1100 Service Manual

8/14/2019 1100 Service Manual

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EB000000

XVS1100 (L)SERVICE MANUAL

1998 by Yamaha Motor Co.,Ltd.First edition, October 1998

All rights reserved. Any reproduction orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.

is expressly prohibited.


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NOTE:

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and

their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe andunfit for use.

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

Designs and specifications are subject to change without notice.

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person inspecting or repairing themotorcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

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


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12 6

3

5

4

7

8

EB002000

HOW TO USE THIS MANUALMANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See Illustrated symbols)1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2 : This title indicates the section of the chapter and only appears on the first page of eachsection. It is located in the upper right corner of the page.

3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-nied by corresponding illustrations.

EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-moval and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed bya circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks6 . The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition tothe exploded diagram and the job instruction chart.


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24

21

18

15 16 17

10

12

13

11

14

1

3

5

7

9

2

4

8

6

19 20

22 23

25

EB003000

ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are printed on thetop right of each page and indicate the subject ofeach chapter.

1 General information

2 Specifications

3 Periodic inspections and adjustments

4 Engine

5 Cooling system

6 Carburetion

7 Chassis

8 Electrical

9 Troubleshooting

Illustrated symbols 10 to 17 are used to identifythe specifications appearing in the text.

10 Can be serviced with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Torque

15 Wear limit, clearance16 Engine speed

17 , V, A

Illustrated symbols 18 to 23 in the exploded dia-grams indicate the types of lubricants and lu-brication points.

18 Apply engine oil

19 Apply gear oil

20 Apply molybdenum disulfide oil

21 Apply wheel bearing grease

22 Apply lightweight lithium-soap base grease

23 Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the exploded dia-grams indicate where to apply locking agent 24

and when to install new parts 25 .

24 Apply locking agent (LOCTITER)

25 ReplaceE004000


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INSPADJ

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION ANDADJUSTMENTS

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GENINFO 1

SPEC 2

3

ENG 4

CARB 5

CHAS 6

ELEC 7TRBLSHTG 8

CHAPTER TITLES


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GEN

INFO 1


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GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PREPARATION FOR REMOVAL PROCEDURES 1-2. . . . . . . . . . . . . . .

REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . .

LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . .

BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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


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1-1

MOTORCYCLE IDENTIFICATIONGENINFO

EB100000

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEB100010

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head.

MODEL LABELThe model label 1 is affixed to the frame. Thisinformation will be needed to order spare parts.


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1-2

IMPORTANT INFORMATIONGENINFO

EB101000

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCE-DURES1. Remove all dirt, mud, dust and foreign mate-

rial before removal and disassembly.

2. Use proper tools and cleaning equipment.Refer to the SPECIAL TOOLS section.

3. When disassembling the machine, alwayskeep mated parts together. This includes

gears, cylinders, pistons and other parts thathave been mated through normal wear.Mated parts must always be reused or re-placed as an assembly.

4. During machine disassembly, clean all partsand place them in trays in the order of disas-sembly. This will speed up assembly and al-low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS1. Use only genuine Yamaha parts for all re-

placements. Use oil and grease recom-mended by Yamaha for all lubrication jobs.

Other brands may be similar in function andappearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS1. Replace all gaskets, seals and O-rings when

overhauling the engine. All gasket surfaces,oil seal lips and O-rings must be cleaned.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the oilseal lips.


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1-3

IMPORTANT INFORMATIONGENINFO

CAUTION:

EB101030

LOCK WASHERS/PLATES AND COTTERPINS1. Replace all lock washers/plates 1 and cot-

ter pins after removal. Bend lock tabs alongthe bolt or nut flats after the bolt or nut hasbeen tightened to specification.

EB101040

BEARINGS AND OIL SEALS1. Install bearings and oil seals so that the

manufacturers marks or numbers are vis-

ible. When installing oil seals, apply a lightcoating of lightweight lithium base grease tothe seal lips. Oil bearings liberally wheninstalling, if appropriate.

1 Oil seal

Do not use compressed air to spin the bear-ings dry. This will damage the bearing sur-faces.

1 Bearing

EB101050

CIRCLIPS1. Check all circlips carefully before reassemb-

ly. Always replace piston pin clips after oneuse. Replace distorted circlips. When instal-

ling a circlip 1 , make sure that the sharp-edged corner 2 is positioned opposite thethrust 3 it receives. See sectional view.

4 Shaft


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1-5

SPECIAL TOOLSGENINFO

EB102001

SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appropriate special tools; this will help prevent damage caused by the use of inappropriate tools orimprovised techniques. Special tools may differ by shape and part number from country to country. Insuch a case, two types are provided.When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/How to use Illustration

Weight90890-01084

Bolt90890-01085

Slide hammer bolt/weight

These tools are used to remove the rockerarm shaft.

90890-01135

Crankcase separating tool

This tool is used to remove the crankshaft.

90890-01229

Coupling gear/Middle shaft tool

This tool is needed when removing orinstalling the final pinion shaft nut.

Final gear

backlash band90890-01230Middle gear

backlash band90890-01231

Final gear backlash band

This tool is needed when measuring final gear/middle gear backlash.

Installer pot90890-01274

Bolt90890-01275

Crankshaft installer pot/bolt/adapter/ spacer

Adaptor

90890-04130Spacer

90890-04060

These tools are used to install the crankshaft.

90890-01304

Piston pin puller

This tool is used to remove the piston pin.

90890-01312

Fuel level gauge

This gauge is used to measure the fuel levelin the float chamber.


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T-handle

90890-01326Holder

90890-01460

T-handle/damper rod holder

These tools are needed to loosen and tightenthe damper rod holding bolt.

Puller90890-01362

Adapter90890-04131

Flywheel puller/adapter

These tools are needed to remove the rotor.

Weight

90890-01367Adapter90890-01381

Fork seal driver weight/adapter

These tools are needed when installing theslide metal, oil seal and dust seal into the fork.

Ring nut wrench90890-01403Exhaust nut

wrench90890-01268

Ring nut wrench/ehaust and steering nutwrench

This tool is needed to loosen and tighten thesteering stem ring nut.

90890-01701

Sheave holder

This tool is needed to hold the rotor when re-moving or installing the rotor bolt.

90890-03081

Compression gauge set

These tools are needed to measure enginecompression.

90890-03094

Vacuum gauge

This gauge is needed for carburetor synchro-nization.

90890-03112

Pocket tester

This instrument is needed for checking theelectrical system.

90890-03113

Engine tachometer

This tool is needed for observing engine r/min.


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1-7



90890-03141

Timing light

This tool is necessary for checking ignitiontiming.

90890-04014

Valve guide remover & installer

This tool is needed to remove and install thevalve guide.

90890-04019

Valve spring compressor

This tool is needed to remove and install thevalve assemblies.

Adapter90890-01277Shock puller90890-01290

Weight90890-01291

Crankshaft installer bolt adapter/armatureshock puller/weight

These tools are needed when removing thefinal pinion shaft.

90890-04137

Bearing retainer wrench

This tool is needed when removing or instal-ling the middle drive shaft assembly.

Wrench90890-04138

Holder90890-04055

Middle drive shaft nut wrench/Middle driveshaft holder

These tools are needed when removing orinstalling the middle drive shaft bearing.

90890-04062

Universal joint holder

This tool is needed when removing or instal-ling the driven pinion gear nut.

90890-04077

Bearing retainer wrench

This tool is needed when removing or instal-ling the final drive pinion gear assembly.

90890-04086

Clutch holding tool

This tool is needed to hold the clutch when re-

moving or installing the clutch boss nut.


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1-8



90890-04090

Damper spring compressor

This tool is needed when removing or instal-ling the damper spring.

90890-06754

Dynamic spark testerIgnition checker

This instrument is necessary for checking theignition system components.

90890-85505

Yamaha bond No.1215

This sealant (bond) is used on crankcase mat-ing surfaces, etc.


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SPEC 2


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E

SPEC

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TORQUE SPECIFICATIONS 2-20. . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERSION TABLE 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-21. . . . . . . . . . . . . . . .

ENGINE 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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2-1

GENERAL SPECIFICATIONS SPEC

Temp. _C

SPECIFICATIONSGENERAL SPECIFICATIONS

Item StandardModel code: XVS1100: 5EL1 (For Europe)

5EL2 (For D, A, FIN)5EL3 (For Australia)

Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearance

Minimum turning radius

2,405 mm895 mm1,095 mm690 mm1,640 mm145 mm

3,200 mmBasic weight:

With oil and a full fuel tank 274 kg (5EL2 : 275kg)

Engine:Engine typeCylinder arrangementDisplacementBore strokeCompression ratioCompression pressure (STD)Starting system

Air cooled 4-stroke, SOHCV-type 2-cylinder1.063 L95 75mm8.3 : 11,000 kPa (10 kg/cm2, 10 bar) at 400 r/minElectric starter

Lubrication system: Wet sump

Oil type or grade:Engine oil API standard:

SE or higher gradeACEA standard:

G4 or G5

Final gear oil: SAE80API GL-4 Hypoid Gear Oil

Oil quantity:Engine oilPeriodic oil changeWith oil filter replacementTotal amount

Final gear case oilTotal amount

3.0 L3.1 L3.6 L

0.2 L

Air filter: Dry type element

Fuel:TypeFuel tank capacityFuel reserve amount

Regular unleaded gasoline17 L4.5 L


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2-2


Item Standard

Carburetor:

Type/quantityManufacturer BSR37/2MIKUNI

Spark plug:

Type

Manufacturer

Spark plug gap

BPR7ES/W22EPRU

NGK/DENSO

0.7X 0.8 mm

Clutch type: Wet, multiple-disc

Transmission:

Primary reduction system

Primary reduction ratio

Secondary reduction systemSecondary reduction ratio

Transmission type

Operation

Gear ratio 1st

2nd

3rd

4th

5th

Spur gear

78/47 (1.660)

Shaft drive44/47 19/18 32/11 (2.875)

Constant mesh 5-speed

Left foot operation

40/17 (2.353)

40/24 (1.667)

36/28 (1.286)

32/31 (1.032)

29/34 (0.853)

Chassis:

Frame type

Caster angleTrail

Double cradle

33_136 mm

Tire:

Type

Size front

rear

Manufacturer front

rear

Type front

rear

With tube

110/90-18 61S

170/80-15M/C 77S

BRIDGESTONE/DUNLOP

BRIDGESTONE/DUNLOP

EXEDRA L309/K555F

EXEDRA G546/ K555

Maximum load-except motorcycle: 201 kg (5EL2 : 200kg)Tire pressure (cold tire):

0X 90 kg (0 X 198 lb) load *

front

rear

90 kg (198 lb)X Maximum load *

front

rear

200 kPa (2.00 kg/cm2)

225 kPa (2.25 kg/cm2)

225 kPa (2.25 kg/cm2)

250 kPa (2.50 kg/cm2)

* Load is the total weight of the cargo, rider,

passenger and accessories.

Brake:Front brake type

operation

Rear brake type

operation

Dual disc brake

Right hand operation

Single disc brake

Right foot operation


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2-3


Item Standard

Suspension:

Front suspensionRear suspension Telescopic forkSwingarm (link suspension)

Shock absorber:

Front shock absorber

Rear shock absorber

Coil spring/Oil damper

Coil spring/Gas-oil damper

Wheel travel:

Front wheel travel

Rear wheel travel

140 mm

113 mm

Electrical:

Ignition system

Generator systemBattery type

Battery capacity

T.C.I. (digital)

A.C. magnetoGT14B-4

12 V 12 AH

Headlight type: Quartz bulb (halogen)

Bulb wattage quantity:

Headlight

Auxiliary light

Tail/brake light

Turn signal

Licence light

Meter light

Neutral indicator light

High beam indicator light

Turn indicator light

Oil level caution light

Engine warning light

12 V 60 W/55 W 1

12 V 4 W 1

12 V 5 W/21 W 1

12 V 21 W 4

12 V 5 W 1

14 V 1.4 W 2

12 V 1.7 W 1

12 V 1.7 W 1

12 V 1.7 W 1

12 V 1.7 W 1

12 V 1.7 W 1


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2-4

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONSENGINE

Item Standard LimitCylinder head:

Warp limit SSS 0.03 mm

Cylinder:

Bore sizeMeasuring point 95.00X

95.01 mm40 mm 95.1 mmSSS

Camshaft:

Drive method

Cam cap inside diameter

Camshaft outside diameter

Shaft-to-cap clearance

Cam dimensions

Intake A

B

C

Exhaust A

B

C

Camshaft runout limit

Chain drive (left & right)

25.000X 25.021 mm

24.96X 24.98 mm

0.020X 0.061 mm

39.112X 39.212 mm

#1: 32.093X 32.193 mm

#2: 32.127X 32.227 mm7.162 mm

39.145X 39.245 mm

32.200X 32.300 mm

7.195 mm

SSS

SSS

SSS

SSS

SSS

39.012 mm

#1: 31.993 mm

#2: 32.027 mm7.012 mm

39.045 mm

32.100 mm

7.045 mm

0.03 mm


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2-5

Margin ThicknessHead Dia Face width Seat Width


Item Standard Limit

Timing chain:

Timing chain type/No. of linksTiming chain adjustment method SILENT CHAIN/98LAutomatic

SSS

SSS

Rocker arm/rocker arm shaft:

Bearing inside diameter

Shaft outside diameter

Arm-to-shaft clearance

14.000 mmX 14.018 mm

13.985 mmX 13.991 mm

0.009 mmX 0.033 mm

14.036 mm

13.95 mm

0.086 mm

Valve, valve seat, valve guide:

Valve clearance (cold) IN

EX

0.07X 0.12 mm

0.12X 0.17 mm

SSS

SSS

Valve dimensions:

A head diameter IN

EX

B face width IN

EX

C seat width IN

EXD margin thickness IN

EX

Stem outside diameter IN

EX

Guide inside diameter IN

EX

Stem-to-guide clearance IN

EX

47.0X 47.2 mm

39.0X 39.2 mm

2.1 mm

2.1 mm

1.2X 1.4 mm

1.2X 1.4 mm1.1X 1.5 mm

1.1X 1.5 mm

7.975X 7.990 mm

7.960X 7.975 mm

8.000X 8.012 mm

8.000X 8.012 mm

0.010X 0.037 mm

0.025X 0.052 mm

SSS

SSS

SSS

SSS

1.8 mm

1.8 mm0.8 mm

0.8 mm

SSS

SSS

SSS

SSS

0.08 mm

0.10 mm


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2-6


Item Standard Limit

Stem runout limit

Valve seat width IN

EX

SSS

1.2X 1.4 mm

1.2X 1.4 mm

0.03 mm

2.0 mm

2.0 mm

Valve spring:

Free length IN

EX

Set length (valve closed) INEX

Compressed pressure IN

(installed) EX

Tilt limit IN

EX

Direction of winding

(top view) IN

EX

44.6 mm

44.6 mm

40 mm40 mm

160.7 N (16.4 kg)

160.7 N (16.4 kg)

SSS

SSS

Clockwise

Clockwise

43.5 mm

43.5 mm

SSS

SSS

SSS

SSS

2.5_/1.9mm

2.5_/1.9mm

SSS

SSS

Piston:

Piston to cylinder clearance

Piston size D

Measuring point H

Piston off-set

0.025X 0.050 mm

94.960X 94.975 mm

5 mm

0 mm

0.15 mm

SSS

SSS

SSS


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2-7


1 2 3 4 5

Item Standard Limit

Piston pin bore inside diameter

Piston pin outside diameter

22.004X 22.015 mm

21.991X

22.000 mm

SSS

SSS

Piston rings:

Top ring:

Type

Dimensions (B T)

End gap (installed)

Side clearance (installed)

2nd ring:

Type

Dimensions (B T)

End gap (installed)

Side clearance

Oil ring:

Dimensions (B T)

End gap (installed)

Plain

1.5 3.8 mm

0.3X 0.5 mm

0.04X 0.08 mm

Taper

1.2 3.8 mm

0.30X 0.45 mm

0.03X 0.07 mm

2.5 3.4 mm

0.2X 0.7 mm

SSS

SSS

0.8 mm

0.1 mm

SSS

SSS

0.8 mm

0.1 mm

SSS

SSS

Connecting rod:

Oil clearance

Color code (corresponding size)

0.044X 0.073 mmBlue Black Brown Green Yellow

SSS

SSS

Crankshaft:

Crank width A

Runout limit C

Big end side clearance D

101.95X 102.00 mm

SSS

0.320X 0.474 mm

SSS

0.02 mm

SSS


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2-9


Item Standard Limit

Lubrication system:

Oil filter typeOil pump type

Tip clearance A or B

Side clearance

Relief valve operating pressure

Paper typeTrochoid type

0.03X 0.09 mm

0.03X 0.08 mm

450X 550 kPa (4.5X 5.5 kg/cm2)

SSS

SSS

0.15 mm0.15 mmSSS

Shaft drive:

Middle gear backlash

Final gear backlash

0.1X 0.2 mm

0.1X 0.2 mm

SSS

SSS


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2-10


Item Standard

Lubrication chart:


29/354

Left crankcase Right crankcase


2-11

Cylinder head tightening sequence:

Crankcase tightening sequence:


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2-12


Tightening torques

Part to be tightened Part name

Thread

Qty

Tighteningtorque

RemarksNm mSkg

Cylinder headCylinder headPlateCylinder head coverCylinder head (exhaust pipe)Rocker arm shaftCamshaft sprocket coverTappet coverRocker arm shaft (oil passage)

Stopper plate (camshaft)Spark plugCylinderLower cylinder head coverUpper cylinder head coverConnecting rodRotorValve adjusting locknutCamshaft sprocketTiming chain tensionerTiming chain tentioner capTiming chain guide

Oil pumpOil strainer coverOil filter coverOil pump gearOil pump capOil deliuery pipe (cylinder head)

(crankcase)Drain boltCarburetor coverAir filter case stayAir filter case assembly

Exhaust pipe joint and cylinder headExhaust pipe joint and mufflerassemblyMufflerCrankcase (cylinder)Crankcase (cylinder)CrankcaseCrankcaseBearing retainer (middle drive piniongear)Crankcase cover (left)Crankcase cover (right)

ClampOne-way clutchPrimary drive gear

NutNutBolt

ScrewStud boltUnion bolt

BoltBoltBolt

BoltBoltBolt

ScrewNutNutNutBoltBoltBoltBolt

BoltBoltBoltBoltBolt

Union boltUnion bolt

BoltBoltBolt

NutBolt

BoltStud boltStud bolt

BoltBoltBolt

BoltBolt

BoltBoltNut

M12M10M8M6M8M16M6M6M16

M8M14M6M6M6M9M16M8M10M6M6M6

M6M6M6M6M6M16M10M14M5M6M5

M8M8

M10M12M10M10M6M8

M6M6

M6M6M20

822442484

422684142424

33511211223

42

2823103

1311

181

5035204

12.537.5101038

20201010548175275510810

10101012102020437102

2020

252420

38.51025

1010

1012110

5.03.52.00.4

1.253.751.01.03.8

2.02.01.01.00.54.8

17.52.75.51.00.81.0

1.01.01.01.21.02.02.04.30.71.00.2

2.02.0

2.52.42.0

3.851.02.5

1.01.0

1.01.211.0

Use lock washer

Use lock washer


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2-13


Part to be tightened Part nameThread

Qty

Tightening

torque Remarkss ze

Nm mSkg

Clutch spring

Clutch adjuster

Clutch boss

Push lever axle

Middle drive pinion gear

Bearing retainer (middle driven shaft)

Yoke (middle driven shaft)

Bearing housing (middle drive shaft)

Shift lever stopper

Guide bar stopperShift dram segment

Shift arm

Shift pedal adjuster

Stator coil

Pickup coil

Starter motor

Neutral switch

Ignition coil

Speed sensor

Bolt

Nut

Nut

Screw

Nut

Nut

Nut

Bolt

Bolt

ScrewScrew

Bolt

Nut

Screw

Screw

Bolt

Screw

Bolt

M6

M8

M20

M8

M44

M88

M14

M8

M8

M6M5

M6

M6

M6

M5

M6

M10

M5

M6

6

1

1

1

1

1

1

4

1

21

1

2

3

2

2

1

4

1

8

12

70

12

110

110

25

22

74

10

10

10

7

10

20

2.5

7

0.8

1.2

7.0

1.2

11.0

11.0

2.5

2.2

0.70.4

1.0

1.0

1.0

0.7

1.0

2.0

0.25

0.7

Use lock washer

Stake

Stake

Stake

Use lock washer

1 of 2 has LH

thread


32/354

2-14


CHASSIS

Item Standard Limit

Steering system:Steering bearing type Angular bearing SSS

Front suspension:

Front fork travel

Fork spring free length

Fitting length

Collar length

Spring rate (K1)

(K2)

Stroke (K1)

(K2)

Optional spring

Oil capacity

Oil level

Oil grade

140 mm

356.9 mm

319.4 mm

183 mm

8.8 N/mm (0.9 kg/mm)

12.7 N/mm (1.3 kg/mm)

0X 77.5 mm

77.5X 140 mm

No

0.464 L

108 mm

Fork oil 10W or equivalent

SSS

350 mm

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

Rear suspension:

Shock absorber travel

Spring free length

Fitting length

Spring rate (K1)

Stroke (K1)

Optional spring

113 mm

179.5 mm

163 mm

117.7 N/mm (12 kg/mm)

0X 50 mm

No

SSS

SSS

SSS

SSS

SSS

SSS

Swingarm:

Free play limit end SSS 0 mm

Front wheel:

Type

Rim size

Rim material

Rim runout limit radial

lateral

Spoke wheel

18 2.15

Steel

SSS

SSS

SSS

SSS

SSS

1.0 mm

0.5 mm

Rear wheel:

TypeRim size

Rim material

Rim runout limit radial

lateral

Spoke wheel15M/C MT4.50

Steel

SSS

SSS

SSS

SSS

SSS

1.0 mm

0.5 mm


33/354

2-15


Item Standard Limit

Front brake:

TypeDisc outside diameter thickness

Disc deflection limit

Pad thickness inner

Pad thickness outer

Master cylinder inside diameter

Caliper cylinder inside diameterCaliper cylinder inside diameter

Brake fluid type

Dual disc298 5 mm

SSS

6.2 mm

6.2 mm

14.0 mm

25.4 mm30.1 mm

DOT 4

SSS

4.5 mm

0.15 mm

0.8 mm

0.8 mm

SSS

SSS

SSS

SSS

Rear brake:

Type

Disc outside diameter thickeness

Disc deflection limit

Pad thickness inner

outer

Master cylinder inside diameter

Caliper cylinder inside dimeter

Brake fluid type

Single disc

282 6 mm

SSS

5.55 mm

5.55 mm

12.7 mm

42.9 mm

DOT 4

SSS

5.5 mm

0.15 mm

0.5 mm

0.5 mm

SSS

SSS

Brake lever & brake pedal:

Brake lever free play (at lever end)

Brake pedal position

Brake pedal free play

Clutch lever free play (at lever end)

Throttle grip free play

5X 8 mm

81.8 mm

0 mm

5X 10 mm

4X 6 mm

SSS

SSS

SSS

SSS


34/354

2-16


Tightening torques

Part to be tightened Thread size

Tighteningtorque

RemarksNm mSkg

Upper bracket and inner tubeLower bracket and inner tubeUpper bracket and steering shaftRing nut (steering shaft)Handlebar holder (lower) and upper bracketHandlebar holder (lower) and handlebarholder (upper)Master cylinder (front brake)Union bolt (brake hose)

Brake hose holder and lower bracketBrake hose joint and brake pipeBrake hose joint and brake hose holderFront fender and outer tubeHeadlight stay and lower bracketHeadlight stay and headlightFront flasher light and lower bracketEngine mounting:

Frame and stay (front - upper)Frame and stay (front - lower)Stay and engine (front - upper)Stay and engine (front - lower)

Frame and engine (rear - upper)Frame and engine (rear - lower)

Down tube and framelgnition coil and stayMuffler stay and frameRear shock absorber and relay armRear shock absorber and framePivot shaft and swingarmRelay arm and frameConnecting arm and relay armConnecting arm and swingarm

Final gear case and swingarmSwingarm end and holderFuel tank and fuel cockFuel tank bracket and frameRiders seatPassenger seatFuel tank and top coverLicence bracket and rear fender stayRear fender and rear fender stayRear fender and tail/brake lightRear fender stay and rear flasher lightFrame and rear fender

Side cover (left)Battery coverSide cover (right)Starter relay and leads

M8M10M22M12M8

M6M10

M6M10M6M8M6M6M6

M10M10M12M10

M10M10M10M5M8M10M10M16M10M12M12

M10M8M6M8M6M6M5M6M5M6M12M8

M6M6M6M6

2030110183228

1030

10191010787

48487448

484848430484090484848

9023723774746726

7777

2.03.011.01.83.22.8

1.03.0

1.01.91.01.00.70.80.7

4.84.87.44.8

4.84.84.80.43.04.84.09.04.84.84.8

9.02.30.72.30.70.70.40.70.40.60.72.6

0.70.70.70.7

See NOTE


35/354

2-17


NOTE:

Part to be tightenedThread

Tighteningtorque Remarks

s zeNm mSkg

Passenger footrest and frameSidestand bracket and frameSidestand and sidestand bracketSidestand switchBrake pedal/footrest and frameRear brake master cylinder and master cylinderbracketMaster cylinder bracket and down tubeFootrest and frameFront wheel axleFront wheel axle pinch bolt

Brake caliperBrake disc and front wheelCaliper bleed screwRear wheel axle nutRear brake caliper and caliper bracketCaliper bracket and swingarmBrake hose union boltCaliper bleed screwClutch hub and damperFinal gear case stud boltFinal gear case stud bolt

Bearing housing (final gear case)Bearing housing (final gear case)Drive pinionBearing retainer (final drive pinion gear)Oil filter bolt (final gear)Oil drain bolt (final gear)Housing cover

M8M10M10M5M6M8

M8M10M16M8

M10M8M7M16M10M10M10M8M10M10M8

M8M10M14M65M14M14M10

2664564723

23645920

40236

107404030662189

2340130115232342

2.66.45.60.40.72.3

2.36.45.92.0

4.02.30.6

10.74.04.03.00.66.21.80.9

2.34.0

13.011.52.32.34.2

LH thread

1. First, tighten the ring nut approximately 52 Nm (5.2 mSkg) by using the torque wrench, then

loosen the ring nut completely.

2. Retighten the ring nut to specification.


36/354

2-18


ELECTRICAL

Item Standard Limit

Voltage: 12 VSSS

Ignition system:

Ignition timing (B.T.D.C.)

Advancer type

10_ at 1,000 r/min

Digital type

SSS

SSS

T.C.I.:

Pickup coil resistance/color

T.C.I. unit model/manufacturer

189X 231 at 20_C/ Gray Black

J4T101/MITSUBISHI

SSS

SSS

Ignition coil:

Model/manufacturer

Primary winding resistance

Secondary winding resistance

F6T507/MITSUBISHI

3.57X 4.83 at 20_C

10.7X 14.5 k at 20_C

SSS

SSS

SSS

Spark plug cap:

Type

Resistance

Resin type

10 k

SSS

SSS

Charging system:

Type

Model/manufacturer

Nominal output

Stator coil resistance/color

A.C. magneto

F4T654/MITSUBISHI

14 V 350 W at 5,000 r/min

0.36X 0.44 at 20_C/White White

SSS

SSS

SSS

SSS

Voltage regulator:

TypeModel/manufacturer

No load regulated voltage

Semi-conductor, short-circuit typeSH650D-11/SHINDENGEN

14.1X 14.9 V

SSS

SSS

SSS

Rectifier:

Model/manufacturer

Capacity

Withstand voltage

SH650D-11/SHINDENGEN

18 A

200 V

SSS

SSS

SSS

Battery:

Specific gravity 1.320 SSS

Electric starter system:

TypeStarter motor:

Model/manufacturer

Output

Armature coil resistance

Brush overall length

Brush spring pressure

Commutator diameter

Mica undercut

Starter relay:

Model/manufacturer

Amperage rating

Constant mesh type

SM-13/MITSUBA

0.6 kW

0.026X 0.034 at 20_C

12.5 mm

7.65X 10.01 N (780X 1021 g)

28 mm

0.7 mm

MS5F-421/JIDECO

180 A

SSS

SSS

SSS

SSS

5 mm

SSS

27 mm

SSS

SSS

SSS


37/354

2-19


Item Standard Limit

Horn:

TypeQuantity

Model/manufacturer

Maximum amperage

Plane type1

YF-12/NIKKO

3 A

SSS

SSS

SSS

SSS

Flasher relay:

Type

Model/manufacturer

Self cancelling device

Flasher frequency

Wattage

Full transistor type

FE246BH/DENSO

No

75X 95 cycle/min

21 W 2 + 3.4W

SSS

SSS

SSS

SSS

SSS

Oil level gauge:

Model/manufacturer 5EL/DENSO SSS

Starting circuit cut-off relay

Model/manufacturer G8R-30Y-B/OMRON SSS

Fuel pump relay:

Model/manufacturer G8R-30Y-B/OMRON SSS

Circuit breaker:

Type

Amperage for individual circuit

MAIN

HEAD LIGHT

SIGNALS

IGNITION

BACK UP

Carburetor heater

Reserve

Reserve

Reserve

Reserve

Fuse

30 A 1

15 A 1

10 A 1

10 A 1

5 A 1

15 A 1

30 A 1

15 A 1

10 A 1

5 A 1

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS


38/354

2-20

GENERAL TORQUE SPECIFICATIONS/CONVERSION TABLE SPEC

GENERAL TORQUESPECIFICATIONS

This chart specifies torque for standard fasten-ers with standard I.S.O. pitch threads. Torquespecifications for special components or as-semblies are provided for each chapter of thismanual. To avoid warpage, tighten multi-fasten-er assemblies in a crisscross fashion, in pro-gressive stages, until the specified torque isreached. Unless otherwise specified, torquespecifications require clean, dry threads. Com-ponents should be at room temperature.

A: Distance between flatsB: Outside thread diameter

10 mm 6 mm 6 0,6

12 mm 8 mm 15 1,5

14 mm 10 mm 30 3,0

19 mm 14 mm 85 8,5

22 mm 16 mm 130 13,0

17 mm 12 mm 55 5,5

A

(nut)

B

(Bolt)

General torque

specifications

Nm mSkg

EAS00028

CONVERSION TABLEAll specification data in this manual are listed

in SI and METRIC UNITS.Use this table to convert METRIC unit data toIMPERIAL unit data.

Ex.

CONVERSION TABLE

EB202001

METRIC MULTIPLIER IMP

** mm x 0.03937 = ** in

2 mm x 0.03937 = 0.08 in

METRIC TO IMP

Known Multiplier Result

Torque

mSkgmSkgcmSkgcmSkg

7.23386.7940.07230.8679

ftSlbinSlbftSlbinSlb

Weightkgg

2.2050.03527

lboz

Distance

km/hrkmmmcm

mm

0.62140.62143.2811.0940.3937

0.03937

mphmiftydin

in

Volume/Capacity

cc (cm3)cc (cm3)lt (liter)It (liter)

0.035270.061020.87990.2199

oz (IMP liq.)cuSinqt (IMP liq.)gal (IMP liq.)

Miscella-neous

kg/mmkg/cm2

Centigrade

55.99714.22349/5 (_C) + 32

lb/inpsi (lb/ in2)Fahrenheit (_F)


39/354

2-21

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EB203000

LUBRICATION POINTS AND LUBRICANT TYPESENGINE

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 lobe/journal

Rocker arm shaft

Valve stem (IN, EX)

Valve stem end (IN, EX)

Timing chain drive gear shafts/sprokets

Oil pump rotor (inner/outer), housing

Idle gear surface

Starter idle gear

Starter idle gear shaft

Starter oneway cam

Middle drive gear

Primary driven gear

Push rod 1, 2

Transmission gear (wheel/pinion)

Shift cam

Shift fork/guide bar

Shift shaft assemblyPush rod ball

Push lever assembly


40/354

2-22

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

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 pedal shaft

Shift pedal shaft

Sidestand bolt, sidestand sliding surface

Tube guide (throttle grip) inner surface

Brake lever pivot bolt, contact surface

Clutch lever pivot bolt, contact surface

Rear shock absorber (lower) oil seal lip

Swingarm pivot bearing inner surface

Swingarm pivot oil seal lip

Relay arm bearing, collar and oil seal

Drive shaft spline

Drive shaft dust cover


41/354

2-23

LUBRICATION DIAGRAMS SPEC

4 Oil pump

5 Drive axle6 Middle drive shaft

1 Rocker arm shaft (intake)

2 Rocker arm shaft (exhaust)3 Oil filter

EB205000

LUBRICATION DIAGRAMS


42/354

2-24

4 Middle drive shaft1 Oil pump2 Releaf valve3 Oil filter



43/354

2-25

4 Middle drive shaft5 Drive axle6 Connecting rod big end

1 Camshaft2 Crankshaft3 Main axle



44/354

2-26

CABLE ROUTING SPEC

19 Fuel hose (carburetor-fuel pump)

20 Brake hose21 Heat protector22 Fuel breather hose (fuel tank-

roll over valve) (for California)23 Speedometer lead24 Wireharness25 Purge hose (carburetor-solenoid

valve) (for California)

10 Alarm connector

11 Fuel pump lead12 Speed sensor lead13 Sidestand switch lead14 Neutral switch lead15 Pickup coil lead16 AC magneto lead17 Ventilation hose18 Sensing hose (AIS-carburetor

joint)

1 Clutch cable

2 Starter cable3 Handlebar switch lead (left)4 Handlebar switch lead (right)5 High tension code6 Starter cable7 Throttle cable8 Fuel hose (fuel cock-fuel filter)9 Fuse box

EB206000

CABLE ROUTING


45/354

2-27

F Push the wire harness insideof the tool box plate.

G Route the sidestand leadinside of engine cover.

H Position the all connectorsinside of the connector cover.

I Route the clutch cable throughthe cable guide.

B Position the throttle cable andstarter cable as shown, andclamp them with holder.

C Clamp the wire harness withthe hook of frame side.

D When installing the pipe ofthrottle cables, press it inside.

E Connect the sensing hose(carburetor joint-AIS side) witha nozzle.

26 Purge hose (carburetor-solenoidvalve) (for California)

A Fasten the handlebar switchleads (left and right) to thehandlebar with plastic lockingtie.

CABLE ROUTING SPEC

27


46/354

2-28

M Fasten the AC magneto leadand sidestand switch lead with aplastic locking tie.

N Fasten the alarm lead with aplastic band on the lid.

J Fasten the handlebar switchleads (left and right) under thehandle crown with a plasticband.Set the band at four notches,and install it no slacking.

K Route the each hoses throughthe frame guide and do notpinch it.

L When installing the fitting plate,do not pinch the each hosesand wire harness.

CABLE ROUTING SPEC


47/354

E

2-29

23 Handlebar switch lead (left)24 Throttle position sensor lead25 Carburetor heater lead26 Thermo switch lead27 Starting circuit cutoff relay28 Down tube29 High tension code30 Purge hose (carburetor-

solenoid valve) (for California)31 Carburetor heater lead32 Oil level switch lead

12 Ignition coil13 Master cylinder reservoir hose14 Breather hose15 Air filter drain hose16 Battery negative () lead17 Rear brake switch lead18 Rear brake hose19 Carburetor heater connector20 Rectifier/regulator21 Main switch lead22 Flasher relay

1 Battery2 Battery positive (+) lead3 Starter motor positive (+) lead4 Speedometer lead5 Fuel hose (carburetor-fuel pump)6 High tension code7 Main switch lead8 Throttle cable9 Brake hose

10 Handlebar switch lead (right)11 Headlight lead

CABLE ROUTING SPEC


48/354

E

2-30

H Fasten the rear brake switchlead and master cylinderreservoir hose to the downtube with a plastic locking tie.

I Fasten the wire harness,starter motor positive (+) leadand battery negative () lead tothe frame with a plastic locking tie.

J Route the rectifier/ regulatorlead and carburetor heater leadthrough inside of battery boxhole to outside it and connectthem.

D Connect the purge hose(carburetor side-solenoid valveside) with joint. (for California)

E Route the front turn signal lightlead and headlight lead throughthe rear of headlight body hole.

F Connect the ignition coil lead atred tape to the right side.

G Fasten the rear brake switchlead to the brake switch bracketwith a plastic locking tie.

A Clamp the battery positive (+)lead to the battery with batteryband.

B Connect the battery negative() lead connector and push itinto the space between batterybox and battery.

C Route the rectifier/ regulatorlead, wire harness and startermotor positive (+) lead throughthe outside of frame bracketand fasten them to the framewith a plastic locking tie.

CABLE ROUTING SPEC


49/354

E

2-31

K To rear brake caliperL Clamp the handlebar switch

lead (right) and main switchlead to the frame with a holder.

M Arrange the throttle positionsensor connector, carburetorheater connector and thermoswitch connector between thestarting circuit cutoff relay andhigh tension code.

N Fasten the rear brake switchto the down tube with a plasticlocking tie.

CABLE ROUTING SPEC


50/354

E

2-32

20 Starter cable21 Fuel hose (fuel cock-fuel filter)22 Carburetor heater lead23 Thermo switch lead24 Igniter unit25 Taillight lead26 Throttle position sensor lead27 Fuel filter28 Igniter unit lead29 Frame30 Wire harness

A Clamp the throttle cables withthe holder.

11 Battery negative () leadconnector

12 Battery13 Battery positive (+) lead14 Taillight lead15 Starter relay16 Starter motor positive (+) lead17 Speedometer lead connector18 Fuel tank breather hose

(fuel tank-roll over valve) (forCalifornia)

19 Ventilation hose

1 Brake hose2 Throttle cable3 Master cylinder reservoir hose4 High tension code5 Purge hose (carburetor-solenoid

valve) (for California)6 Rear brake switch lead7 Brake hose8 Sensing hose (AIS-carburetor

joint)9 Fuel hose (carburetor-fuel

pump)10 Battery negative () lead

CABLE ROUTING SPEC


51/354

E

2-33

J Fasten the wire harness with aband on the tool box plate.

K Fasten the wire harness to theframe with a plastic locking tie.Position the locking tie front ofthe solder.

F Route the battery positive (+)lead through the slit of thebattery box.

G Clamp the igniter unit lead tothe frame with a holder.

H To the rear fender.I Route the fuel tank breather

hose under the fuel filter andconnect it (fuel tank side-rollover valve side) with a joint.Position the end of clip outside.

B Route the rear brake switchlead under the master cylinderreservoir hose.

C Position the band end of rightside bracket.

D Position the steel band end toforward.

E Position the steel band end toright side.

CABLE ROUTING SPEC


52/354

E

2-34

P Route the igniter lead throughthe igniter plate hole to the wireharness.

Q Clamp the taillight lead withmud guard clamp.

R Clamp the taillight lead with aholder on the mud guard.

L Route wire harness outside ofthe guide on the frame.

M Clamp the clutch cable andstarter cable with a holder.Position the end of holder downside.

N Route the throttle positionsensor lead and carburetorheater lead left side of thetappet cover.

O To the wire harness.

CABLE ROUTING SPEC


53/354

E

1 Throttle cable2 Starter cable3 Clutch cable4 Handlebar switch lead (left)5 Headlight lead6 Brake hose

A Route the handlebar switchlead (right) rear side of thethrottle cable.

2-35

CABLE ROUTING SPEC


54/354

INSP

ADJ 3


55/354

INSP

ADJ

CHAPTER 3

PERIODIC INSPECTIONS AND ADJUSTMENTS

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

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

FUEL TANK AND SEATS 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE VALVE CLEARANCE 3-5. . . . . . . . . . . . . . . . . . . . . . .

SYNCHRONIZING THE CARBURETORS 3-8. . . . . . . . . . . . . . . . . . . . . .ADJUSTING THE ENGINE IDLING SPEED 3-10. . . . . . . . . . . . . . . . . . . .

ADJUSTING THE THROTTLE CABLE FREE PLAY 3-11. . . . . . . . . . . . .

CHECKING THE SPARK PLUGS 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE IGNITION TIMING 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . .

MEASURING THE COMPRESSION PRESSURE 3-14. . . . . . . . . . . . . . .

CHECKING THE ENGINE OIL LEVEL 3-16. . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING THE ENGINE OIL 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE CLUTCH CABLE FREE PLAY 3-18. . . . . . . . . . . . . . . .

CLEANING THE AIR FILTER ELEMENT 3-19. . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CARBURETOR JOINT AND INTAKE

MANIFOLD 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BREATHER HOSE 3-20. . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE EXHAUST SYSTEM 3-21. . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE FRONT BRAKE 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE REAR BRAKE 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BRAKE FLUID LEVEL 3-24. . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-25. . . . . . . . . . . . . . .

CHECKING THE BRAKE HOSES 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-26. . . . . . . . . . . . . . . .

ADJUSTING THE SHIFT PEDAL 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE FINAL DRIVE OIL LEVEL 3-28. . . . . . . . . . . . . . . . . . . .

CHANGING THE FINAL DRIVE OIL 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING AND ADJUSTING THE STEERING HEAD 3-29. . . . . . . . . .

CHECKING THE FRONT FORK 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-31. . . . . .

CHECKING THE TIRES 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING AND TIGHTENING THE SPOKES 3-35. . . . . . . . . . . . . . . . .

CHECKING AND LUBRICATING THE CABLES 3-36. . . . . . . . . . . . . . . . .

LUBRICATING THE LEVERS AND PEDALS 3-36. . . . . . . . . . . . . . . . . . .

LUBRICATING THE SIDESTAND 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .LUBRICATING THE REAR SUSPENSION 3-36. . . . . . . . . . . . . . . . . . . . .


56/354


57/354

3-1

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INSPADJ

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTION

This chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.

EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

EVERY

NO. ITEM CHECKS AND MAINTENANCE JOBSInitial

(1,000 km)

6,000 kmor

6 months(whichever

comes first)

12,000 kmor

12 months(whichever

comes first)

1 * Fuel line (manual cock)S Check fuel hoses for cracks or damage.

S Replace if necessary.

2 * Fuel filterS Check condition.


3 Spark plugsS Check condition.

S Clean, regap or replace if necessary.

4 * Valves (arm SOHC)S Check valve clearance.

S Adjust if necessary.

5 Air filter S Clean or replace if necessary.

6 ClutchS Check operation.

S Adjust or replace cable.

7 * Front brake (disc)

S Check operation, fluid level and vehicle for fluid leakage.(See NOTE.)

S Correct accordingly.

S Repalce brake pads if necessary.

8 * Rear brake (disc)

S Check operation, fluid level and vehicle for fluid leakage.

(See NOTE.)


S Replace brake pads if necessary.

9 * Wheels (spoke)S Check balance, runout, spoke tightness and for damage.

S Tighten spokes and rebalance, replace if necessary.

10 * Tires (EUR)

S Check tread depth and for damage.


S Check air pressure.

S

Correct if necessary.

11 * Wheel bearingsS Check bearing for looseness or damage.


12 * Swingarm (no nipple)

S Check swingarm pivoting point for play.

S Correct if necessary.

S Lubricate with molybdenum disulfide grease every

24,000 km or 24 months (whichever comes first).

13 * Steering bearings

S Check bearing play and steering for roughness.


S Lubricate with lithium soap base grease every 24,000

km or 24 months (whichever comes first).

14 * Chassis fasteners

S Make sure that all nuts, bolts and screws are properly

tightened.

S

Tighten if necessary.

15 SidestandS Check operation.

S Lubricate and repair if necessary.

16 * Sidestand switchS Check operation.



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3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJ

NOTE:

EVERY

NO. ITEM CHECKS AND MAINTENANCE JOBSInitial

(1,000 km)

6,000 kmor

6 months

(whichevercomes first)

12,000 kmor

12 months

(whichevercomes first)

17 * Front forkS Check operation and for oil leakage.


18 *Rear shock absorber

assembly

S Check operation and shock absorber for oil leakage.

S Replace shock absorber assembly if necessary.

19 * Carburetors (multi)

S Check engine idlilng speed, synchronization and start-

er operation.

S Adjust if necessary.

20 Engine oil

S Check oil level and vehicle for oil leakage.

S Correct if necessary.

S Change. (Warm engine before draining.)

21 * Engine oil filterelement

S Replace.

22 Final gear oil

S Check oil level and vehicle for oil leakage.

S Change oil at initial 1,000 km and thereafter every

24,000 km or 24 months (whichever comes first).

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

SThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.SHydraulic brake system When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check

the brake fluid level regularly and fill as required.

Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. Replace the brake hoses every four years or if cracked or damaged.


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Order Job name/Part name Qty Remarks

1234

5678

Fuel tank and seats removalPassenger seatSeat bracketRiders seatFuel hose

Ignitor plateMud guardMeter lead couperFuel tank assembly

1111

1111

Remove the parts in the order below.

Set the fuel cock to OFF before dis-connecting the fuel hose.

For installation, reverse the removal

procedure.

NOTE:

7 Nm (0.7mSkg)

23Nm (2.3mSkg)

7 Nm (0.7mSkg)

3-3

FUEL TANK AND SEATSINSPADJ

FUEL TANK AND SEATS


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3-4

FUEL TANK AND SEATSINSPADJ

NOTE:

NOTE:

REMOVAL1. Remove:S Ignitor plate

To remove the quick fastener, push its center inwith a screwdriver, then pull the fastener out.

INSTALLATION1. Install:S Ignitor plate

To install the quick fastener, push its pin so that itprotrudes from the fastener head, then insertthe fastener into the cowling and push the pin a

in with a screwdriver. Make sure that the pin isflush with the fasteners head.


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3-5

ADJUSTING THE VALVE CLEARANCEINSPADJ

NOTE:

EAS00047

ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.

SValve clearance adjustment should be madeon a cold engine, at room temperature.

SWhen the valve clearance is to be measured oradjusted, the piston must be at top dead center(TDC) on the compression stroke.

1. Remove:S riders seat

S fuel tankRefer to FUEL TANK AND SEATS.

2. Disconnect:Sspark plug caps

3. Remove:Sspark plugs

4. Remove:Sair intake box 1

5. Remove:Scylinder head cover (rear cylinder) 1

Scylinder head cover (front cylinder)


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3-6


6. Remove:S tappet covers 1

7. Remove:Scamshaft sprocket cover (rear cylinder) 1

Scamshaft sprocket cover (front cylinder)

8. Remove:S timing plug 1

Sstraight plug 2

9. Measure:Svalve clearanceOut of specification! Adjust.

Valve clearance (cold):

Intake valve:0.07X 0.12 mm

Exhaust valve:0.12X 0.17 mm


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3-7


A B

a

b

a. Turn the crankshaft counterclockwise.b. When the piston is at TDC on the compres-

sion stroke, align either the camshaft sprock-et plate hole a with the stationary pointer b

on the cylinder head. When the camshaftsprocket plate hole or camshaft sprocketpunch mark is aligned with the stationarypointer, the piston is at top dead center(TDC).

c. Align the TDC mark c on the generator rotorwith the stationary pointer d on the crank-case.

A Rear cylinder (TI mark)

B Front cylinder (I mark)

d. Measure the valve clearance with a thick-ness gauge 1 .

e. Turn the crankshaft crockwise 290_, andthen measure the front cylinder.

10. AdjustSvalve clearance

a. Loosen the locknut 1 .b. Insert a thickness gauge between the end of

the adjusting screw and the valve tip.c. Turn the adjusting screw 2 in direction a or

b until the specified valve clearance is ob-tained.

DirectionValve clearance isdecreased.

DirectionValve clearance isincreased.

d. Hold the adjusting screw to prevent it frommoving and tighten the locknut to specifica-

tion.


64/354

ADJUSTING THE VALVE CLEARANCE/SYNCHRONIZING THE CARBURETORS

INSPADJ

3-8

NOTE:

10 Nm (1.0 mSkg)

10 Nm (1.0 mSkg)

20 Nm (2.0 mSkg)

NOTE:

NOTE:

Locknut:27 Nm (2.7 mSkg)

e. Measure the valve clearance again.f. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust-ment steps until the specified clearance isobtained.

11. Install:Sall removed parts

Install all removed parts in the reverse order oftheir disassembly. Note the following points.

Scamshaft sprocket covers

S tappet covers

Sspark plugs

EAS00051

SYNCHRONIZING THE CARBURETORS

Prior to synchronizing the carburetors, the valveclearance and the engine idling speed shouldbe properly adjusted and the ignition timingshould be checked.

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

2. Remove:S riders seatS fuel tankRefer to FUEL TANK AND SEATS.

3. Remove:Sair duct 1

4. Remove:Svacuum plugs 1


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3-9

SYNCHRONIZING THE CARBURETORSINSPADJ

NOTE:

5. Install:Svacuum gauge 1

Sengine tachometer 2

(to the spark plug lead of cyl. #2)

Vacuum gauge:90890-03094

Engine tachometer:90890-03113

6. Start the engine and let it warm up for severalminutes.

7. Check:Sengine idling speedOut of specification! Adjust.

Refer to ADJUSTING THE ENGINE IDLINGSPEED.

Engine idling speed:950X 1,050 r/min

8. Adjust:SCarburetor synchronization

a. Synchronize carburetor #1 to carburetor #2by turning the synchronizing screw 1 in ei-ther direction until both gauges read the

same.b. Rev the engine two or three times, each time

for less than a second, and check the syn-chronization again.

Vacuum pressure at idle speed:34.7X 37.3 kPa (260X 280 mmHg)

The difference between the two carburetorsshould not exceed 1.33 kPa (10 mmHg).


10. Stop the engine and remove the measuringequipment.

11. Adjust:S throttle cable free playRefer to ADJUSTING THE THROTTLECABLE FREE PLAY.


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SYNCHRONIZING THE CARBURETORS/ADJUSTING THE ENGINE IDLING SPEED

INSPADJ

3-10

NOTE:

a

b

Throttle cable free play (at theflange of the throttle grip)

4X 6 mm

12. Install:Svacuum plugsSair ductS fuel tankSseat

EAS00054

ADJUSTING THE ENGINE IDLING SPEED

Prior to adjusting the engine idling speed, thecarburetor synchronization should be adjusted

properly, the air filter should be clean, and theengine should have adequate compression.

1. Start the engine and let it warm up for severalminutes.

2. Remove:Scylinder head cover 1

3. Install:Sengine tachometer(to the spark plug lead of cyl. #1)




5. Adjust:Sengine idling speed

a. Turn the pilot screw 1 in until it is lightlyseated.

b. Turn the pilot screw out the specified numberof turns.

Pilot screw3 turns out

c. Turn the throttle stop screw 2 in direction a

or b until the specified engine idling speed isobtained.

DirectionEngine idling speed isincreased.

DirectionEngine idling speed isdecreased.


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3-11

ADJUSTING THE ENGINE IDLING SPEED/ADJUSTING THE THROTTLE CABLE FREE PLAY

INSPADJ

NOTE:

NOTE:

a

b

NOTE:

6. Adjust:S throttle cable free playRefer to ADJUSTING THE THROTTLE

CABLE FREE PLAY.


4X 6 mm

EAS00058

ADJUSTING THE THROTTLE CABLE FREEPLAY

Prior to adjusting the throttle cable free play, theengine idling speed should be adjusted.

1. Check:S throttle cable free play a

Out of specification! Adjust.


4X 6 mm

2. Remove:S riders seatS fuel tank

Refer to FUEL TANK AND SEATS.3. Adjust:S throttle cable free play

When the motorcycle is accelerating, the accel-erator cable 1 is pulled.

Carburetor sidea. Loosen the locknut 2 on the accelerator cable.b. Turn the adjusting nut 3 in direction a or b

until the specified throttle cable free play isobtained.

DirectionThrottle cable free playis decreased.

DirectionThrottle cable free playis increased.

c. Tighten the locknuts.

If the specified throttle cable free play cannot beobtained on the carburetor side of the cable, usethe adjusting nut on the handlebar side.


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3-12

ADJUSTING THE THROTTLE CABLE FREE PLAY/CHECKING THE SPARK PLUGS

INSPADJ

a

b

WARNING

CAUTION:

Handlebar sidea. Loosen the locknut 1 .b. Turn the adjusting nut 2 in direction a or b

until the specified throttle cable free play isobtained.

DirectionThrottle cable free play isincreased.

DirectionThrottle cable free play isdecreased.

c. Tighten the locknut.

After adjusting the throttle cable free play,

turn the handlebar to the right and to the leftto ensure that this does not cause the en-gine idling speed to change.

EAS00059

CHECKING THE SPARK PLUGSThe following procedure applies to all of thespark plugs.1. Remove:Scylinder head covers 1

2. Disconnect:Sspark plug cap

3. Remove:Sspark plug

Before removing the spark plugs, blow awayany dirt accumulated in the spark plug wellswith compressed air to prevent it from fal-ling into the cylinders.

4. Check:Sspark plug typeIncorrect! Change.

Spark plug type (manufacturer)BPR7ES (NGK)W22EPR-U (DENSO)

5. Check:Selectrode 1

Damage/wear! Replace the spark plug.S insulator 2

Abnormal color! Replace the spark plug.Normal color is a medium-to-light tan color.6. Clean:Sspark plug(with a spark plug cleaner or wire brush)


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3-13

CHECKING THE SPARK PLUGS/CHECKING THE IGNITION TIMING

INSPADJ

20 Nm (2.0 mSkg)

NOTE:

NOTE:

7. Measure:Sspark plug gap a

(with a wire gauge)

Out of specification! Regap.

Spark plug gap0.7X 0.8 mm

8. Install:Sspark plug

Before installing the spark plug, clean the sparkplug and gasket surface.

9. Connect:Sspark plug cap

EAS00064

CHECKING THE IGNITION TIMING

Prior to checking the ignition timing, check thewiring connections of the entire ignition system.Make sure that all connections are tight and freeof corrosion.

1. Remove:S timing plug 1

2. Install:S timing light 1

Sengine tachometer 2

(to the spark plug lead of cyl. #1)

Timing light:90890-03141



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3-14

CHECKING THE IGNITION TIMING/MEASURING THE COMPRESSION PRESSURE

INSPADJ

NOTE:

NOTE:

3. Check:S ignition timing

a. Start the engine, warm it up for several min-utes, and then let it run at the specified en-gine idling speed.


b. Check that the stationary pointer a is withinthe firing range b on the generator rotor.Incorrect firing range ! Check the ignitionsystem.

The ignition timing is not adjustable.

4. Install:S timing plug 1

EAS00065

MEASURING THE COMPRESSION PRES-SUREThe following procedure applies to all of the cyl-inders.

Insufficient compression pressure will result in aloss of performance.

1. Check:Svalve clearanceOut of specification! Adjust.Refer to ADJUSTING THE VALVE CLEAR-ANCE.

2. Start the engine, warm it up for several min-utes, and then turn it off.

3. Disconnect:Sspark plug cap

4. Remove:Sspark plug


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3-15

MEASURING THE COMPRESSION PRESSUREINSPADJ

CAUTION:

WARNING

NOTE:

Before removing the spark plugs, use com-

pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinders.

5. Install:Scompression gauge 1

Compression gauge set:90890-03081

6. Measure:Scompression pressure

Above the maximum pressure!

Inspect thecylinder head, valve surfaces, and pistoncrown for carbon deposits.Below the minimum pressure! Squirt a fewdrops of oil into the affected cylinder andmeasure again.

SRefer to the following table.

Compression pressure(with oil applied in the cylinder)

Reading Diagnosis

Higher than

without oil

Piston wear or damage!

Repair.

Same aswithout oil

Piston ring(-s), valves, cylin-der head gasket or pistonpossibly defective! Repair.

Compression pressure (at sealevel)

Standard:1,000 kPa (10 kg/cm2, 10 bar)

Minimum:900 kPa (9 kg/cm2, 9 bar)

Maximum:

1,100 kPa (11 kg/cm2, 11 bar)

a. Turn the main switch to ON.b. With the throttle wide open, crank the engine

until the reading on the compression gaugestabilized.

To prevent sparking, ground all spark plugleads before cranking the engine.

The difference in compression pressure be-tween cylinders should not exceed 100 kPa (1kg/cm2, 1 bar).


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3-16

MEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVEL

INSPADJ

20 Nm (2.0 mSkg)

NOTE:

CAUTION:

7. Install:Sspark plug

8. Connect:S

spark plug cap

EAS00069

CHECKING THE ENGINE OIL LEVEL1. Stand the motorcycle on a level surface.

SPlace the motorcycle on a suitable stand.SMake sure that the motorcycle is upright.

2. Let the engine idle for a few minutes.

3. Check:Sengine oil levelThe engine oil level should be between theminimum level marks a and maximum level

marks b .Below the minimum level mark ! Add therecommended engine oil to the proper level.

Recommended engine oilRefer to the chart for theengine oil grade which is bestsuited for certain atmospherictemperatures.API standard

SE or higher gradeACEA standard

G4 or G5

SEngine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives or use engineoils with a grade of CD a or higher and do

not use oils labeled ENERGY CONSERV-ING II b or higher.

SDo not allow foreign materials to enter thecrankcase.


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3-17

CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL

INSPADJ

NOTE:

WARNING

43 Nm (4.3 mSkg)


5. Check the engine oil level again.

Before checking the engine oil level, wait a fewminutes until the oil has settled.

EAS00075

CHANGING THE ENGINE OIL1. 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:Sengine oil filler cap 1So-ringSengine oil drain bolt 2Sgasket

4. Drain:Sengine oil(completely from the crankcase)

5. If the oil filter element is also to be replaced,perform the following procedure.

Oil filter element replacement should bemade cold exhaust pipe and muffler, at roomtemperature.

a. Remove the muffler 1 , rear brake reservoirtank 2 , element cover 3 and exhaust pipe(front cylinder) 4 .

b. Remove the oil filter element cover plate 5 ,element cover 6 and oil filter element 7 .

c. Check the O-ring 8 and replace it if it iscracked or damaged.

d. Install the new oil filter element and the ele-ment cover.

Oil filter element cover bolt10 Nm (1.0 mSkg)

e. Install the exhaust pipe (front cylinder), ele-ment cover plate, rear brake reservoir tankand muffler.Refer to ENGINE in chapter 4.

6. Check:Sengine oil drain bolt gasketDamage! Replace.

7. Install:SgasketSengine oil drain bolt

8. Fill:Scrankcase(with the specified amount of the recom-mended engine oil)


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3-18

CHANGING THE ENGINE OIL/ADJUSTING THE CLUTCH CABLE FREE PLAY

INSPADJ

b

c

NOTE:

QuantityTotal amount

3.6 L

Without oil filter elementreplacement

3.0 LWith oil filter elementreplacement

3.1 L

9. Install:So-ringSengine oil filter cap


11. Check:Sengine(for engine oil leaks)

12. Check:Sengine oil levelRefer to CHECKING THE ENGINE OILLEVEL.

EAS00078

ADJUSTING THE CLUTCH CABLE FREEPLAY1. Check:Sclutch cable free play a


Clutch cable free play (at the endof the clutch lever)

5X 10 mm

2. Adjust:Sclutch cable free play

Handlebar sidea. Loosen the locknut 1 .b. Turn the adjusting screw 2 in direction b or

c until the specified clutch cable free play isobtained.

DirectionClutch cable free play isincreased.

DirectionClutch cable free play isdecreased.


If the specified clutch cable free play cannot beobtained as described above, perform the mech-

anism adjustment procedure described below.

3. Remove:S left side cover 1Sclutch adjusting cover 2


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3-19

ADJUSTING THE CLUTCH CABLE FREE PLAY/CLEANING THE AIR FILTER ELEMENT

INSPADJ

4. Adjust:Sclutch mechanism

Engine sidea. 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 clutch cable free play again and

ajust it if necessary.

EAS00086

CLEANING THE AIR FILTER ELEMENT1. Remove:

Sair filter case cover 1Sair filter element 2

2. Clean:Sair filter elementApply compressed air to the outer surface ofthe air filter element.

3. Check:Sair filter elementDamage! Replace.

4. Install:Sair filter elementS

air filter case cover


76/354

CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/

CHECKING THE BREATHER HOSE

INSPADJ

3-20

CAUTION:

NOTE:

CAUTION:

Never operate the engine without the air filter

element installed. Unfiltered air will causerapid wear of engine parts and may damagethe engine. Operating the engine without theair filter element will also affect the carburetorturning, leading to poor engine performanceand possible overheating.

When installing the air filter element into the airfilter case cover, be sure their sealing surfacesare aligned to prevent any air leaks.

EAS00094

CHECKING THE CARBURETOR JOINT ANDINTAKE MANIFOLD1. Check:Scarburetor joint 1

Cracks/damage! Replace.Refer to CARBURETOR in chapter 6.

EAS00098

CHECKING THE BREATHER HOSE1. Remove:Scylinder head cover

2. Check:S

cylinder head breather hose 1Cracks/damage! Replace.Loose connection! Connect properly.

Make sure that the cylinder head breatherhose is routed correctly.


77/354


78/354

3-22

ADJUSTING THE FRONT BRAKEINSPADJ

b

c

WARNING

CAUTION:

EAS00108

CHASSISADJUSTING THE FRONT BRAKE1. Check:Sbrake lever free play a


Brake lever free play (at the endof the brake lever)

5X 8 mm

2. Adjust:Sbrake lever free play

a. Loosen the locknut 1 .

b. Turn the adjusting bolt 2 in direction b or cuntil the specified brake lever free play is ob-tained.

Direction ! Brake lever free play isincreased.

Direction ! Brake lever free play isdecreased.


A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident. Therefore, inspect and, if nec-essary, bleed the brake system.

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


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3-23

ADJUSTING THE REAR BRAKEINSPADJ

b

c

WARNING

WARNING

CAUTION:

EAS00110

ADJUSTING THE REAR BRAKE1. Check:Sbrake pedal position

(distance a from the top of the rider footrestto the top of the brake pedal)Out of specification! Adjust.

Brake pedal position (below thetop of the rider footrest)

81.8 mm

2. Adjust:Sbrake pedal position

a. Loosen the locknut 1 .

b. Turn the adjusting bolt 2 in direction b or cuntil the specified brake pedal position is ob-tained.

Direction ! Brake pedal is raised.

Direction ! Brake pedal is lowered.

After adjusting the brake pedal position,check that the end of the adjusting bolt 2 isvisible through the hole d .

c. Tighten the locknut 1 to specification.

Locknut16 Nm (1.6 mSkg)

A soft or spongy feeling in the brake pedalcan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brake

system. Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident. Therefore, inspect and, if nec-essary, bleed the brake system.

After adjusting the brake pedal position,make sure that there is no brake drag.

3. Adjust:S rear brake light switchRefer to ADJUSTING THE REAR BRAKELIGHT SWITCH.


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3-24

A

B

CHECKING THE BRAKE FLUID LEVELINSPADJ

NOTE:

WARNING

CAUTION:

NOTE:

EAS00115

CHECKING THE BRAKE FLUID LEVEL1. Stand the motorcycle on a level surface.


2. Check;Sbrake fluid levelBelow the minimum level mark a !Add therecommended brake fluid to the proper level.

Recommended brake fluidDOT 4

A Front brake

B Rear brake

SUse only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poor

brake performance.SRefill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.

SWhen refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.

In order to ensure a correct reading of the brakefluid level, make sure that the top of the reser-voir is horizontal.


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3-25

ADJUSTING THE REAR BRAKE LIGHT SWITCH/CHECKING THE BRAKE HOSES

INSPADJ

NOTE:

a

b

EAS00128

ADJUSTING THE REAR BRAKE LIGHTSWITCH

The rear brake light switch is operated by move-ment of the brake pedal.The rear brake light switch is properly adjustedwhen the brake light comes on just before thebraking effect starts.

1. Check:S rear brake light operation timingIncorrect! Adjust.

2. Adjust:

S rear brake light operation timing

a. Hold the main body 1 of the rear brake lightswitch so that it does not rotate and turn theadjusting nut 2 in direction a or b until therear brake light comes on at the proper time.

Direction ! Brake light comes onsooner.

Direction ! Brake light comes onlater.

EAS00131

CHECKING THE BRAKE HOSESThe following procedure applies to all of thebrake hoses and clamps.1. Check:S

brake hoseCracks/damage/wear ! Replace.2. Check:Sbrake hose clampLoose connection! Tighten.

3. Hold the motorcycle upright and apply thebrake.

4. Check:Sbrake hoseActivate the brake several times.Brake fluid leakage!Replace the damagedhose.

Refer to FRONT AND REAR BRAKES inchapter 7.


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3-26

A

B

BLEEDING THE HYDRAULIC BRAKE SYSTEMINSPADJ

WARNING

NOTE:

NOTE:

EAS00134

BLEEDING THE HYDRAULIC BRAKE SYS-TEM

Bleed the hydraulic brake system whenever:S the system was disassembled,Sa brake hose was loosened or removed,S the brake fluid level is very low,Sbrake operation is faulty.

SBe careful not to spill any brake fluid or allowthe brake master cylinder reservoir or brake

fluid reservoir to overflow.SWhen bleeding the hydraulic brake system,make sure that there is always enough brakefluid before applying the brake. Ignoring thisprecaution could allow air to enter the hydrau-lic brake system, considerably lengthening thebleeding procedure.

S If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours. Repeatthe bleeding procedure when the tiny bubblesin the hose have disappeared.

1. Stand the motorcycle on alevel surface.


2. Bleed:Shydraulic brake system

a. Add the recommended brake fluid to theproper level.

b. Install the diaphragm (brake master cylinderreservoir or brake fluid reservoir).

c. Connect a clear plastic hose 1 tightly to thebleed screw 2 .

A : Front B : Rear

d. Place the other end of the hose into a con-tainer.

e. Slowly apply the brake several times.f. Fully squeeze the brake lever or fully de-

press the brake pedal and hold it in position.g. Loosen the bleed screw.

This will release the tension and cause thebrake lever to contact the throttle grip or thebrake pedal to fully extend.


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3-27

BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE SHIFT PEDAL

INSPADJ

WARNING

NOTE:

b

c

h. Tighten the bleed screw and then release thebrake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the air

bubbles have disappeared from the brakefluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw6 Nm (0.6 mSkg)

k. Fill the reservoir to the proper level.Refer to CHECKING THE BRAKE FLUIDLEVEL.

After bleeding the hydraulic brake system,check the brake operation.

EAS00137

ADJUSTING THE SHIFT PEDAL

The shift pedal position is determined by the ad-

justing bolt length a .

1. Measure:Sadjusting the length a

Incorrect! Adjust.

Adjusting bolt length114.7 mm

2. Adjust:Sadjusting bolt length a

a. Loosen both locknuts 1

b. Turn the adjusting bolt 2 in direction b or c

to obtain the correct shift pedal position.

Direction ! shift pedal is raised.

Direction ! shift pedal is lowered.


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3-28

CHECKING THE FINAL DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OIL

INSPADJ

NOTE:

23 Nm (2.3 mSkg)

23 Nm (2.3 mSkg)

EAS00144

CHECKING THE FINAL DRIVE OIL LEVEL1. Stand the motorcycle on a level surface.


2. Remove:S final drive housing oil filler bolt 1

3. Check:S final drive oil levelThe final drive oil level should be to the bot-tom brim 2 of the filler hole.Below the bottom brim ! Add the recom-

mended final drive oil to the proper level.

Recommended final drive oilSAE 80 hypoid gear oil gradedGL-4, GL-5 or GL-6ormulti-purpose SAE 80W90hypoid gear oil

4. Install:S final drive housing oil filler bolt

EAS00145

CHANGING THE FINAL DRIVE OIL1. Place a container under the final drive hous-

ing.2. Remove:Sfinal drive housing oil filler bolt 1

S final drive housing oil drain bolt 2

Completely drain the final drive housing of itsoil.

3. Check:S final drive housing oil drain bolt gasketDamage! Replace.

4. Install:S final drive housing oil drain bolt

5. Fill:S final drive housing(with the specified amount of the recom-mended final drive oil)


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3-29

CHANGING THE FINAL DRIVE OIL/CHECKING AND ADJUSTING THE STEERING HEAD

INSPADJ

WARNING

NOTE:

Quantity0.2 L

Refer to CHECKING THE FINAL DRIVE OILLEVEL.

EAS00146

CHECKING AND ADJUSTING THE STEER-ING HEAD1. Stand the motorcycle on a level surface.

Securely support the motorcycle so thatthere is no danger of it falling over.

Place the motorcycle on a suitable stand so thatthe front wheel is elevated.

2. Check:S

steering headGrasp the bottom of the front fork legs andgently rock the front fork.Looseness or binding! Adjust the steeringhead.

3. Remove:Supper bracket pinch bolt 1

Ssteering stem nut 2

Supper bracket 3

4. Adjust:Ssteering head

a. Remove the lock washr 1 , the upper ring nut2 , and the rubber washer 3 .


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CHECKING AND ADJUSTING THE STEERING HEADINSPADJ

3-30

NOTE:

WARNING

NOTE:

110 Nm (11.0 mSkg)

20 Nm (2.0 mSkg)

b. Loosen the lower ring nut 4 and then tightenit to specification with a ring nut wrench 5 .

Set the torque wrench at a right angle to the ringnut wrench.

Ring nut wrench90890-01403

Date post:	30-May-2018
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1100 Service Manual

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