and pedals at their pivoting YJ Recommended lubricant: S| SAE 20W40 motor oil vi 3 SIDESTAND LUBRICATION Lubricate the sidestand at pivoting paints. RS Recommended lubricant: \,] Lithium soap base grease yi CENTERSTAND LUBRICATION Lubricate the centerstand at points. Recommended lubricant: Lithium soap base grease S pivoting REAR SUSPENSION LUBRICATION Lubricate the rear suspension at pivoting points. NS Recommended lubricant: Molybdenum disulfide greaseBATTERY INSPECTION ELECTRICAL BATTERY INSPECTION NOTE: Since the MF battery is a sealed type bat- tery, it is not possible to measure the spe- cific gravity of the electrolyte in order to check the state of charge of the battery. Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals. _ CAUTION: © CHARGING METHOD + This is a sealed type battery. Never remove the sealing caps. If the sealing caps have been removed, the balancing will not be maintained, and battery per- formance will deteriorate. + Never add water, as this will affect the chemical reaction in the battery and cause loss of performance. Charging time, charging current and charging voltage for the MF battery are different from general type batterie The MF battery should be charged as explained in “CHARGING METHOD”. If the battery is overcharged, the electro- lyte level will drop considerably. There- fore, take special care when charging the battery. + Never use an electrolyte other than speci- fied. The specific gravity of the MF bat- tery electrolyte is 1.32 at 20°C, whereas the specific gravity of a general type bat- tery electrolyte is 1.28. If electrolyte with a specific gravity lower than 1.32 is used, the concentration of sulfuric acid will decrease, resulting in poor battery perfor- mance. If an electrolyte with a specific gravity higher than 1.32 is used, the bat- tery plates will corrode and battery life will be shortened,BATTERY INSPECTION [sy Q Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: * Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye + Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): # SKIN - Flush with water. s EVES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL! + Drink large quantities of water or milk fol- tow with milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries generate explosive hydrogen Always follow the following preventive jes in a well-ventilated area. «Keep batteries away from fire, sparks, or ‘open flames (e.g., welding equipment, lighted cigarettes, etc.) DO NOT SMOKE when charging or han- dling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. 1.Remove: # Side cover (right) Refer to “SIDE COVER, FUEL TANK AND COWLING”. 2.Remove: «Cover ® 3.Disconnect: + Battery leads Disconnect the negative lead @ first, then the positive lead @. 4,Remove: « Batteryue vonage Open ‘Opan-cireult vortage (V1 BATTERY INSPECTION Relationship between open-circuit voltage ‘and charging time at 20°C (83) es 5 6s 10 Charging time (Hours) yoo 75 ~~80 3025200 Condition of charge in battery (%) Lip og mite 5.Cheek: # Battery condition Battery condition checking steps: Connect a digital voltmeter to the battery terminals. Teste Test (+) lead + Battery (+) terminal (4 lead — Battery (-) terminal NOTE: The charge state of an MF battery can be checked by measuring the open circuit volt- age (i.e. when the positive terminal is dis- connected). Open-circuit voltage | Charging time 12.8V or higher a @Check the condition of the battery using the charts. 6.5 hours n of the battery = 20 ~ 30% ‘Charging method of MF batteries CO —— elf it is impossible to set the standard charging current, be careful not to over- charge. When charging the battery, be sure to remove it from the motorcycle. (If charg- ing has to be done with the battery mounted on the motorcycle for some rea- son, be sure to disconnect the wire at the negative terminal.) Never remove the sealing caps of an MF battery. © Take care that the charging clips are in a full contact with the terminal and that they are not shorted. (A corroded clip of the charger may cause the battery to gen- erate heat at the contact area. A weak clip spring may cause sparks.)BATTERY INSPECTION | ADJ « Before removing the clips from the bat- tery terminals, be sure to turn off the power switch of the charger. + The open-circuit voltage variation of the MF battery after charging is shown below. As shown in the figure, the open- circuit voltage stabilizes about 30 min- utes after charging has been completed. Therefore, to check the condition of the battery after charging, wait 30 minutes before measuring the open-circuit volt- age.BATTERY INSPECTION NSE Q Charging method using a variable-current (voltage) type charger Charger NOTE: AMP meter | Measure the open-circuit | \citage should be measured 30 mi voltage prior to charging. | nutes after the machine is stopped aS wore Connect a charger and | set the changing voltage at 16-17 AMP meter to the battery | the setting is lower. charging wrt bo etfent. too highe Be and start charging Sonery wal be ovr cherged) i Make sure the current is YES higher than the standard NO charging current written j on the battery By turing the charging volt- age adjust dial, set the charg- ing voltage at 20 - 25 v. —__—iL_ ‘Adjust the voltage so that Monitor the amperage for 3-5 current is at standard charg-|,%ES___| minutes to check if the stan- ing level. dard charging current is rea~ ched. No Set the timer according ta the If current does charging time suitable for the not evesed:stans open-circuit voltae. ‘dard: ‘charging Refer to "Battery condition rept ane B checking steps” minuees., replace the bat- tery. In cage that charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current, t Measure the battery open-circuit voltage after having left the battery unused for more than 30 minutes. 12.8 v or more --~ Charging is complete. 12.7 v or less --- Recharging is required Under 12.0 v --- Replace the battery. 3-48BATTERY INSPECTION INGE Q Charging method using a constant-voltage type charger ‘NOTE: EE Measure the open-circuit | Voltage should be measured 30° minutes voltage prior to charging, | ster the machise topped a, Connect a charger and AMP meter to the bat- tery, and start charging Make sure the current is YES higher than the standard charging current written on the battery NO ‘Charge the battery until the battery's charging voltage is 15 volts. This type of battery charger cannot charge the MF battery. A variable voltage charger is recommended. NOTE: Set the charging time at 20 hours (rmaamem| Charger Check the open-circuit voltage after having left the battery for 30 minutes after charging. 12.8 v or more---Charging is complete. 12.7 v oF less---Recharging is necessary Under 12 v---Replace the battery. Vote mater | ‘Charging method using a constant current type charger This type of battery charger cannot charge the MF battery.BATTERY INSPECTION/FUSE INSPECTION 6.Inspect: e Battery terminal Dirty > Clean with a wire brush. Poor connection ~+ Correct. Nore: — After cleaning the terminals, grease them light! install: » Battery 8.Connect: « Battery leads Connect the po: ative lead ©. id @ first, then the QInstall: * Side cover (right) Refer to “SIDE COVER, FUEL TANK AND COWLING’. FUSE INSPECTION “CAUTION: © Iways turn off the main switch when checking or replacing the fuse. Otherwise, a short circuit may occur. 1.Remove: ®* Side cover (right) Refer to “SIDE COVER, FUEL TANK AND COWLING”.FUSE INSPECTION 2.Inspect: « Fuses ee eRER REET EMME MMH RRA IEE REE Inspection steps: @Connect the pocket tester to the fuse and check it for continuity. NOTE: Sot the tester selector to "Ox 1”. |S Pocket tester: \F _| 90890-03112 lf the tester indicates ~, replace the fuse. 3.Replace: ¢ Blown fuse Petter ss Replacement steps: @Turn off the ignition. @ install a new fuse of proper amperage. Turn on the switches to verify operation of related electrical devices. elf the fuse immediately blows again, check the electrical circuit. Deseription ‘Quantity Main 30A 1 Head 15A 1 Signal 1 1 1 & WARNING Never use a fuse with a rating other than specified. Never use other materials in place of a fuse. An improper fuse may cause extensive damage to the electrical system, malfunction of lighting and igni- tion and possibly cause a fire. A.install: © Side cover (right) Refer to “SIDE COVER, FUEL TANK AND COWLING”HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT HEADLIGHT BEAM ADJUSTMENT 1.Adjust: « Headlight beam (vertically) Turn the adjuster @ in or out. Turning in > Headlight beam higher. Turning out —> Headlight beam lower. 2.Adjust: 2 Headlight beam (horizontally) Turn the adjuster @ in or out. Turning in Headlight beam to the right. Turning out — Headlight beam to the left. HEADLIGHT BULB REPLACEMENT 1.Disconnect: » Headlight lead © 2.Remove: = Cover @ 3.Unhook: * Bulb holder @ 4.Remove: 2 Bulb® Keep flammable products and your ds away from the bulb while it is on, as it will be hot. Do not touch the bulb until it has cooled down.HEADLIGHT BULB REPLACEMENT/ DIGITAL CLOCK ADJUSTMENT 5.install: = Bulb (new), ‘Secure the new bulb with the bulb holder. ~ CAUTION: Avoid touching part of the bulb. Keep it free from oil; otherwise, the trans- parency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lac quer thinner. 6.Hook: = Bulb holder T.install: «Cover 8.Connect: « Headlight lead DIGITAL CLOCK ADJUSTMENT regardless of the main switch position. 1.Adjust: « Digital clock © Digital clock adjustment steps: @Turn the main switch to “ON”. @The time (hour) setting can be made by pushing or holding the “H” switch @. @The time (minute) setting can be made by pushing or holding the “M” switch @. NOTE: —____ When setting the clock after is power source is cut by a removed battery, etc., first set the time for 1:00 AM, then, go on to set it for the correct time. 9-53 AA ARHAENASRERERENNHERA EE REE EEREencine removat | ENG| gp ENGINE OVERHAUL ENGINE REMOVAL PEG Securely support the motorcycle so there is no danger of it falling over. Nore: —__ It is not necessary to remove the engine in order to remove the following components: « Cylinder head « Piston » Clutch * Oil cooler « Starter motor * AC. generator * Oil pan FUEL TANK AND COWLINGS 1.Remove: «Seat ¢ Fuel tank * Cowling * Side cover Refer to “SIDE COVER, FUEL TANK AND. COWLING” in CHAPTER 3. ENGINE OIL 1.Drain: « Engine oil Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3, BATTERY LEADS 1.Disconnect: © Battery leads Disconnect the negative lead © first and ‘then disconnect the positive lead ©. aENGINE REMOVAL [ enc] AIR FILTER CASE 1.Remove: «Air filter case Refer to “VALVE CLEARANCE ADJUST- MENT” in CHAPTER 3. ALLS. (AIR INDUCTION SYSTEM) 1.Remove: * ALLS. (AIR INDUCTION SYSTEM) Refer to “VALVE CLEARANCE ADJUST- MENT" in CHAPTER 3. CARBURETOR: 1.Remnove: « Carburetor Refer to “CARBURETOR” in CHAPTER 5. « Carburetor joint © HOSES AND LEADS 1.Disconnect: « Spark plug caps © 2.Remove: « Spark plug 3.Disconnect: * Breather hose © + A.C. generator coupler * Pickup coil coupler 4.Remove: « BandsENGINE REMovaL | ENG |%om 5.Remove: « Side stand switch lead @ from the clamp. CLUTCH CABLE 1.Remove: «Clutch cable © FEMORIS DEE SE SEE Here HEE Removal steps: @Loosen the locknut ©. eTurn the adjuster @ enough to free the clutch cable. @Unhook the cable end ®. + Cable stay © SHIFT PEDAL 1.Remove: 2 Bolt D 2.Disconnect: # Shift arm @ ‘STARTER MOTOR ‘1.Disconnect: Starter motor lead 2Remove: « Starter motor ©a ENGINE REMOVAL A.C. GENERATOR 1.Remove: + AC. generator @ EXHAUST PIPE 1.Loosen: * Bolt 2.Remove: * Muffler @ 3.Remove: = Bolt © Nuts « Exhaust pipe @ + Gasket OIL COOLER 1,.Remove: * Oil cooler O When removing the union bolt @, be sure to secure the hexagonal part © to stop it turning 2.Remove: « Oil filter housing @ + Oil pipe @ 4ENGINE REMOVAL DRIVE SHAFT RUBBER BOOT 1.Peel back: « Rubber boot ® ENGINE REMOVAL 1.Place suitable stand under the frame and engine. eae) Securely support the motorcycle 60 there is no danger of it falling over. 2.Remove: « Mounting bolt (front) ® + Engine stay (front) © « Down tube (right) @ + Cross tube (front) @ « Mounting bolt (rear - upper) © + Mounting bolt (rear - lower) © « Engine stay (rear) @ 3.Remove: » Engine assembly (from the right side of the motorcycle) Cover the front fender with a rug to pr vent scratching.ENGINE DISASSEMBLY ENGINE DISASSEMBLY CYLINDER HEAD COVER, CAMSHAFT AND CYLINDER HEAD NOTE: With the engine mounted, the cylinder head cover, camshaft and cylinder head can be maintained by removing the following parts: «Fuel tank + Cowling « Air filter case » Carburetor ALS. assembly « Cylinder head cover NOTE Loosen the bolts in a crisscross pattern 1/4 turn each. Remove them after all are loos- ened. 2.Remove: « Timing plate cover © 3.Align: « “TOC” mark (with stationary pointer) NOTE: « Turn the erankshaft counterclockwise and align the “TDC” mark @ with the align mark © when #1 piston is at TDC on com- pression stroke. +The #1 piston is in compression stroke TDC when the cam lobes are turned away from each other, as shown.ENGINE DISASSEMBLY 4.Loosen: '« Bolts (cam sprockets) D 5.Loosen: « Tensioner bolt © 6.Remove: « Timing chain tensioner @ 7.Remove: # Chain guide (exhaust side) © 8. Remove: « Camshaft caps (intake) + Camshaft caps (exhaust) + Dowel pins NOTE: Remove the camshaft cap bolts in a criss- cross pattern from the outside working inwards. & The bolts (camshaft caps) must be removed evenly to prevent damage to the cylinder head, camshaft or camshaft caps. 9.Remove: « Camshaft (intake @ and exhaust @} NOTE: Attach a wire @ to the timing chain to pre- vent it from falling into the crankcase.ENGINE DISASSEMBLY 10.Remove: + Nuts (cylinder head) a « Loosen the bolts in their proper loosening sequence. « Start by loosening each nut 1/2 turn until allare loose, 11.Remove: Cylinder head ® + Gasket (oylinder head) @ +» Dowel pins @ * O-rings © CYLINDER AND PISTON a With the engine mounted, the cylinder and piston can be maintained by removing the following parts: s Fuel tank * Cowling + Airfilter case « Carburetor + A.LS. assmbly . ooler + Cylinder head 1.Remove: eo Nut ® + WasherRemove: + Cylinder « Gasket (oylinder) © + Dowel pins © the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase cavity. + Put identification marks on each piston head for reference during reinstallation. Before removing the piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and piston pin is still difficult to remove, use the pis- ton pin puller @. [se Piston pin puller: IF _| 90890-01304 Do not use a hammer to drive the piston pin out. 4.Remove: # Oil-vet nozzles © (with O-ring)ENGINE DISASSEMBLY [eNG| PICKUP COIL 1.Remove: « Bolt (timing plate) «Timing plate @ 2Pin@ « Pickup coil base @ CLUTCH en With the engine mounted, the clutch assembly can be maintained by removing the following part: * Clutch cover 1.Remove: + Circlip@ «Washer + Pull lever © » Return spring « Plate washer 2.Remove: ‘* Clutch cable bracket « Clutch cover * Gasket + Dowel pins NOTE: ———_____ Working in @ crisscross pattern, loosen the bolts 1/4 turn each. Remove them after all are loosened. 3.Remove: « Circlip © «Washer ® # Clutch pull lever shaft @ + Gear®ENGINE DISASSEMBLY | ENG — 4.Remove: # Bolts (clutch spring) © Clutch springs @ « Pressure plate @ « Pull rod @ « Washer © * Friction plates © + Clutch plates © + Oil guide plates @ 5.Straighten the lock washer tabs. 6.Loosen: Nut (clutch boss) © ee Loosen the nut (clutch boss) @) while hold- ing the clutch boss @ with the universal clutch holder. GZs] Universal clutch holder: \7_| 90890-04086 7.Remove: * Nut (clutch boss) © « Lock washer @ « Clutch boss @ « Thrust plate @ * Spacer @ + Bearing « Clutch housing © il pump drive sprocket * Collar® « Washer © NOTE: Install a 6 mm screw @ onto the spacer. Then remove the spacer by pulling on the screw. OIL PAN AND OIL PUMP I With the engine mounted, the oil pan, oil fi- ter and oil strainer can be maintained by removing the following part: « Exhaust pipeENGINE DISASSEMBLY [enc] 4m] 1.Remove «Oil level switch © + Oil pan @ « Gasket + Dowel pins NOTE: Loosen the bolts in a crisscross pattern 1/4 turn each. Remove them after all are loos- ened. 2.Remove: + Oil pump assembly @ 3.Disconnect: + Neutral switch lead @ 4,Remove: + Neutral switch @ SHIFT SHAFT. 1.Remove: Shift shaft lever cover ©: + Gasket «Dowel pins 2.Remove: «Covers @ « Gaskets 3.Remove: Shift shaft © + Washer « Shift lever @ * Spring « Stopper lever ® DO ns Release the shift arm @ from the drum pins while pulling out the shift shaft assembly.