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Yamaha BT1100 2002 Service Manual

Other manuals for BT1100 2002: Service Manual

Summary of BT1100 2002

  • Page 1

    Bt1100 service manual 2002 5jn1-ae1.

  • Page 2

    Easb0000 bt1100 2002 service manual © 2001 by belgarda s.P.A. First edition, november 2001 all rights reserved. Any reproduction or unauthorized use without the written permission of belgarda s.P.A. Is expressly prohibited. Printed in italy.

  • Page 3

    Easb0001 notice this manual was produced by the belgarda s.P.A. Primarily for use by yamaha dealers and their quali- fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on yamaha vehicles...

  • Page 4

    Eas00007 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex- planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 the manual is ...

  • Page 5

    Eb003000 illustrated symbols the following symbols are not relevant to every vehicle. Illustrated symbols 1 to 8 are printed on the top right of each page and indicate the subject of each chapter. 1 general information 2 specifications 3 periodic inspections and adjustments 4 engine 5 carburetion 6 ...

  • Page 6: General Information

    General information table of contents gen info 1 specifications spec 2 periodic inspection and adjustments insp adj 3 engine eng 4 carburetion carb 5 chassis chas 6 electrical elec 7 troubleshooting trbl shtg 8 ? E004000

  • Page 8: Gen

    1 gen info.

  • Page 9: Gen

    Gen info chapter 1. General information motorcycle identification ......................................................................................1-1 vehicle identification number..........................................................................1-1 model label ............................

  • Page 10: Gen

    Gen info.

  • Page 11: Gen

    Gen info motorcycle identification 1-1 1 1 eb100010 general information motorcycle identification vehicle identification number the vehicle identification number 1 is stamped into the frame under the seat. Model label the model label 1 is affixed to the frame under the seat. This information will be...

  • Page 12: Gen

    Gen info important information 1-2 eb101000 important information preparation for removal procedures 1. Remove all dirt, mud, dust and foreign materi- al before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to the “special tools” section. 3. When disassembling the machin...

  • Page 13: Gen

    Gen info important information 1-3 eb101030 lock washers/plates and cotter pins 1. Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. Eb101040 bearings and oil seals 1. Install bearing...

  • Page 14: Gen

    Gen info checking of connections 1-4 eb801000 checking of connections check the connectors for stains, rust, moisture, etc. 1. Disconnect: • connector 2. Check: • connector moisture → dry each terminal with an air blower. Stains/rust → connect and disconnect the terminals several times. 3. Check: • ...

  • Page 15: Gen

    Gen info special tools 1-5 eb102001 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may diffe...

  • Page 16: Gen

    Gen info special tools 1-6 tool no. Puller 90890-01362 adapter 90890-04131 flywheel puller/adapter these tools are needed to remove the rotor. Weight 90890-01367 adapter 90890-01374 fork seal driver weight/adapter (Ø 43 mm) these tools are needed when installing the slide metal, oil seal and dust se...

  • Page 17: Gen

    Gen info special tools 1-7 tool no. 90890-04014 valve guide remover & installer this tool is needed to remove and install the valve guide. 90890-04019 valve spring compressor this tool is needed to remove and install the valve assemblies. Adapter 90890-01277 shock puller 90890-01290 weight 90890-012...

  • Page 18: Gen

    Gen info attrezzi speciali 1-8 tool no. 90890-04090 damper spring compressor this tool is needed when removing or installing the damper spring. 90890-06754 dynamic spark tester ignition checker this instrument is necessary for checking the ignition system compo- nents. 90890-85505 yamaha bond no.121...

  • Page 19: Spec

    2 spec.

  • Page 20

    Spec chapter 2. Specifications general specifications ............................................................................................ 2-1 maintenance specifications ....................................................................................2-4 engine ..............................

  • Page 21

    Spec.

  • Page 22

    Spec general specifications 2-1 specifications general specifications item standard model code: bt1100: 5jn1 dimensions: overall length 2,200 mm overall width 800 mm overall height 1,140 mm seat height 812 mm wheelbase 1,530 mm minimum ground clearance 168 mm minimum turning radius 2,980 mm basic we...

  • Page 23

    Spec general specifications 2-2 item standard carburetor: type/quantity bsr37/2 manufacturer mikuni spark plug: type bpr7es/w22epr-u manufacturer ngk/denso spark plug gap 0.7 0.8 mm clutch type: wet, multiple-disc transmission: primary reduction system spur gear primary reduction ratio 78/47 (1.660)...

  • Page 24

    Spec general specifications 2-3 item standard suspension: front suspension telescopic fork rear suspension swingarm (link suspension) shock absorber: front shock absorber coil spring/oil damper rear shock absorber coil spring/gas-oil damper/spring preload adjustable wheel travel: front wheel travel ...

  • Page 25

    Spec maintenance specifications 2-4 maintenance specifications engine item standard limit cylinder head: warp limit ••• 0.03 mm cylinder: bore size 95.00 95.01 mm 95.1 mm measuring point 40 mm ••• camshaft: drive method chain drive (left & right) ••• cam cap inside diameter 25.000 25.021 mm ••• cams...

  • Page 26

    Spec maintenance specifications 2-5 item standard limit timing chain: timing chain type/no. Of links silent chain/98l ••• timing chain adjustment method automatic ••• rocker arm/rocker arm shaft: bearing inside diameter 14.000 mm 14.018 mm 14.036 mm shaft outside diameter 13.985 mm 13.991 mm 13.95 m...

  • Page 27

    Spec maintenance specifications 2-6 item standard limit stem runout limit ••• 0.03 mm valve seat width in 1.2 1.4 mm 2.0 mm ex 1.2 1.4 mm 2.0 mm valve spring: free length in 44.6 mm 43.5 mm ex 44.6 mm 43.5 mm set length (valve closed) in 40 mm ••• ex 40 mm ••• compressed pressure (installed) in 160....

  • Page 28

    Spec maintenance specifications 2-7 item standard limit piston pin bore inside diameter 22.004 22.015 mm 22.045 piston pin outside diameter 21.991 22.000 mm 21.975 piston rings: top ring: type plain ••• dimensions (b x t) 1.5 3.8 mm ••• end gap (installed) 0.3 0.5 mm 0.8 mm side clearance (installed...

  • Page 29

    Spec maintenance specifications 2-8 item standard limit clutch: friction plate thickness 2.9 3.1 mm 2.8 mm quantity 8 ••• clutch plate thickness 2.5 2.7 mm 0.1 mm quantity 1 ••• clutch plate thickness 1.9 2.1 mm 0.1 mm quantity 7 ••• clutch spring free length 7.2 mm 6.5 mm quantity 1 ••• clutch hous...

  • Page 30

    Spec maintenance specifications 2-9 item standard limit lubrication system: oil filter type paper type ••• oil pump type trochoid type ••• tip clearance “a” or “b” 0.03 0.09 mm 0.15 mm side clearance 0.03 0.08 mm 0.15 mm relief valve operating pressure 450 550 kpa (4.5 5.5 kg/cm 2 ) ••• shaft drive:...

  • Page 31

    Spec maintenance specifications 2-10 item standard lubrication chart: needle bearing (starter) connecting rod big end crankshaft main axle drive axle pinin drive middle driveshaft rocker arm (in) camshaft (in) camshaft (ex) rocker arm (in) rocker arm (ex) rocker arm (ex) oil filter oil pump relief v...

  • Page 32

    Spec maintenance specifications 2-11 cylinder head tightening sequence: crankcase tightening sequence: right crankcase left crankcase.

  • Page 33

    Spec maintenance specifications 2-12 tightening torques part thread tightening part to be tightened name size q’ty torque remarks n · m m · kg cylinder head nut m12 8 50 5.0 cylinder head nut m10 2 35 3.5 plate bolt m8 2 20 2.0 cylinder head cover screw m6 4 4 0.4 cylinder head (exhaust pipe) stud b...

  • Page 34

    Spec maintenance specifications 2-13 part thread tightening part to be tightened name size q’ty torque remarks n · m m · kg exhaust pipe strap screw m8 3 18 1.8 silencer fastener to passenger board support screw m10 2 47 4.7 exhaust pipe guard fastener screw m6 2 7 0.7 crankcase (cylinder) stud bolt...

  • Page 35

    Spec maintenance specifications 2-14 item standard limit steering system: steering bearing type angular bearing ••• front suspension: front fork travel 130 mm ••• fork spring free length 363.3 mm ••• fitting length 339.8 mm ••• collar length 150 mm ••• spring rate (k1) 7.0 n/mm (0.71 kg/mm) ••• (k2)...

  • Page 36

    Spec maintenance specifications 2-15 item standard limit front brake: type dual disc ••• disc outside diameter thickness 298 5 mm 4.5 mm disc deflection limit ••• 0.2 mm pad thickness inner 5.5 mm 0.5 mm outer 5.5 mm 0.5 mm master cylinder inside diameter 14.0 mm ••• caliper cylinder inside diameter...

  • Page 37

    Spec maintenance specifications 2-16 tightening part to be tightened thread torque remarks size n · m m · kg headlight assembly/cowling: lower headlight support m6 10 1.0 upper headlight support (right and left) m6 7 0.7 headlight bracket (right and left) m6 10 1.0 plastic cover m5 4 0.4 front flash...

  • Page 38

    Spec maintenance specifications 2-17 tightening part to be tightened thread torque remarks size n · m m · kg rear brake/footrests: brake caliper torque rod m8 25 2.5 rear brake adjuster m6 10 1.0 rear brake pedal fastening screw (special) m8 16 1.6 rear master cylinder fastening screw m6 10 1.0 rear...

  • Page 39

    Spec maintenance specifications 2-18 item standard limit voltage: 12 v ••• ignition system: ignition timing (b.T.D.C.) 10° at 1,000 r/min ••• advancer type digital type ••• t.C.I.: pickup coil resistance/color 189 231 Ω at 20 °c / gray–black ••• t.C.I. Unit model/manufacturer j4t101/mitsubishi ••• i...

  • Page 40

    Spec maintenance specifications 2-19 item standard limit horn: type plane type ••• quantity 1 ••• model/manufacturer k80 l-12v/leb ••• maximum amperage 3 a ••• flasher relay: type semi-transistor ••• model/manufacturer fb222m/nippondenso ••• self cancelling device no ••• flasher frequency 75 95 cycl...

  • Page 41

    Spec general torque specifications/ conversion table 2-20 eb202001 general torque specifications this chart specifies torque for standard fasteners with standard i.S.O. Pitch threads. Torque specifi- cations for special components or assemblies are provided for each chapter of this manual. To avoid ...

  • Page 42

    Spec lubrication points and lubricant types 2-21 eb203000 lubrication points and lubricant types engine lubrication point symbol oil seal lips o-ring bearing connecting rod bolt/nut connecting rod small end and big end crankshaft pin crankshaft journal/big end piston surface piston pin camshaft cam ...

  • Page 43

    Spec lubrication points and lubricant types 2-22 eb203010 chassis lubrication point symbol steering head pipe (upper/lower), bearing steering head pipe, bearing cover lip steering head pipe, oil seal lip front wheel oil seal lip (right/left) rear wheel oil seal lip clutch hub fitting area rear brake...

  • Page 44

    Spec lubrication diagrams 2-23 eb205000 lubrication diagrams 1 rocker arm shaft (intake) 2 rocker arm shaft (exhaust) 3 oil filter 4 oil pump 5 drive axle 6 middle drive shaft.

  • Page 45

    Spec lubrication diagrams 2-24 1 oil pump 2 releaf valve 3 oil filter 4 middle drive shaft.

  • Page 46

    Spec lubrication diagrams 2-25 1 camshaft 2 crankshaft 3 main axle 4 middle drive shaft 5 drive axle 6 connecting rod big end.

  • Page 47

    Spec cable routing 2-26 eb206000 cable routing 1 relays group 2 flasher relay 3 speed sensor 4 sidestand switch 5 fuel drain hose 6 engine earth 7 neutral switch 8 carburetor heater 9 filler tank cap fuel drain pipe 0 filler tank cap fuel drain pipe q fuel hose (carburetor-3 way) w handlebar switch ...

  • Page 48

    Spec cable routing 2-27 o brake cable (front master cylinder) p thermo swicth a rubber cap for front wiring connections s horn d front brake hose (right) f a.I.S. Pipe to the front cylinder g starter motor h starter motor lead j oil level gauge k rear brake hose l brake fluid reservoir hose ; igniti...

  • Page 49

    Spec cable routing 2-28 c spark plug cap (rear cylinder) v a.I.S. Pipe to the rear cylinder b a.I.S. System n throttle position sensor (tps) m ignition coil (front cylinder) , handlebar switch leads (right) . Throttle cables ç check that the wires of the igni- tion coil do not remain tensioned. ∂ fi...

  • Page 50

    Spec cable routing 2-29 / rubber cap for front wiring connections ! Spark plug lead (front) @ throttle cable # depression fuel cock $ battery % fuel hose ^ spark plug lead (rear) & battery positive (+) terminal * fuse box ( battery negative (-) terminal ) igniter unit q fuel filter w fuel pump e fue...

  • Page 51

    Spec.

  • Page 52: Insp

    3 insp adj.

  • Page 53

    Insp adj chapter 3. Periodic inspections and adjustments introduction ..........................................................................................................3-1 periodic maintenance/lubrication intervals ........................................3-1 seat, side covers and fuel tank ....

  • Page 54

    Insp adj electrical system ............................................................................................3-37 checking and charging the battery ..................................................3-37 checking the fuses .......................................................................

  • Page 55

    Insp adj introduction/periodic maintenance/ lubrication intervals 3-1 eb300000 periodic inspections and adjustments introduction this chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more ...

  • Page 56

    Introduction/periodic maintenance/ lubrication intervals 3-2 insp adj odometer reading (x 1,000 km) annual n0. Item check or maintenance job 1 10 20 30 40 check rear shock ✓ ✓ ✓ ✓ 19 * absorber • check operation and shock absorber for oil leakage. Assembly • rear suspension relay arm and • check ope...

  • Page 57

    Insp adj seat, side covers and fuel tank 3-3 seat, side covers and fuel tank order job name/part name q’ty remarks seat, side covers and fuel tank remove the parts in the order below. Removal 1 seat 1 2 side cover 2 3 panel 2 4 fuel overflow pipe 2 5 fuel hose 1 6 fuel hose 1 7 fuel meter sender uni...

  • Page 58

    Adjusting the valve clearance 3-4 insp adj easb0045 engine adjusting the valve clearance the following procedure applies to all of the valves. Note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston...

  • Page 59

    Insp adj adjusting the valve clearance 3-5 7. Remove: • camshaft sprocket cover (rear cylinder) 1 • camshaft sprocket cover (front cylinder) 8. Remove: • timing plug 1 • straight plug 2 9. Measure: • valve clearance out of specification → adjust. Valve clearance (cold): intake valve: 0.07 ~ 0.12 mm ...

  • Page 60

    Adjusting the valve clearance 3-6 insp adj d. Measure the valve clearance with a thickness gauge 1 . E. Turn the crankshaft crockwise 290° and then measure the front cylinder. 10. Adjust: • valve clearance a. Loosen the locknut 1 . B. Insert a thickness gauge between the end of the adjusting screw a...

  • Page 61

    Insp adj synchronizing the carburetors 3-7 easb0002 synchronizing the carburetors note: prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Start the engine and let it warm up for several mi...

  • Page 62

    Synchronizing the carburetors 3-8 insp adj 9. Check: • engine idling speed out of specification → adjust. Refer to "adjusting the engine idling speed". 10. Adjust: • carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction unti...

  • Page 63

    Insp adj adjusting the engine idling speed 3-9 eas00054 adjusting the engine idling speed note: prior to adjusting the engine idling speed, the car- buretor synchronization should be adjusted prop- erly, the air filter should be clean, and the engine should have adequate compression. 1. Start the en...

  • Page 64

    Adjusting the throttle cable free play 3-10 insp adj 1 2 a b easb0003 adjusting the throttle cable free play note: prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: • throttle cable free play a out of specification → adjust. 2. Remove: • carbureto...

  • Page 65

    Insp adj adjusting the throttle cable free play/ checking the spark plugs 3-11 easb0004 checking the spark plugs the following procedure applies to all of the spark plugs. 1. Remove: • cylinder head covers 1 2. Disconnect: • spark plug caps 2 3. Remove: • spark plugs before removing the spark plugs,...

  • Page 66

    Checking the spark plugs/ checking the ignition timing 3-12 insp adj eas00064 checking the ignition timing note: prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion. 1. Remove: • timing plug...

  • Page 67

    Insp adj measuring the compression pressure 3-13 eas00065 measuring the compression pres- sure the following procedure applies to all of the cylin- ders. Note: insufficient compression pressure will result in a loss of performance. 1. Check: • valve clearance out of specification → adjust. Refer to ...

  • Page 68

    Measuring the compression pressure 3-14 insp adj a. Turn the main switch to "on". B. With the throttle wide open, crank the engine until the reading on the compression gauge stabilized. Warning to prevent sparking, ground all spark plug leads before cranking the engine. Note: the difference in compr...

  • Page 69

    Insp adj checking the engine oil level 3-15 eas00069 checking the engine oil level 1. Stand the motorcycle on a level surface. Note: • place the motorcycle on a suitable stand. • make sure that the motorcycle is upright. 2. Let the engine idle for a few minutes. 3. Check: • engine oil level • the en...

  • Page 70

    Changing the engine oil 3-16 insp adj easb0005 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • engine oil filler cap 1 • o-ring • engine oil drain bolt 2 • gasket 4. Drain: • engin...

  • Page 71

    Insp adj changing the engine oil/ adjusting the clutch cable free play 3-17 quantity total amount: 3.6 l without oil filter element replacement: 3.0 l with oil filter element replacement: 3.1 l 9. Install: • o-ring • engine oil filter cap 10. Start the engine, warm it up for several min- utes, and t...

  • Page 72

    Adjusting the clutch cable free play/ cleaning the air filter element 3-18 insp adj 4. Adjust: • clutch mechanism engine side a. Loosen the locknut 1 . B. Turn in the adjusting screw 2 until it is lightly seated. C. Turn the adjusting screw out 1/4 of a turn. D. Tighten the locknut. E. Check the clu...

  • Page 73

    Insp adj cleaning the air filter element/ checking the carburetor joint and intake manifold 3-19 5. Clean: • air filter element apply compressed air to the outer surface of the air filter element. 6. Check: • air filter element damage → replace. 7. Install: • air filter element • air filter case cov...

  • Page 74

    Checking the breather hose/ checking the exhaust system 3-20 insp adj eas00098 checking the breather hose 1. Remove: • cylinder head cover 2. Check: • cylinder head breather hose 1 cracks/damage → replace. Loose connection → connect properly. Make sure that the cylinder head breather hose is routed ...

  • Page 75

    Insp adj 3-21 adjusting the front brake 1 2 3 4 1 2 a eb304001 chassis adjusting the front brake 1. Adjust: • brake lever position (distance a between the brake lever and the handlebar grip) a. Turn the adjusting dial 1 while holding the lever pushed away from the handlebar grip note: align the sett...

  • Page 76

    Adjusting the rear brake 3-22 insp adj easb0008 adjusting the rear brake 1. Check: • brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) out of specification → adjust. 2. Adjust: • brake pedal position a. Loosen the bolt 1 of the adjusting dial 2 . B. T...

  • Page 77

    Insp adj checking the brake fluid level 3-23 eas00115 checking the brake fluid level 1. Stand the motorcycle on a level surface. Note: • place the motorcycle on a suitable stand. • make sure that the motorcycle is upright. 2. Check: • brake fluid level below the minimum level mark a → add the recomm...

  • Page 78

    Checking the brake hoses/ bleeding the hydraulic brake system 3-24 insp adj eas00131 checking the brake hoses the following procedure applies to all of the brake hoses and clamps. 1. Check: • brake hose cracks/damage/wear → replace. 2. Check: • brake hose clamp loose connection → tighten. 3. Hold th...

  • Page 79

    Insp adj bleeding the hydraulic brake system 3-25 1. Stand the motorcycle on a level surface. Note: • place the motorcycle on a suitable stand. • make sure that the motorcycle is upright. 2. Bleed: • hydraulic brake system a. Add the recommended brake fluid to the prop- er level. B. Install the diap...

  • Page 80

    Adjusting the shift pedal/ checking the final drive oil level 3-26 insp adj easb0009 adjusting the shift pedal 1. Check: • shift pedal position (distance a from the top of the rider footrest to the top of the shift pedal) out of specification → adjust. 2. Adjust: • shift pedal position a. Loosen bot...

  • Page 81

    Insp adj checking the final drive oil level/ changing the final drive oil 3-27 4. Install: • final drive housing oil filler bolt eas00145 changing the final drive oil 1. Place a container under the final drive hous- ing. 2. Remove: • final drive housing oil filler bolt 1 • final drive housing oil dr...

  • Page 82

    Checking and adjusting the steering head 3-28 insp adj easb0010 checking and adjusting the steering head 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. Note: place the motorcycle on a suitable stand so that the front...

  • Page 83

    Insp adj checking and adjusting the steering head 3-29 note: set the torque wrench at a right angle to the ring nut wrench 5 . C. Loosen the lower ring nut 4 completely, then tighten it to specification. Warning do not overtighten the lower ring nut. D. Check the steering head for looseness or bindi...

  • Page 84

    Checking and adjusting the steering head/ checking the front fork 3-30 insp adj 12. Install: • handle 13. Install: • upper handle holder refer to “installing the handlebar” in chapter 6. 14. Connect: • main switch coupler 15. Install: • meter assy eas00149 checking the front fork 1. Stand the motorc...

  • Page 85

    Insp adj adjusting the front fork 3-31 eas00155 adjusting the front fork the following procedure applies to both of the fork legs. Warning • always adjust both fork legs equally, other- wise poor handling and loss of stability may result. • securely support the motorcycle so that there is no danger ...

  • Page 86

    Adjusting the rear shock absorber assembly 3-32 insp adj easb0011 adjusting the rear shock absorber assembly warning securely support the motorcycle so that there is no danger of it falling over. Spring preload never go beyond the maximum or minimum adjustment positions. 1. Adjust: • spring preload ...

  • Page 87

    Insp adj checking the tires 3-33 eas00162 checking the tires the following procedure applies to both of the tires. 1. Measure: • tire pressure out of specification → regulate. Warning • the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperatur...

  • Page 88

    Checking the tires 3-34 insp adj 2. Check: • tire surfaces damage/wear → replace the tire. 1 tire tread depth 2 side wall 3 wear indicator warning • do not use a tubeless tire on a wheel designed only for tube tires to avoid tire fail- ure and personal injury from sudden defla- tion. • when using a ...

  • Page 89

    Insp adj checking the tires/checking the wheels 3-35 front tire (tubeless) rear tire (tubeless) warning new tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high- speed riding is don...

  • Page 90

    Checking and lubricating the cables/lubricating the levers and pedals/lubricating the sidestand 3-36 insp adj eas00170 checking and lubricating the cables the following procedure applies to all of the cable sheaths and cables. Warning damaged cable sheaths may causes the cable to corrode and interfe...

  • Page 91

    Insp adj checking and charging the battery 3-37 eb305020 electrical system checking and charging the battery warning batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • ...

  • Page 92

    Checking and charging the battery 3-38 insp adj note: since mf batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by meas- uring the voltage at the battery term...

  • Page 93

    Insp adj checking and charging the battery 3-39 open-circuit voltage (v) warning do not quick charge a battery. • make sure that the battery breather hose and battery vent are free of obstructions. • never remove the mf battery sealing caps. • do not use a high-rate battery charger. They force a hig...

  • Page 94

    Checking and charging the battery 3-40 insp adj charging method using a variable-current (voltage) type charger charger note: voltage should be measured 30 minutes after the machine is stopped. Note: set the charging voltage at 16 ~ 17 v (if the setting is lower, charging will be insufficient. If to...

  • Page 95

    Insp adj checking and charging the battery 3-41 charging method using a constant-voltage type charger measure the open-circuit voltage prior to charging. Connect a charger and amp meter to the battery and start charging. Make sure the current is higher than the standard charging current written on t...

  • Page 96

    Checking and charging the battery 3-42 insp adj 6. Check: • battery breather hose obstruction → clean. 7. Connect: • battery leads (to the battery terminals) first, connect the positive lead 1, then the negative lead 2. 8. Check: • battery terminals dirt → clean with a wire brush. Loose connection →...

  • Page 97

    Insp adj checking the fuses 3-43 eas00181 checking the fuses the following procedure applies to all of the fuses. To avoid a short circuit, always turn the main switch to "off" when checking or replacing a fuse. 1. Remove: • seat • storage compartment 1 2. Check: • fuse caution: a. Connect the pocke...

  • Page 98

    Checking the fuses/ replacing the headlight bulb 3-44 insp adj warning never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical sys- tem, cause the lighting and ignition systems to malf...

  • Page 99

    Insp adj replacing the headlight bulb 3-45 avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affect- ed. If the headlight bulb gets soiled, thorough- ly clean it with a c...

  • Page 100

    Adjusting the headlight beam 3-46 insp adj 1 a b easb0013 adjusting the headlight beam 1. Adjust: • headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b . ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ direction a → headlight beam is raised. Direction b → headligh...

  • Page 101: Eng

    4 eng.

  • Page 102

    Eng chapter 4. Engine engine removal ....................................................................................................4-1 seat, storage compartment, side covers, fuel tank, air filter case assembly, carburetor assembly and exhaust system ..............................................

  • Page 103

    Eng clucth ....................................................................................................................4-38 right crankcase cover ............................................................................4-38 clutch assembly.....................................................

  • Page 104

    Eng transmission ........................................................................................................4-68 checking the shift forks ........................................................................4-69 checking the shift drum assembly ..........................................

  • Page 105

    Eng.

  • Page 106

    Eng engine removal 4-1 engine engine removal seat, storage compartment, side covers, fuel tank, air filter case assembly, carburetor assembly and exhaust system order job name/part name q’ty remarks removing the seat, storage remove the parts in the order listed. Compartment, side covers, fuel tank,...

  • Page 107

    Engine removal 4-2 eng order job name/part name q’ty remarks 2 battery leads 2 disconnect side covers fuel tank air filter case assembly carburetor assembly 3 a.I.S. System cover 1 4 a.I.S. System 1 5 muffler assembly 2 6 exhaust pipes 2 for installation, reverse the removal procedure. Refer to "sea...

  • Page 108

    Eng engine removal 4-3 leads, shift pedal and clutch cable order job name/part name q’ty remarks removing the leads, shift pedal and remove the parts in the order listed. Clutch cable 1 ac magneto lead/pickup lead/ 1/1/1/1 disconnect side stand switch lead/ speed sensor lead/ neutral switch lead 2 s...

  • Page 109

    Engine removal 4-4 eng engine mounting bolts order job name/part name q’ty remarks engine mounting bolt removal remove the parts in the order below. Place a suitable stand under the frame and engine. Lift the front fork upper bracket. 1 engine ground lead connector 1 disconnect 2 main footrest brack...

  • Page 110

    Eng engine 4-5 easb0014 installing the engine 1. Tighten the bolts in the following order: 2. Install: • shift arm 1 note: • align the punch mark in the shift shaft with the slot 2 in the shift arm • install the shift rod joint pin in the shift pedal. Refer to "adjusting the shift pedal" in chapter ...

  • Page 111

    Cylinder heads 4-6 eng cylinder heads rear cylinder head order job name/part name q’ty remarks cylinder head removal remove the parts in the order listed. Engine assembly refer to "engine removal". 1 tappet cover (exhaust)/o-ring 1/1 2 tappet cover (intake)/o-ring 1/1 3 exhaust pipe joint/gasket 1/1...

  • Page 112

    Eng cylinder heads 4-7 order job name/part name q’ty remarks 8 timing chain tensioner/gasket 1/1 refer to "removing/installing the 9 camshaft sprocket 1 cylinder heads". 10 cylinder head 1 11 dowel pins 2 refer to "installing the cylinder 12 cylinder head gasket 1 heads". For installation, reverse t...

  • Page 113

    Order job name/part name q’ty remarks cylinder head removal remove the parts in the order listed. Engine assembly refer to "engine removal". Oil delivery pipes refer to "rear cylinder head". Right crankcase cover refer to "clutch". 1 tappet cover (exhaust)/o-ring 1/1 2 tappet cover (intake)/o-ring 1...

  • Page 114

    Eng cylinder heads 4-9 10 nm (1.0 m•kg) 10 nm (1.0 m•kg) 50 nm (5.0 m•kg) 35 nm (3.5 m•kg) 20 nm (2.0 m•kg) 55 nm (5.5 m•kg) 10 nm (1.0 m•kg) 10 nm (1.0 m•kg) order job name/part name q’ty remarks 7 timing chain tensioner/gasket 1/1 8 camshaft sprocket plate 1 refer to "removing/installing the 9 cam...

  • Page 115

    Cylinder heads 4-10 eng eas00226 removing the cylinder heads rear cylinder head 1. Remove: • camshaft sprocket cover • tappet covers 2. Align: • "t" mark a (with the stationary pointer b ) a. Temporarily install the left crankcase cover without the pickup coil and stator coil. B. Turn the crankshaft...

  • Page 116

    Eng cylinder heads 4-11 4. Remove: • timing chain tensioner • gasket 5. Remove: • bolt (camshaft sprocket) 1 • camshaft sprocket 2 note: to prevent the timing chain from falling into the crankcase fasten a wire to it. 6. Remove: • cylinder head note: • loosen the bolts and nuts in the proper sequenc...

  • Page 117

    Cylinder heads 4-12 eng eas00228 checking the cylinder heads the following procedure applies to all of the cylin- der heads. 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) note: do not use a sharp instrument to avoid damaging or scratching: • spark plug threads • valve s...

  • Page 118

    Eng cylinder heads 4-13 eb401430 checking the timing chain tensioner 1. Check: • timing chain tensioner cracks/damage/rough movement → replace. A. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. Note: while pressing the timing chain tensioner rod, wind i...

  • Page 119

    Cylinder heads 4-14 eng 3. Install: • camshaft sprocket a. Temporarily install the rotor nut and left crankcase cover without the pickup coil and stator coil. B. Turn the crankshaft clockwise. C. Align the "t" mark a with the stationary point- er b on the crankcase cover (left). D. Install the camsh...

  • Page 120

    Eng cylinder heads 4-15 d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and tight- en the cap bolt to the specified torque. 5. Install: • bolt (camshaft sprocket) 1 note: • be sure the projection on the camshaft sprock- et plate is aligned with the hole in the spro...

  • Page 121

    Rocker arms and camshaft 4-16 eng rocker arms and camshaft order job name/part name q’ty remarks removing the rocker arm and remove the parts in the order listed. Camshaft cylinder heads refer to "cylinder head". 1 stopper plate 1 2 camshaft bushing 1 refer to "removing/installing the 3 camshaft/dow...

  • Page 122

    Eng rocker arms and camshaft 4-17 eas00202 removing the rocker arms and camshaft 1. Remove: • rocker arm shafts (intake and exhaust) 1 • rocker arms 2 note: use a slide hammer 3 and weight 4 to remove the rocker arm shafts. 2. Remove: • camshaft bushing 1 • camshaft 2 note: screw a 10 mm bolt 3 into...

  • Page 123

    Rocker arms and camshafts 4-18 eng eb401410 checking the rocker arms and rock- er arm shafts the following procedure applies to all of the rock- er arms and rocker arm shafts. 1. Check: • rocker arm damage/wear → replace. • rocker arm lobe 1 • valve adjuster 2 excessive wear → replace. 2. Check: • r...

  • Page 124

    Eng rocker arms and camshafts 4-19 eas00220 installing the camshaft and rocker arms 1. Lubricate: • camshaft 2. Install: • camshaft 1 • camshaft bushing 2 note: • the dowel pin a on the end of the camshaft must align with the timing mark b on the cylin- der head. • make sure that the n o .1 camshaft...

  • Page 125

    Rocker arms and camshafts 4-20 eng 5. Install: • rocker arms • rocker arm shafts note: make sure that the rocker arm shafts is completely pushed into the cylinder head..

  • Page 126

    Eng valves and valve springs 4-21 valves and valve springs order job name/part name q’ty remarks removing the valves and valve remove the parts in the order listed. Springs cylinder heads refer to "cylinder heads". Rocker arms and camshafts refer to "rocker arms and cam- shaft". 1 valve cotters 4 re...

  • Page 127

    Valve and valve springs 4-22 eng eas00237 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Check: • va...

  • Page 128

    Eng valve and valve springs 4-23 out of specification → replace the valve guide. 2. Replace: • valve guide note: to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °k) in an oven. A. Remove the valve guide with a valve guide remover 1...

  • Page 129

    Valve and valve springs 4-24 eng 5. Measure: • valve margin thickness a out of specification → replace the valve. 6. Measure: • valve stem runout out of specification → replace the valve. Note: • when installing a new valve, always replace the valve guide. • if the valve is removed or replaced, alwa...

  • Page 130

    Eng valve and valve springs 4-25 4. Lap: • valve face • valve seat note: after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. A. Apply a coarse lapping compound to the valve face. Do not let the lapping compound enter the gap betwe...

  • Page 131

    Valve and valve springs 4-26 eng eas00241 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a out of specification → replace the valve spring. 2. Measure: • compressed spring force a out of specification → replace the valve...

  • Page 132

    Eng valve and valve springs 4-27 note: install the valve spring with the larger pitch a fac- ing up. B smaller pitch 4. Install: • valve cotters note: install the valve cotters by compressing the valve spring with the valve spring compressor 1 . 5. To secure the valve cotters onto the valve stem, li...

  • Page 133

    Cylinders and pistons 4-28 eng cylinders and pistons order job name/part name q’ty remarks removing the cylinders and pistons remove the parts in the order listed. Cylinder heads refer to "cylinder heads". 1 timing chain guide 1 the "5el" mark should face towards the cylinder head. 2 cylinder 1 refe...

  • Page 134

    Eng cylinders and pistons 4-29 eas00254 removing the pistons the following procedure applies to all of the pis- tons. 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 do not use a hammer to drive the piston pin out. Note: • before removing the piston pin clip, cover the crankcase opening wit...

  • Page 135

    Cylinder and pistons 4-30 eng 2. Measure: • piston-to-cylinder clearance a. Measure cylinder bore "c" with the cylinder bore gauge. A 40 mm from the top of the cylinder note: measure cylinder bore "c" by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of th...

  • Page 136

    Eng cylinder and pistons 4-31 eb404410 checking the piston rings 1. Measure: • piston ring side clearance out of specification → replace the piston and piston rings as a set. Note: before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston ...

  • Page 137

    Cylinders and pistons 4-32 eng eas00266 checking the piston pins the following procedure applies to all of the piston pins. 1. Check: • piston pin blue discoloration/grooves → replace, then inspect the lubrication system. 2. Measure: • piston pin outside diameter a out of specification → replace the...

  • Page 138

    Eng cylinders and pistons 4-33 2. Install: • piston 1 • piston pin 2 • piston pin clip (new) 3 note: • apply engine oil onto the piston pin. • make sure that the "ex" mark a on the piston faces towards the exhaust side of the engine. • before installing the piston pin clip, cover the crankcase openi...

  • Page 139

    Timing gears 4-34 eng timing gears order job name/part name q’ty remarks removing the timing gears remove the parts in the order listed. Cylinder heads refer to "cylinder head". Cylinders refer to "cylinders and pistons". Clutch assembly refer to "clutch". 1 primary drive gear nut 1 2 timing drive g...

  • Page 140

    Eng timing gears 4-35 removing the timing drive gear front cylinder 1. Straighten the lock washer tab. 2. Remove: • primary drive gear nut 1 note: while holding the generator rotor with the sheave holder, loosen the primary drive gear nut. 3. Remove: • timing drive gear 2 • dowel pins • springs note...

  • Page 141

    Timing gears 4-36 eng eas00292 checking the primary drive 1. Check: • primary drive gear • primary driven gear damage/wear → replace the primary drive and primary driven gears as a set. Excessive noise during operation → replace the primary drive and primary driven gears as a set. 2. Check: • primar...

  • Page 142

    Eng timing gears 4-37 front cylinder 1. Install: (front cylinder) • springs 1 • dowel pins • timing drive gear 2 note: • insert the suitable pin 3 into the hole of timing chain drive gear sprocket and match the gear teeth. • push the projections a on the timing drive gear into the spaces b . • align...

  • Page 143

    Clutch 4-38 eng clutch right crankcase cover order job name/part name q’ty remarks removing the right clutch cover remove the parts in the order listed. Stand the motorcycle on a level surface. Engine oil refer to "engine oil replacement" in chapter 3. 1 oil filter cover plate 1 2 oil filter cover 1...

  • Page 144

    Eng clutch 4-39 order job name/part name q’ty remarks 6 dowel pins 2 7 crankcase cover gasket 1 for installation, reverse the removal procedure..

  • Page 145

    Clutch 4-40 eng clutch assembly order job name/part name q’ty remarks removing the clutch remove the parts in the order listed. 1 clutch spring bolts 6 2 clutch spring plate 1 3 clutch spring 1 4 clutch spring seat 1 refer to "installing the clutch". 5 clutch pressure plate 1 6 bearing/shart clutch ...

  • Page 146

    Eng clutch 4-41 70 nm (7.0 m•kg) 8 nm (0.8 m•kg) order job name/part name q’ty remarks 15 thrust washer 1 16 clutch housing 1 17 long clutch push rod 1 for installation, reverse the removal procedure..

  • Page 147

    Clutch 4-42 eng eas00278 removing the clutch 1. Straighten the lock washer tab. 2. Loosen: • clutch boss nut 1 note: while holding the clutch boss 2 with the clutch holding tool 3 , loosen the clutch boss nut. 3. Remove: • clutch boss nut 1 • lock washer 2 • clutch boss 3 note: there is a built-in d...

  • Page 148

    Eng clutch 4-43 eas00286 checking the pressure plate 1. Check: • pressure plate cracks/damage → replace. • bearing damage/wear → replace. Eas00285 checking the clutch boss 1. Check: • clutch boss splines damage/pitting/wear → replace the clutch boss. Note: pitting on the clutch boss splines will cau...

  • Page 149

    Clutch 4-44 eng eas00281 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge 1 ) out of specification → replace the c...

  • Page 150

    Eng clutch 4-45 eas00295 installing the clutch 1. Install: • clutch housing 1 note: if the wire circlip 2 has been removed, carefully install a new one as shown. 2. Tighten: • lock washer • clutch boss nut 1 note: while holding the clutch boss with the clutch hold- ing tool 2 , tighten the clutch bo...

  • Page 151

    Clutch 4-46 eng note: make sure that the semicircular slot a in the fric- tion plate is aligned with the mark b on the clutch housing. 7. Install: • clutch pressure plate • clutch spring plate seat • clutch spring 1 • clutch spring plate 2 • clutch spring bolts 3 note: tighten the clutch spring bolt...

  • Page 152

    Eng generator and starter clutch 4-47 generator and starter clutch stator coil and pickup coil order job name/part name q’ty remarks removing the startor coil remove the parts in the order listed. Engine oil refer to "engine oil replacement" in chapter 3. Left side cover ac magneto lead/pickup lead/...

  • Page 153

    Generator and starter clutch 4-48 eng generator and starter clutch order job name/part name q’ty remarks removing the generator and starter remove the parts in the order listed. Clutch 1 rotor 1 2 dowel pins 6 refer to "removing/installing the 3 springs 6 generator". 4 woodruff key 1 5 shaft 1 6 sta...

  • Page 154

    Eng generator and starter clutch 4-49 eas00347 removing the generator 1. Remove: • camshaft sprocket cover • tappet covers refer to "rear cylinder head". 2. Align: • "t" mark a (with the stationary pointer b ) a. Temporarily install the ac magneto cover without the pickup coil and stator coil. B. Tu...

  • Page 155

    Generator and starter clutch 4-50 eng note: • remove the rotor by pushing back the rotor, the flywheel puller 2 and the adapter 3 . • install the flywheel puller bolts and tighten the center bolt, making sure that the tool body stays parallel to the rotor. If necessary, one holding bolt may be backe...

  • Page 156

    Eng generator and starter clutch 4-51 installing the generator 1. Install: • starter clutch assembly note: align the hole a on the starter clutch housing with the hole b on the rotor. 2. Install: • timing drive gear 1 • springs 2 • dowel pins 3 note: • align the punch mark a on the timing drive gear...

  • Page 157

    Generator and starter clutch 4-52 eng 4. Check: • tdc on the compression stroke if the marks do not align → adjust. A. Align the "t" mark a with the stationary point- er b on the left crankcase cover. B. When the "t" mark is aligned with the station- ary pointer, the punch mark c on the camshaft spr...

  • Page 158

    Eng shift shaft 4-53 shift shaft order job name/part name q’ty remarks removing the shift shaft and stopper remove the parts in the order listed. Lever engine oil refer to "engine oil replacement" in chapter 3. Left crankcase cover refer to "generator and starter rotor assembly clutch". 1 shift shaf...

  • Page 159

    Shift shaft 4-54 eng eas00328 checking the shift shaft 1. Check: • shift shaft 1 • shift lever 2 bends/damage/wear → replace. • shift lever spring 3 damage/wear → replace. Eb408410 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper...

  • Page 160

    Eng oil pump 4-55 oil pump order job name/part name q’ty remarks removing the oil pump remove the parts in the order listed. Rotor assembly refer to "generator and starter clutch". Crankcase cover (right) refer to " clutch". 1 driven gear cover 1 2 driven gear (oil pump)/ 1/1 oil pump drive chain 3 ...

  • Page 161

    Oil pump 4-56 eng order job name/part name q’ty remarks disassembling the oil pump disassembly the parts in the order listed. 1 oil pump cover 1 2 oil pump body 1 3 oil pump rotor (inner) 1 4 oil pump rotor (outer) 1 refer to "assembling the oil pump". 5 pin 1 6 oil pump body 1 7 oil pump rotor (inn...

  • Page 162

    Eng oil pump 4-57 eas00364 checking the oil pump 1. Check: • oil pump driven gear • oil pump body • oil pump driven gear cover cracks/damage/wear → replace the defec- tive part(-s). 2. Measure • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-body-side clearance b • oil-pump-bod...

  • Page 163

    Oil pump 4-58 eng eas00376 assembling the oil pump 1. Assemble: • oil pump after tightening the bolts, make sure that the oil pump turns smoothly. Note: align the pin a with the slots b on the inner rotor. Caution: 10 nm (1.0 m•kg).

  • Page 164

    Eng crankshaft and connecting rods 4-59 crankshaft and connecting rods crankcase order job name/part name q’ty remarks removing the crankshaft assembly remove the parts in the order listed. Engine assembly refer to "engine removal". Cylinder head refer to "cylinder heads". Cylinder and piston refer ...

  • Page 165

    Crankshaft and connecting rods 4-60 eng order job name/part name q’ty remarks removing the crankshaft and remove the parts in the order listed. Connecting rod 1 crankshaft assembly 1 refer to "removing/installing the crankshaft". 2 oil pump drive sprocket 1 3 bearing 1 4 nuts (connecting rod caps) 4...

  • Page 166

    Eng crankshaft and connecting rods 4-61 eas00386 disassembling the crankcase 1. Remove: • crankcase bolts note: • loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numerical order ...

  • Page 167

    Crankshaft and connecting rods 4-62 eng eb412111 removing the crankshaft 1. Remove: • crankshaft assembly 1 note: • remove the crankshaft assembly with the crankcase separating tool 2 . • make sure that the crankcase separating tool is centered over the crankshaft assembly. Eb412121 removing the con...

  • Page 168

    Eng crankshaft and connecting rods 4-63 do not interchange the big end bearings and connecting rods. To obtain the correct crank- shaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions. A. Clean the big end bearings, crank...

  • Page 169

    Crankshaft and connecting rods 4-64 eng refer to "installing the connecting rods". F. Remove the connecting rod and big end bear- ings. Refer to "removing the connecting rods". G. Measure the compressed plastigauge ® width 1 on each crankshaft pin. If the clearance is out of specification, select re...

  • Page 170

    Eng crankshaft and connecting rods 4-65 eb412440 checking the bearings and oil seals 1. Check: • bearings clean and lubricate the bearings, then rotate the inner race with your finger rough movement → replace. 2. Check: • oil seals damage/wear → replace. Installing the crankshaft 1. Install: • conne...

  • Page 171

    Crankshaft and connecting rods 4-66 eng • when tightening the nuts be sure to use an f-type torque wrench. • without pausing tighten to full torque speci- fication. Apply continuous torque between 4.3 and 4.8 m•kg. Once you reach 4.3 m•kg do not stop tightening until final torque is reached. If the ...

  • Page 172

    Eng crankshaft and connecting rods 4-67 2. Tighten: • crankcase bolts (follow the proper tightening sequence) note: the numbers embossed on the crankcase indi- cate the crankcase tightening sequence. 4 6 (m10) 1 3 , 7 o (m6) note: • lubricate the bolt threads with engine oil. • tighten the bolts in ...

  • Page 173

    Transmission 4-68 eng transmission order job name/part name q’ty remarks transmission removal remove the parts in the order listed. Crankcase separation refer to "crankshaft". 1 guide bar 1 2 shift fork 1 “r” 1 3 shift fork 2 “c” 1 4 shift fork 3 “l” 1 refer to "installing the 5 shift drum 1 transmi...

  • Page 174

    Eng transmission 4-69 eas00421 checking the shift forks the following procedure applies to all of the shift forks and related components. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 bends/damage/scoring/wear → replace the shift fork. 2. Check: • shift fork guide bar roll the shift fork...

  • Page 175

    Transmission 4-70 eng eas00424 checking the transmission 1. Measure: • main axle runout (with a centering device and dial gauge) out of specification → replace the main axle. 2. Measure: • drive axle runout (with a centering device and dial gauge) out of specification → replace the drive axle. 3. Ch...

  • Page 176

    Eng transmission 4-71 eas00430 installing the transmission 1. Install: • shift drum assembly note: turn the shift drum assembly to the neutral posi- tion. 2. Install: • main axle assembly 1 • drive axle assembly 2 • shift fork “l” 3 • shift fork “c” 4 • shift fork “r” 5 • shift fork guide bars 6 not...

  • Page 177

    Middle gear 4-72 eng middle gear middle drive pinion gear order job name/part name q’ty remarks removing the middle drive pinion remove the parts in the order listed. Gear separate the crankcase refer to "crankshaft and connecting rod". 1 bearing retainer 1 refer to "removing the middle drive shaft ...

  • Page 178

    Eng middle gear 4-73 middle drive pinion gear order job name/part name q’ty remarks removing the middle driven pinion remove the parts in the order listed. Gear 1 bolts 3 refer to “removing the middle 2 circlips 2 driven shaft assembly/ 3 bearings 2 installing the universal joint”. 4 driven yoke 1 5...

  • Page 179

    Middle gear 4-74 eng order job name/part name q’ty remarks 10 collapsible collar 1 refer to "installing the middle 11 middle driven shaft 1 gear assembly and adjusting the backlash". 12 oil seal 1 refer to "assembling the middle 13 bearing 1 driven shaft assembly". 14 bearing for installation, rever...

  • Page 180

    Eng middle gear 4-75 removing the middle drive shaft assembly 1. Remove: • bearing retainer • middle drive shaft assembly a. Straighten the thread on the bearing retainer. B. Attach the bearing retainer wrench 1 . C. Remove the bearing retainer and middle drive shaft assembly. Disassembling the midd...

  • Page 181

    Middle gear 4-76 eng removing the middle driven shaft assembly 1. Remove: • universal joint a. Remove the circlips 1 . B. Place the universal joint in a press. C. With a pipe of the proper diameter positioned beneath the universal joint driven yoke as shown, press the bearing into the pipe. Note: it...

  • Page 182

    Eng middle gear 4-77 3. Check: • o-ring • oil seal damage → replace the defective part(-s). 4. Check: • universal joint movement rough movement → replace the universal joint. Eas00441 assembling the middle drive shaft assembly 1. Tighten: • middle drive shaft nut 1 note: • set the torque wrench at a...

  • Page 183

    Middle gear 4-78 eng assembling the middle driven shaft assembly note: the following points are critical when assembling the middle gears: • the collapsible collar must be replaced when- ever the middle driven shaft assembly is removed from the middle driven shaft bearing housing. • when performing ...

  • Page 184

    Eng middle gear 4-79 2. Install: • shim • middle drive shaft assembly 3. Install: • bearing retainer install steps: • attach the bearing retainer wrench 1 • tighten the bearing retainer. • lock the threads on the bearing retainer by staking them with a center punch. 4. Adjust: • middle gear backlash...

  • Page 185

    Middle gear 4-80 eng do not over tighten the middle driven pinion gear nut. If over tighten the middle driven pinion gear nut, replace the collapsible collar and adjust the backlash. F. Stake the middle driven pinion gear shaft thread. Caution: installing the universal joint 1. Install: • universal ...

  • Page 186

    Eng middle gear 4-81 eas00452 aligning the middle gear note: aligning the middle gear is necessary when any of the following parts are replaced: • crankcase • middle drive shaft 1. Select: • middle drive gear shim(-s) 1 note: select the middle drive gear shim(-s) 1 by calcu- lating the middle drive ...

  • Page 187

    Middle gear 4-82 eng hundredths rounded value 0, 1, 2 0 3, 4, 5, 6 5 7, 8, 9 10 shims are supplied in the following thickness. Middle drive pinion gear shim: thickness (mm) 0.10 ; 0.15; 0.20 ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲.

  • Page 188: Carb

    5 carb.

  • Page 189

    Carb chapter 5. Carburetion carburetor ............................................................................................................5-1 checking the carburetors ......................................................................5-4 assembling the carburetors ..........................

  • Page 190

    Carb.

  • Page 191

    Carb carburetor 5-1 carburetion carburetor order job name/part name q’ty remarks removing the carburetors remove the parts in the order listed. Seat refer to "seat, side covers and fuel tank fuel tank" in chapter 3. 1 air filter case assembly 1 2 air ducts 2 3 cylinder head breather hose 1 disconnec...

  • Page 192

    Carburetor 5-2 carb order job name/part name q’ty remarks disassembling the carburetor disassemble the parts in the order listed. 1 carburetor heater leads 2 2 carburetor heaters 2 12v 30w 3 float chamber/gasket 1 4 float 1 5 needle valve set 1 6 main jet 1 7 jet holder 1 8 pilot jet 1 9 starter jet...

  • Page 193

    Carb carburetor 5-3 order job name/part name q’ty remarks w diaphragm set 1 refer to "assembling the carburetors". E throttle position sensor 1 refer to "checking and adjusting the throttle position sensor (tps)". R pilot screw 1 t main air jet 1 y pilot air jet 1 1 u pilot air jet 2 1 i throttle st...

  • Page 194

    Carburetor 5-4 carb ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ eb600031 checking the carburetors the following procedure applies to all of the car- buretors. 1. Check: • carburetor body • float chamber • jet housing cracks/dama...

  • Page 195

    Carb carburetor 5-5 8. Check: • vacuum chamber cover 1 • piston valve spring 2 • plastic cap 3 • o-ring 4 • spring 5 cracks/damage → replace. 9. Check: • jet needle 1 • needle jet 2 • main jet 3 • pilot screw 4 • pilot jet 5 • main air jet 6 • starter jet 7 bends/damage/wear → replace. Obstruction →...

  • Page 196

    Carburetor 5-6 carb eb600042 assembling the carburetors the following procedure applies to both of the car- buretors. • before assembling the carburetors, wash all of the parts in a petroleum-based solvent. • always use a new gasket. 1. Install: • coasting enricher diaphragm • coasting enricher spri...

  • Page 197

    Carb carburetor 5-7 eb600063 measuring and adjusting the fuel level 1. Measure: • fuel level a out of specification → adjust. A. Stand the motorcycle on a level surface. B. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. C. Install the fuel level gauge...

  • Page 198

    Carburetor 5-8 carb eb600071 checking and adjusting the throttle position sensor note: before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Inspect: • throttle position sensor a. Disconnect the throttle position sensor cou- pler. B. Connect the pocke...

  • Page 199

    Carb carburetor 5-9 closed-throttle resistance 0.56 ~ 0.84 k Ω at 20 °c (68 °f) (yellow – black) c. Tighten the throttle position sensor screws. Note: remove the pocket tester leads and connect the throttle position sensor coupler. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲.

  • Page 200

    Air induction system (ais) 5-10 carb eb601000 air induction system (ais) air indution this system burns the unburned exhaust gases by injecting fresh air (secondary air) at the exhaust port. This is to reduce the output of the hydrocar- bons. When there is negative pressure around the ex- haust port...

  • Page 201

    Carb air induction system (ais) 5-11 1 reed valve 2 air filter 3 orifice 4 carburetor joint (near cylinder) [a] to the front cylinder head [b] to the rear cylinder head air induction system inspection 1. Inspect: • hose connections poor connections → properly connect. • hoses • reed valves • air cut...

  • Page 202

    Carb.

  • Page 203: Chas

    6 chas.

  • Page 204

    Chas chapter 6. Chassis front wheel and brake discs ........................................................................6-1 removing the front wheel ......................................................................6-3 checking the front wheel ...................................................

  • Page 205

    Chas handlebar ............................................................................................................6-51 removing the handlebar..........................................................................6-53 checking the handlebar ...................................................

  • Page 206

    Chas front wheel and brake discs 6-1 chassis front wheel and brake discs order job name/part name q’ty remarks removing the front wheel and brake remove the parts in the order listed. Discs 1 brake hose holder (right/left) 1/1 2 brake caliper (right/left) 1/1 refer to “removing/installing the 3 fron...

  • Page 207

    Front wheel and brake discs 6-2 chas order job name/part name q’ty remarks disassembling the front wheel disassemble the parts in the order listed. 1 oil seals 2 2 bearings 2 3 collar 1 for assembly, reverse the disassembly procedure..

  • Page 208

    Chas front wheel and brake discs 6-3 easb0015 removing the front wheel 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. Note: place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove: • b...

  • Page 209

    Front wheel and brake discs 6-4 chas 4. Check: • wheel bearings front wheel turns roughly or is loose → replace the wheel bearings. • oil seals damage/wear → replace. 5. Replace: • wheel bearings (new) • oil seals (new) a. Clean the outside of the front wheel hub. B. Remove the oil seals 1 with a fl...

  • Page 210

    Chas front wheel and brake discs 6-5 brake disc deflection limit front: 0.2 mm rear: 0.15 mm ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a. Place the motorcycle on a suitable stand so that the wheel is elevated b. Before measuring the front brake disc deflec- tion, turn the handlebar t...

  • Page 211

    Front wheel and brake discs 6-6 chas 1 2 easb0016 installing the front wheel the following procedure applies to both brake discs. 1. Lubricate: • wheel axle • oil seallips 2. Install: • front brake disc 1 note: • apply loctite® 648 to the thread of the bolts. • tighten the brake disc bolts in stages...

  • Page 212

    Chas front wheel and brake discs 6-7 eas00549 adjusting the front wheel static bal- ance note: • after replacing the tire, wheel or both, the front wheel static balance shourd be adjusted. • adjust the front wheel static balance with the brake discs installed. 1. Remove: • balancing weight (-s) note...

  • Page 213

    Front wheel and brake discs 6-8 chas b. Turn the front wheel 90° so that the heavy spot is positioned as shown c. If the heavy spot does not stay in that position, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. 4. Check: • front wheel static balance a. Turn ...

  • Page 214

    Chas rear wheel and brake disc 6-9 rear wheel and brake disc rear wheel order job name/part name q’ty remarks removing the rear wheel and brake remove the parts in the order listed. Disc stand the motorcycle on a level surface. 1 brake caliper tension bar front bolt 1 loosen 2 brake caliper bolt 2 3...

  • Page 215

    Rear wheel and brake disc 6-10 chas order job name/part name q’ty remarks disassembling the rear wheel remove the parts in the order listed. 1 brake disc 1 2 oil seal 1 3 bearing 1 4 spacer 1 5 plate cover 1 6 hub clutch 1 7 bearings 2 8 damper 6 9 bearing 1 0 collar 1 for assembly, reverse the disa...

  • Page 216

    Chas rear wheel and brake disc 6-11 easb0017 removing the rear wheel 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. Note: place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Loosen: • brak...

  • Page 217

    Rear wheel and brake disc chas 2. Install: • rear wheel assembly recommended lubricant lithium soap base grease easb0018 checking the rear wheel 1. Check: • rear wheel axle • rear wheel • wheel bearings • oil seals refer to “front wheel and brake discs”. 2. Check: • tire damage/wear → replace. Refer...

  • Page 218

    Chas rear wheel and brake disc 6-13 a. Install the rear wheel in the swingarm b. Install the spacers, brake caliper bracket and rear wheel axle 1 . C. Tighten the rear wheel axle nut with specified torque. Rear wheel axle 110 nm (11.0 m•kg) ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ d...

  • Page 219

    Front and rear brakes 6-14 chas front and rear brakes front brake pads order job name/part name q’ty remarks removing the front brake pads remove the parts in the order listed. 1 brake hose retainer 1 2 brake caliper 1 3 pad pin clip 2 4 pad pin 1 refer to "replacing the front 5 pad spring 1 brake p...

  • Page 220

    Chas front and rear brakes 6-15 rear brake pads order job name/part name q’ty remarks removing the rear brake pads remove the parts in the order listed. 1 caliper 1 2 cover 1 3 pad pin clip 2 refer to “replacing the rear 4 pad pin 2 brake pads”. 5 pad spring 1 6 brake pads/shim 2/2 for installation,...

  • Page 221

    Front and rear brakes 6-16 chas eb702100 disc brake components rarely require disas- sembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake sys- tem is disconnected, the entire brake sys...

  • Page 222

    Chas front and rear brakes 3. Remove: • brake pads 1 (along with the brake pad shims) 4. Measure: • brake pad wear limit a out of specification → replace the brake pads as a set. 5. Install: • brake pad shims (onto the brake pads) • brake pads • brake pad spring note: always install new brake pads, ...

  • Page 223

    Front and rear brakes 6-18 chas easb0021 replacing the rear brake pads note: when replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassemble the brake caliper. 1. Remove: • rake caliper 1 2. Remove: • brake pad cover 2 • pad pin clips • brake pad pins 3 3. Remove: • ...

  • Page 224

    Chas 6-19 front and rear brakes 6. Install: • brake pad pins • pad pin clips • brake pad cover • brake caliper 7. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 8. Check: • brake...

  • Page 225

    6-20 chas front and rear brakes front brake master cylinder order job name/part name q’ty remarks removing the front brake master remove the parts in the order listed. Cylinder drain the brake fluid 1 brake lever 1 2 front brake switch lead 2 3 front brake switch 1 4 union bolt 1 5 copper washers/br...

  • Page 226

    Chas 6-21 front and rear brakes order job name/part name q’ty remarks disassembling the front brake remove the parts in the order listed. Master cylinder 1 dust boot 1 2 circlip 1 3 master cylinder cup 1 4 spring 1 for assembly, reverse the disassembly procedure. New.

  • Page 227

    6-22 chas front and rear brakes rear brake master cylinder order job name/part name q’ty remarks removing the rear brake master remove the parts in the order listed. Cylinder side cover (right) drain the brake fluid 1 rear brake master cylinder bolts 2 2 rear brake master cylinder cover 1 3 union bo...

  • Page 228

    Chas 6-23 front and rear brakes order job name/part name q’ty remarks disassembling the rear brake master disassembly the parts in the order listed. Cylinder 1 master cylinder boot 1 2 circlip 1 3 master cylinder cup 1 4 spring 1 for assembly, reverse the disassembly procedure..

  • Page 229

    6-24 chas front and rear brakes eb702210 removing the front brake master cylinder note: before removing the front brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Disconnect: • brake switch leads 1 (from brake switch) 2. Remove: • union bolt 2 • copper washers 3 • brak...

  • Page 230

    Chas 6-25 front and rear brakes eb702242 checking the front and rear brake master cylinders the following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) obstr...

  • Page 231

    6-26 chas front and rear brakes eb702270 installing the front brake master cylinder warning • before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake com- ponents. 1. Install: • copper washers (new) 1...

  • Page 232

    Chas 6-27 front and rear brakes 4. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 5. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “ble...

  • Page 233

    6-28 chas front and rear brakes recommended brake fluid dot 4 easb0023 installing the rear brake master cylinder 1. Install: • copper washers (new) 3 • brake hose 4 • union bolt 2 • master cylinder cover 1 warning proper brake hose routing is essential to insure safe motorcycle operation. Refer to “...

  • Page 234

    Chas front and rear brakes 6-29 brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: • brake system refer to “bleeding the hydraulic brake system” in chapter 3. Caution: 4. Check: • brake fluid level below the minimum leve...

  • Page 235

    Front and rear brakes 6-30 chas front brake calipers order job name/part name q’ty remarks removing the front brake calipers remove the parts in the order listed. Drain the brake fluid 1 union bolt 1 2 copper washers 2 3 brake hose 1 4 brake caliper assembly 1 for installation, reverse the removal p...

  • Page 236

    Chas front and rear brakes 6-31 order job name/part name q’ty remarks disassembling the front brake remove the parts in the order listed. Calipers 1 pad pin clips 2 2 pad pin 1 3 pad spring 1 4 brake pads 2 5 bleed screw 1 6 brake caliper pistons 4 7 dust seals 4 8 caliper piston seals 4 for assembl...

  • Page 237

    Front and rear brakes 6-32 chas rear brake caliper order job name/part name q’ty remarks removing the rear brake calipers remove the parts in the order listed. Drain the brake fluid 1 union bolt 1 2 copper washers 2 3 brake hose 1 4 brake caliper assembly 1 for installation, reverse the removal proc...

  • Page 238

    Chas front and rear brakes 6-33 order job name/part name q’ty remarks disassembling the rear brake caliper disassembly the parts in the order listed. 1 cover 1 2 pin clips 2 3 pad pins 2 4 pad spring 1 5 brake pads/shim 2/2 6 bleed screw 2 7 caliper pistons 2 8 dust seals 2 9 piston seals 2 for asse...

  • Page 239

    Front and rear brakes 6-34 chas eb702317 disassembling the front brake caliper the following procedure applies to both of the brake calipers. Note: before removing either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 no...

  • Page 240

    Chas front and rear brakes 6-35 eb702322 disassembling the rear brake caliper note: before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 note: put the end of the brake hose into a container and pump out the...

  • Page 241

    Front and rear brakes 6-36 chas 1. Check: • brake caliper pistons 1 rust/scratches/wear → replace the brake caliper piston assembly. • brake caliper cylinders 2 scratches/wear → replace the brake caliper. • brake calipers 3 cracks/damage → replace. • brake fluid delivery passages (brake caliper body...

  • Page 242

    Chas front and rear brakes 6-37 eb702374 installing the front brake calipers the following procedure applies to both of the brake calipers. Warning • before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal ...

  • Page 243

    Front and rear brakes 6-38 chas 5. Bleed: • brake system refer to “bleeding the hydraulic brake system” in chapter 3. 6. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 7. Check: ...

  • Page 244

    Chas front and rear brakes 6-39 easb0024 installing the rear brake caliper warning • before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake com- ponents as they will cause the piston seals to swell a...

  • Page 245

    Front and rear brakes 6-40 chas 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning • use only the designated brake fluid. • other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill ...

  • Page 246

    Chas front fork 6-41 front fork order job name/part name q’ty remarks removing the front fork remove the parts in the order listed. Front wheel brake caliper assembly cowling lift forward 1 bracket 2 2 front fender 1 3 upper bracket bolts 2 4 cap bolts 2 5 lower bracket bolts 4 6 front fork legs 1/1...

  • Page 247

    Front fork 6-42 chas order job name/part name q’ty remarks disassembling the front fork disassemble the parts in the order listed. 1 cap bolt 2 2 o-ring 2 3 washer 2 4 spacer 2 5 spring seat 2 6 fork spring 2 7 piston ring 2 8 rebound spring 2 9 damper rod 2 0 oil lock piece 2 q inner tube 2 w inner...

  • Page 248

    Chas front fork 6-43 order job name/part name q’ty remarks t oil seal 2 y oil seal washer 2 u outer tube bushing 2 i damper rod bolt 2 o gasket 2 p outer tube 2 a protector 2 for assembly, reverse the disassembly procedure. Refer to “disassembling/ assembling the front fork legs”. 30 nm (3.0 m•kg).

  • Page 249

    Front fork 6-44 chas 1 2 3 eas00649 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. Note: place the motorcycle on a suitable...

  • Page 250

    Chas front fork 6-45 4. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) do not scratch the inner tube. Caution: 5. Remove: • damper rod bolt 1 note: while holding the damper rod with the t-handle 3 and damper rod holder 2 , loosen the damper rod bolt. 6. Remove: • inner tube a...

  • Page 251

    Front fork 6-46 chas eas00657 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 bends/damage/scratches → replace. Warning do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: •...

  • Page 252

    Chas front fork 6-47 eb703703 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning • make sure that the oil levels both front fork legs are equal. • uneven oil levels can result in poor handling and a loss of stability. Note: • when assembling the fr...

  • Page 253

    Front fork 6-48 chas 4. Install: • outer tube bushing 1 • oil seal spacer 2 • oil seal 3 (with the fork seal driver weight 4 and adapter 5 ) make sure that the numbered side of the oil seal faces up. Note: • before installing the oil seal, apply lithium soap base grease onto its lips. • lubricate th...

  • Page 254

    Chas front fork 6-49 7. Push down the inner tube into the outer tube. 8. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) • be sure to use the recommended fork oil. • other oils may have an adverse effect on front fork performance. • when disassembling and assembling ...

  • Page 255

    Front fork 6-50 chas note • install the fork spring with its smaller pitch up- word. • before installing the cap bolt, apply grease to the o-ring. • temporarily tighten the cap bolt. Eas00662 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: •...

  • Page 256

    Chas handlebar 6-51 handlebar order job name/part name q’ty remarks removing the handlebar remove the parts in the order listed. Stand the motorcycle on a level surface. 1 plastic locking ties 3 2 clutch cable 1 3 handlebar switch (left) 1 4 grip (left) 1 5 clutch lever assembly/rear view mirror 1/1...

  • Page 257

    Handlebar 6-52 chas order job name/part name q’ty remarks 10 throttle grip assembly 1 11 handlebar holders (upper) 2 12 handlebar 1 13 handlebar holders (lower) 2 for installation, reverse the removal procedure. Refer to “installing the handlebar”..

  • Page 258

    Chas handlebar 6-53 eas00666 removing the handlebar 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • handlebar grip (left) 1 note: blow compressed air between the handlebar and the handlebar grip, and grad...

  • Page 259

    Handlebar 6-54 chas a. Apply a light coat of rubber adhesive onto the left end of the handlebar. B. Slide the handlebar grip over the left end of the handlebar. C. Wipe off any excess rubber adhesive with a clean rag. Warning do not touch the handlebar grip until the rub- ber adhesive has fully drie...

  • Page 260

    Chas handlebar 6-55 a b 1 1 a 72 2 a 1 2 3. Install: • throttle grip 1 • throttle cable warning make sure that the pin a on the throttle cable housing is aligned with the hole b in the han- dlebar. 4. Install: • master cylinder 1 refer to “front and rear brakes”. Note: align the slit in the brake le...

  • Page 261

    Handlebar 6-56 chas 10. Adjust: • clutch cable free play refer to “adjusting the clutch cable free play” in chapter 3. 11. Adjust: • throttle cable free play refer to “adjusting the throttle cable free play” in chapter 3. Clutch cable free play (at the end of the clutch lever) 5 10 mm throttle cable...

  • Page 262

    Chas steering head 6-57 steering head lower bracket order job name/part name q’ty remarks removing the lower bracket remove the parts in the order listed. Front wheel refer to “front wheel and brake discs”. Front fork legs refer to “front fork”. Handlebar refer to ”handlebar”. 1 crown nut/washer pla...

  • Page 263

    Steering head 6-58 chas order job name/part name q’ty remarks 11 bearing 1 12 dust seal 1 13 lower handlebar holder 2 for installation, reverse the removal procedure..

  • Page 264

    Chas steering head 6-59 eas00679 removing the lower bracket 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • upper ring nut 1 • lower ring nut 2 note: hold the lower ring nut with the exhaust and steering ...

  • Page 265

    Steering head 6-60 chas a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. B. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. C. Install a new rubber seal and new bearing races. If the bearing race is not installed properly, the ste...

  • Page 266

    Chas 6-61 rear shock absorber and swingarm rear shock absorber and swingarm order job name/part name q’ty remarks removing the rear shock absorber remove the parts in order listed. And swingarm stand the motorcycle on a level surface. Place a suitable stand under the engine. Seat side covers refer t...

  • Page 267

    Rear shock absorber and swingarm 6-62 chas order job name/part name q’ty remarks rear master cylinder it is not necessary to disconnect the brake hose. Refer to “rear brake master cylinder”. Rear brake pedal main footrest (right and left) main footrest cover (right) passenger footrest holder (right ...

  • Page 268

    Chas 6-63 rear shock absorber and swingarm eas00687 handling the rear shock absorber and gas cylinder warning this rear shock absorber and gas cylinder contain highly compressed nitrogen gas. • before handling the rear shock absorber or gas cylinder, read and make sure you under- stand the following...

  • Page 269

    6-64 chas rear shock absorber and swingarm easb0026 removing the rear shock absorber assembly 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. Note: place the motorcycle on a suitable stand so that the rear wheel is el...

  • Page 270

    Chas 6-65 rear shock absorber and swingarm easb0027 removing the swingarm 1. Stand the motorcycle on a level surface. Warning securely support the motorcycle so that there is no danger of it falling over. Note: place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: •...

  • Page 271

    6-66 chas rear shock absorber and swingarm eas00708 checking the swingarm 1. Check: • swingarm bends/cracks/damage → replace. 2. Check: • pivot shaft damage/wear → replace. 3. Check: • collars 1 • oil seals 2 • bearings 3 damage/wear → replace. Eas00696 checking the rear shock absorber assembly and ...

  • Page 272

    Chas rear shock absorber and swingarm 6-67 easb0028 installing the rear shock absorber assembly 1. Install: • swingarm refer to “installing the swingarm”. 2. Lubricate: • spacers • bearings 3. Install: • rear shock absorber assembly note: when installing the rear shock absorber assem- bly, lift up t...

  • Page 273

    Rear shock absorber and swingarm 6-68 chas eas00712 installing the swingarm 1. Lubricate: • bearings • spacers • oil seals 2. Install: • relay arm • left connecting arm • right connecting arm 3. Install: • rear shock absorber reter to “installing the rear shock absorber assembly”. 4. Install: • rear...

  • Page 274

    Chas shaft drive 6-69 shaft drive eas00715 troubleshooting the following conditions may indicate damaged shaft drive components: note: causes a, b and c may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal operating noises. If there is reason...

  • Page 275

    Shaft drive 6-70 chas inspection notes 1. Investigate any unusual noises. The following noises may indicate a mechani- cal defect: a. A rolling "rumble" during coasting, accelera- tion, or deceleration, (increases with the rear wheel speed, but does not increase with high- er engine or transmission ...

  • Page 276

    Chas shaft drive 6-71 eas00716 troubleshooting chart when causes a and b shown in the chart at the beginning of the “troubleshooting” section exist, check the following points: place the motorcycle on a suitable stand so that the front wheel is elevated and then spin the front wheel. Is the wheel be...

  • Page 277

    Shaft drive 6-72 chas eas00717 checking the final drive oil for con- tamination and inspecting the shaft drive for leaks 1. Drain: • final drive oil (from the final drive housing) refer to “changing the final drive oil” in chapter 3. 2. Check: • final drive oil large amount of metal particles → chec...

  • Page 278

    Chas shaft drive 6-73 eas00719 measuring the ring gear backlash 1. Secure the final drive assembly in a vice. 2. Remove: • final drive oil drain bolt 3. Drain: • final drive oil (from the final drive assembly) 4. Measure: • ring gear backlash out of specification → adjust. A. Install a bolt 1 of the...

  • Page 279

    Shaft drive 6-74 chas g. Rotate the final drive pinion gear 90° h. Reinstall the bolt, special tool, and dial gauge. I. Repeat steps (d) to (h) three more times (for a total of four measurements). J. If any of the readings are over specification, adjust the ring gear backlash. Eas00720 adjusting the...

  • Page 280

    Chas shaft drive 6-75 b. If it is necessary to increase the ring gear backlash by more than 0.2 mm, reduce the thrust washer thickness by 0.2 mm for every 0.2 mm increase of ring gear shim thickness. C. If it is necessary to reduce the ring gear back- lash by more than 0.2 mm, increase the thrust wa...

  • Page 281

    Shaft drive 6-76 chas final drive assembly and drive shaft order job name/part name q’ty remarks removing the final drive assembly remove the parts in the order listed. And drive shaft stand the motorcycle on a level surface. Rear wheel assembly refer to “rear wheel and brake disc”. 1 collar 1 2 dri...

  • Page 282

    Chas shaft drive 6-77 final gear order job name/part name q’ty remarks disassembling the final gear disassemble the parts in the order listed. 1 bolts (bearing housing) 2 2 nuts (bearing housing) 6 3 bearing housing/o-ring 1/1 4 ring gear 1 5 shim(-s) 1 6 thrust washer 1 for assembly, reverse the di...

  • Page 283

    Shaft drive chas easb0029 disassembling the final drive assem- bly 1. Remove: • ring gear bearing housing nuts • ring gear bearing housing bolts note: working in a crisscross pattern, loosen each bolts and nuts 1/4 of a turn. After all of the bolts and nuts are fully loosened, and remove them. 2. Re...

  • Page 284

    Chas shaft drive 6-79 5. Remove: • final drive pinion gear (with the special tools) warning always use new bearings. The final drive pinion gear should only be removed if ring gear replacement is neces- sary. Caution: crankshaft installer bolt adapter 1 90890-01277 armature shock puller 2 90890-0129...

  • Page 285

    Shaft drive 6-80 chas a. Heat the final gear case to approximately 150 °c (302 °f). B. Install the bearing outer races with a socket or appropriate tool that matches the diameter of the races. C. Install the inner race onto the final drive pinion gear. 5. Install: • collar 1 • oil seal 2 • bearing (...

  • Page 286

    Chas shaft drive 6-81 where: a = a numeral (positive or negative) on the ring gear, to be divided by 100 and added to “84” b = a numeral on the final drive housing. Example: if the final drive pinion gear is marked “+01” and the final drive housing is marked “83.50”: a = (84 + 1/100) – (83.50) = (84...

  • Page 287

    Shaft drive 6-82 chas f = the ring gear bearing thickness constant example: if the final drive housing is marked “45.51” the ring gear bearing housing is marked “3.35” the ring gear is marked “-05”, and “f” is 13.00: a = 45.51 + 3.35 – [(35.40 – 5/100) + 13] = 45.51 + 3.35 – [(35.40 – 0.05) + 13] = ...

  • Page 288

    Chas shaft drive 6-83 bearing retainer wrench 90890-04050 3. Install: • gear coupling • self-locking nut (with the special tool 1 ) 4. Install: • ring gear bearing housing (along with the ring gear, but without the thrust washer) 5. Adjust: • ring gear backlash refer to “measuring the ring gear back...

  • Page 289

    Shaft drive 6-84 chas d. Remove the ring gear bearing housing. E. Measure the width of the flattened plastigauge ® 1 . F. If the ring-gear-to-thrust-washer clearance is within specification, install the ring gear bear- ing housing (along with the ring gear). G. If the ring-gear-to-thrust-washer clea...

  • Page 290

    Chas shaft drive 6-85 eas00728 installing the drive shaft 1. Lubricate: • drive shaft splines 2. Apply: • sealant (onto both final drive housing mating sur- faces) 3. Install: • drive shaft (to the final drive pinion gear) 4. Tighten: • final bearing housing nuts 5. Install: • rear wheel assembly re...

  • Page 292: Elec

    7 elec.

  • Page 293

    Elec chapter 7. Electrical electrical components ....................................................................................7-1 switches ..................................................................................................................7-3 checking switch continuity ............

  • Page 294

    3 3 elec carburetor heater system ..........................................................................7-46 circuit diagram ............................................................................................7-46 troubleshooting .............................................................

  • Page 295

    Elec electrical components 7-1 electrical electrical components 1 ignition coils 2 igniter unit 3 speed sensor 4 sidestand switch 5 neutral switch 6 oil level gauge assembly 7 horn.

  • Page 296

    Electrical components 7-2 elec 8 main switch 9 thermo switch 0 fuel meter senser unit q battery w starter relay e relay assembly r flasher relay t diode y fuse assembly u rectifier/regulator.

  • Page 297

    Elec switches 7-3 eas0010 switches checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the coupler terminal slots 1. Always i...

  • Page 298

    Checking the switches 7-4 elec eas00731 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “checking switch continuity”. Damage/wear → repair or replace the switch. Improperly connected → properly connect. Incorre...

  • Page 299

    Elec checking the switches 7-5 1 clutch switch 2 pass switch 3 horn switch 4 dimmer switch 5 turn switch 6 main switch 7 front brake switch 8 lights switch 9 engine stop switch 0 start switch q fuses w rear brake switch e sidestand switch r neutral switch.

  • Page 300

    Checking the bulbs and bulb sockets 7-6 elec eas00732 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected → prope...

  • Page 301

    Elec checking the bulbs and bulb sockets 7-7 warning since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. • be sure to hold the socket firmly when removing the bulb. Never pull the lead, oth- erwise it may be pulled out of t...

  • Page 302

    Checking the bulbs and bulb sockets 7-8 elec checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: check each bulb socket for continuity in the same manne...

  • Page 303

    Elec ignition system 7-9 ignition system circuit diagram 1 pickup coil 3 main switch 4 starter relay 5 battery 6 wire minus lead 8 starting circuit cut-of f relay 0 igniter unit qw ignition coil r sidestand switch t ignition fuse y right handlebar switch j neutral switch lead k neutral switch # alar...

  • Page 304

    Ignition system 7-10 elec 2. Battery • check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Min. Open-circuit voltage 12.8 v or more at 20 °c (68 °f) • is the battery ok? 3. Spark plugs the following procedure applies to all of the spark plugs. • check the c...

  • Page 305

    Elec ignition system 7-11 4. Ignition spark gap the following procedure applies to all of the spark plugs. • disconnect the spark plug cap from the spark plug. • connect the ignition checker 1 as shown. • spark plug cap 2 . • set the main switch to “on”. • measure the ignition spark gap a . • crank ...

  • Page 306

    Ignition system 7-12 elec secondary coil resistance 10.7 14.5 k at 20°c (68°f) • is the ignition coil ok? Replace the ignition coil. Yes no replace the pickup coil. Yes no 7. Pickup coil resistance • disconnect the pickup coil coupler from the wire harness. • connect the pocket tester ( 100) to the ...

  • Page 307

    Elec ignition system 7-13 12. Diode • remove the diode from the wire harness. • check for continuity as follows: tester (+) lead → blue/white 2 con- tester (–) lead → blue/yellow 2 tinuity tester (+) lead → blue/yellow 2 no con- tester (–) lead → blue/white 1 tinuity note: when you switch the “–” an...

  • Page 308

    Electric starting system 7-14 elec electric starting system circuit diagram 3 main switch 4 starter relay 5 battery 6 wire minus lead 7 starter motor 8 starting circuit cut-of f relay r sidestand switch t ignition fuse y right handlebar switch d clutch switch j neutral switch lead k neutral switch #...

  • Page 309

    Elec electric starting system 7-15 eb803010 starting circuit operation the starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the engine stop switch is on “run” and the main switch is on “on” (both switches are closed), the starter...

  • Page 310

    Electric starting system 7-16 elec 2. Battery • check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Min. Open-circuit voltage: 12.8 v or more at 20 °c (68 °f) • is the battery ok? 3. Starter motor • connect the battery positive terminal 1 and starter motor ...

  • Page 311

    Elec electric starting system 7-17 4. Starting circuit cutoff relay • disconnect the relay unit from the coupler. • connect the pocket tester ( 1) and bat- tery (12v) to the relay unit terminals as shown. Battery positive terminal → red/black 1 battery negative terminal → black/yellow 2 tester posit...

  • Page 312

    Electric starting system elec replace the starter re- lay. Yes no 6. Starter relay • disconnect the starter relay from the coupler. • connect the pocket tester ( 1) and bat- tery (12v) to the starter relay coupler as shown. Battery positive terminal → red/white 1 battery negative terminal → blue 2 t...

  • Page 313

    Elec electric starting system 7-19 12. Start switch • check the start switch for continuity. Refer to “checking the switches”. • is the start switch ok? Replace the right handlebar switch. Eas00764 yes no 13. Diode • check the diode for continuity. Refer to “ignition system”. • is the diode ok? Repl...

  • Page 314

    Electric starting system 7-20 elec order job name/part name q’ty remarks removing the starter motor remove the parts in the order listed. 1 starter motor lead 1 2 starter motor assembly 1 for installation, reverse the removal procedure. Disassembling the starter motor disassembly the pats in the ord...

  • Page 315

    Elec electric starting system 7-21 order job name/part name q’ty remarks 6 washer set 1 7 end bracket 1 refer to “assembling the starter motor.” 8 planetary gears 2 9 armature assembly 1 0 brush holder/brush 1/1 q starter motor yoke 1 for assembly, reverse the disassembly procedure. Refer to “assemb...

  • Page 316

    Electric starting system 7-22 elec eas00769 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter a out of specification → replace the starter motor. 3. Measure: • mica undercut a out of specification → scrape the mica to the proper...

  • Page 317

    Elec electric starting system 7-23 5. Measure: • brush length a out of specification → replace the brushes as a set. 6. Measure: • brush spring force out of specification → replace the brush springs as a set. 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • oil seal damage/wear → r...

  • Page 318

    Electric starting system 7-24 elec 3. Install: • starter motor rear cover 1 note: align the match marks a on the rear cover with the match marks b on the front cover..

  • Page 319

    Elec charging system 7-25 charging system circuit diagram 1 pickup coil 2 rectifier/regulator 4 starter relay 5 battery 6 wire minus lead.

  • Page 320

    Charging system 7-26 elec 2. Battery • check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Min. Open-circuit voltage 12.8 v or more at 20 °c (68 °f) • is the battery ok? 3. Charging voltage • connect the engine tachometer to the spark plug lead of cylinder ...

  • Page 321

    Elec charging system 7-27 note: make sure that the battery is fully charged. • is the charging voltage within specification? The charging circuit is ok. No yes replace the stator coil assembly. Yes no 4. Stator coil assembly resistances • remove the left side cover. • connect the pocket tester ( 1) ...

  • Page 322

    Lighting system 7-28 elec lighting system circuit diagram 3 main switch 4 starter relay 5 battery 6 wire minus lead y right handlebar switch i headlight fuse s left handlebar switch h speedometer l headligh . T ail/brake light % license plate light.

  • Page 323

    Elec lighting system 7-29 pocket tester 90890-03112 1. Main and headlight fuses • check the main and headlight fuses for con- tinuity. Refer to “checking the fuses” in chapter 3. • are the main and headlight fuses ok? Replace the fuse(-s). Eas00738 easb0033 troubleshooting check: 1. Main and headlig...

  • Page 324

    Lighting system 7-30 elec 5. Dimmer switch • check the dimmer switch for continuity. Refer to “checking the switches”. • is the dimmer switch ok? The dimmer switch is faulty. Replace the right handlebar switch. Eas00784 yes no 6. Pass switch • check the pass switch for continuity. Refer to “checking...

  • Page 325

    Elec lighting system 7-31 the wiring circuit from the main switch to the headlight cou- pler is faulty and must be repaired. This circuit is ok. Yes no • measure the voltage (12 v) of yellow 1 or green 2 on the headlight coupler (headlight side). • measure the voltage (12v) of yellow 4 on the meter ...

  • Page 326

    Lighting system 7-32 elec the wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired. This circuit is ok. Yes no 2. Voltage • connect the pocket tester (dc 20 v) to the tail/brake light coupler (wire harness side) as shown. Tester positive probe → blue/red...

  • Page 327

    Elec signaling system 7-33 signaling system circuit diagram.

  • Page 328

    Signaling system 7-34 elec 3 main switch 4 starter relay 5 battery 6 wire minus lead t ignition fuse u front brake switch o signal fuse s left handlebar switch f horn g flasher relay h speedometer j neutral switch lead k neutral switch ; front turn signal light (l) z front turn signal light (r) x re...

  • Page 329

    Elec signaling system 7-35 pocket tester 90890-03112 1. Main, ignition and signaling system fuses • check the main, ignition and signaling sys- tem fuses for continuity. Refer to “checking the fuses” in chapter 3. • are the main, ignition and signaling system fuses ok? Replace the fuse(-s). Eas00738...

  • Page 330

    Signaling system 7-36 elec 1. Horn switch • check the horn switch for continuity. Refer to “checking the switches”. • is the horn switch ok? Replace the left han- dlebar switch. Eas00796 checking the signaling system 1. The horn fails to sound. Yes no the wiring circuit from the main switch to the h...

  • Page 331

    Elec signaling system 1. Tail/brake light bulb and socket • check the tail/brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the tail/brake light bulb and socket ok? Replace the tail/ brake lightbulb, socket or both. Eas00797 2. A tail/brake light fail...

  • Page 332

    Signaling system 7-38 elec 2. Turn signal switch • check the turn signal for continuity. Refer to “checking the switches”. • is the turn signal switch ok? Replace the left han- dlebar switch. Yes no the wiring circuit from the main switch to the flasher relay coupler (flasher relay side) is faulty a...

  • Page 333

    Elec signaling system 7-39 • set the main switch to “on”. • set the turn signal switch to “ Î ” or “ ¥ ”. • measure the voltage (12 v) of chocolate 1 or dark green 2 at the turn signal light con- nector (wire harness side). • is the voltage within specification? The wiring circuit from the turn sign...

  • Page 334

    Signaling system 7-40 elec 2. Oil level switch • drain the engine oil and remove the oil level switch from the oil pan. • check the oil level switch for continuity. Refer to “checking the switches”. • is the oil level switch ok? Replace the oil level switch. Yes no 3. Voltage • connect the pocket te...

  • Page 335

    Elec fuel pump system 7-41 fuel pump system circuit diagram 3 main switch 4 starter relay 5 battery 6 wire minus lead 8 starting circuit cut-of f relay 9 fuel pump 0 igniter unit t ignition fuse y right handlebar switch.

  • Page 336

    Fuel pump system 7-42 elec eb808010 fuel pump circuit operation the fuel pump circuit consists of the fuel pump re- lay, fuel pump, engine stop switch and ignitor unit. The ignitor unit includes the control unit for the fu- el pump. 1 battery 2 main fuse 3 main switch 4 ignition fuse 5 engine stop s...

  • Page 337

    Elec fuel pump system 7-43 pocket tester 90890-03112 1. Main and ignition fuses • check the main and ignition fuses for conti- nuity. Refer to "checking the fuses" in chapter 3. • are the main and ignition fuses ok? Replace the fuse(-s). Eas00738 easb0037 troubleshooting check: 1. Main, and ignition...

  • Page 338

    Fuel pump system 7-44 elec replace the fuel pump. Yes no 6. Fuel pump resistance • disconnect the fuel pump coupler from the wire harness. • connect the pocket tester ( 1) to the fuel pump coupler terminals. Tester (+) lead → blue/black terminal 1 tester (–) lead → black terminal 2 • measure the fue...

  • Page 339

    Elec fuel pump system 7-45 easb0038 fuel pump test warning gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or combustion. Be extremely careful and note the following points: • stop the engine before refuelling. • do not smoke and keep away from o...

  • Page 340

    Carburetor heater system 7-46 elec carburetor heater system circuit diagram 3 main switch 4 starter relay 5 battery 6 wire minus lead p carburetor heater fuse v thermo switch b carburetor heater earth n carburetor heater 1 m carburetor heater 2.

  • Page 341

    Elec carburetor heater system 7-47 pocket tester 90890-03112 1. Main and carburetor heater fuses • check the main and carburetor heater fuses for continuity. Refer to "checking the fuses" in chapter 3. • are the main, and carburetor heater fuses ok? Replace the fuse(-s). Eas00738 easb0039 troublesho...

  • Page 342

    Carburetor heater system 7-48 elec • immerse the thermo switch in the water 3 . • check the thermo switch for continuity. Note the temperatures while heating the water with the temperature gauge 4 . Test step water temperature good condition 1 less than 23 ± 3 °c o 2 more than 23 ± 3 °c 3 more than ...

  • Page 343

    Elec self-diagnosis 7-49 easb0043 self-diagnosis this model is equipped with a self-diagnosis device for the following electrical circuits: - tachometer - speedometer - oil level warning light - fuel level warning light - throttle position sensor - speed sensor. When the key is turned to "on", the t...

  • Page 344

    Self-diagnosis 7-50 elec pocket tester 90890-03112 eas00836 1. Throttle position sensor circuit diagram 0 ignitor unit e throttle position sensor easb0044 troubleshooting check: 1. Throttle position sensor 2. Speed sensor note: • before troubleshooting, remove the following part(-s): 1) seat 2) side...

  • Page 345

    Elec self-diagnosis 7-51 2. Speed sensor circuit diagram 0 ignitor unit ! Speed sensor 1. Wire harness • check the wire harness for continuity. Refer to "circuit diagram". • is the wire harness ok? Repair or replace the wire harness. Yes no 2. Speed sensor • place the motorcycle on a suitable stand ...

  • Page 346

    Elec.

  • Page 347: Trbl

    8 trbl shtg ?.

  • Page 348

    Trbl shtg ? Chapter 8. Troubleshooting starting failure/hard starting .......................................................................... 8-1 fuel system ..............................................................................................................8-1 electrical system ..........

  • Page 349

    Trbl shtg ?.

  • Page 350

    Trbl shtg starting failure/hard starting 8-1 ? Eb900000 troubleshooting note: the following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspec- tion, adj...

  • Page 351

    Trbl shtg starting failure/hard starting/ poor idle speed performance/ poor medium-and high-speed performance 8-2 ? Compression system cylinder and cylinder head • loose spark plug • loose cylinder head or cylinder • faulty cylinder head gasket • worn, damaged or seized cylinder • improperly sealed ...

  • Page 352

    Trbl shtg faulty gear shifting/ clutch slipping/dragging 8-3 ? Eb903000 faulty gear shifting hard shifting refer to “clutch dragging”. Shift pedal does not move shift shaft • improperly adjusted shift pedal link • bent shift shaft shift cam, shift fork • groove jammed with impurities • seized shift ...

  • Page 353

    Trbl shtg overheating/faulty brake/front fork oil leakage and front fork malfunction 8-4 ? Eb905000 overheating overheating ignition system • improper spark plug gap • improper spark plug heat range • faulty ignitor unit fuel system • improper carburetor main jet setting • improper fuel level • clog...

  • Page 354

    Trbl shtg unstable handling/ faulty lighting and signal systems 8-5 ? Eb908000 unstable handling unstable handling handlebar • improperly installed or bent steering • improperly installed handlebar crown • bent steering stem • improperly installed steering shaft (improperly tightened ring nut) • dam...

  • Page 355

    Trbl shtg ?.

  • Page 356

    Bt1100 wiring diagram color code b ...........Black br ..........Brown ch .........Chocolate dg .........Dark green g ...........Green gy .........Gray l............Blue lg..........Light green o ...........Orange p ...........Pink r ...........Red sb .........Sky blue w ..........White y .............