Scorpio Service Manual en

SX-4
SERVICEMANUAL
5BP-F8197-E0
SX-4
SERVICE MANUAL
© 2001 by Yamaha Motor Co., Ltd.
First Edition, June 2001
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
NOTICE
This manual was written by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to put an entire mechanic’s education into one man-
ual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha
motorcycle have a basic understanding of the mechanical concepts and procedures inherent in
motorcycle repair technology. Without such knowledge, attempted repairs or service to this model
may render it unfit to use and/or unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by
Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to
all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
TECHNICAL PUBLICATION GROUP 1

SERVICE INFORMATION DIV.
YAMAHA MOTOR CO., LTD
PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander, or a person inspecting or repairing the
motorcycle.
CAUTION: A CAUTION indecates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL
CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is a chapter with its symbol on the upper right of each page.
2nd title 2: This title appears on the upper of each page on the left of the chapter sym-
bol. (For the chapter “Periodic inspection and adjustment” the 3rd title
appears.)
3rd title 3: This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of asterisks “*” with each pro-
cedure preceded by “●”
IMPROTANT FEATURES
● Data and a special tool are framed in a box preceded by a relevant symbol 5.
● An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an
alignment mark 7, the others being indicated by an alphabetical letter in a box 8.

● A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
1 2 ILLUSTRATED SYMBOLS
GEN (Refer to the illustration)
INFO SPEC
Illustrated symbols 1 to 8 are designed as
3 4 thumb tabs to indicate the chapter’s number
and content.
INSP 1 General information
ADJ ENG 2 Specifications
3 Periodic inspection and adjustment
5 6 4 Engine overhaul
5 Carburetion
6 Chassis
CARB CHAS 7 Electrical
8 Troubleshooting
7 8
– + TRBL
ELEC SHTG
9 0 Illustrated symbols 9 to F are used to identify
the specifications appearing.
9 Serviceable with engine mounted
0 Filling fluid
A Lubricant
A B B Special tool
C Tightening
D Wear limit, clearance
E Engine speed
F Ω, V, A
C D
T.
R.
E F
G H I Illustrated symbols G to N in the exploded

diagram indicate grade of lubricant and loca-
tion of lubrication point.
G Apply engine oil
E G M
H Apply gear oil
J K L I Apply molybdenum disulfide oil
J Apply wheel bearing grease
K Apply lightweight lithium-soap base grease
B LS M
L Apply molybdenum disulfide grease
M Apply locking agent (LOCTITE®)
M N N Use new one
LT
New
INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION AND
INSP
ADJUSTMENT ADJ 3
ENGINE OVERHAUL ENG
4
CARBURETION CARB
5
CHASSIS CHAS
6
– +
ELECTRICAL ELEC
7
TROUBLESHOOTING TRBL
SHTG 8
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION ............................................................... 1-1

FRAME SERIAL NUMBER ................................................................... 1-1
ENGINE SERIAL NUMBER .................................................................. 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

GEN
INFO
GEN
MOTORCYCLE IDENTIFICATION INFO
YP100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
YP100020
FRAME SERIAL NUMBER

The frame serial number 1 is stamped into the
frame
EB100030
ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into
the crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
1-1
GEN
IMPORTANT INFORMATION INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1. Remove all dirt, mud, dust and foreign
material before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the “SPECIAL TOOLS” section.
4. When disassembling the machine, always

keep mated parts together. This includes
gears, cylinders, pistons and other parts
that have been “mated” through normal
wear. Mated parts must always be reused
or replaced as an assembly.
5. During machine disassembly, clean all parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
6. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
1-2
GEN
EB101030
LOCK WASHERS/PLATES AND COTTER

PINS
1. Replace all lock washers/plates 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

Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, apply a light coating of light-
weight lithium base grease to the seal lips. Oil
bearings liberally when installing, if appropri-
ate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the
bearings dry. This will damage the bearing
surfaces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassem-
bly. Always replace piston pin clips after one
use. Replace distorted circlips. When
installing a circlip 1, make sure that the
sharp-edged corner 2 is positioned oppo-
site the thrust 3 it receives. See sectional
view.
4 Shaft
1-3
GEN
EB801000
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
• Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two

or three.
4. Pull the lead to check that it will not come
off.
5. If the terminal comes off, bend up the pin 1
and reinsert the terminal into the connector.
6. Connect:
• Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.

NOTE:
• If there is no continuity, clean the terminals.
• Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
• For a field remedy, use a contact revitalizer
available on the market.
• Use the tester on the connector as shown.
1-4
GEN
SPECIAL TOOLS INFO
EB102000
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.
When placing an order, refer to the list provided below to avoid any mistakes
Tool No. Tool name/Usage Illustration
Weight
Slide hammer bolt
90890-01084
90890-01085
These tools are used when removing or
installing the rocker arm shafts.
Crankcase separating tool
90890-01135
This tool is used to separate the crank-
case.
Crankshaft installer pot
Pot Crankshaft installer bolt
90890-01274
Bolt
90890-01275 These tools are used to install the
crankshaft.
Spacer
Spacer Adapter (M10)
90890-01288
Adapter (M10)
90890-01383 These tools are used to install the
crankshaft.
Tappet adjusting tool
90890-01311
This tool is necessary for adjusting
valve clearance.
Fuel level gauge
90890-01312
This gauge is used to measure the fuel
level in the float chamber.
T-handle
T-handle Damper rod holder (19 mm)
90890-01326
Rod holder
90890-04084 These tools are needed to loosen and
tighten the damper rod holding bolt.
1-5
GEN
SPECIAL TOOLS INFO
Flywheel puller
90890-01362
This tool is used for removing the rotor.

Fork seal driver weight
Weight Fork seal driver attachment (ø33)
90890-01367
Attachment These tools are needed when installing
90890-01368 the slide metal, oil seal and dust seal
into the fork.
Steering nut wrench
90890-01403
This tool is used to loosen and tighten
the steering ring nut.
Sheave holder
90890-01701
This tool is used for holding the second-
ary sheave.
Compression gauge
90890-03081
These tools are used to measure the
engine compression.
Pocket tester
90890-03112
These instruments are invaluable for
checking the electrical system.
Engine tachometer
90890-03113
This tool is needed for detecting engine
rpm.
Valve spring compressor
90890-04019
These tools are needed to remove and
install the valve assemblies.
1-6
GEN
SPECIAL TOOLS INFO
Universal clutch holder
90890-04086
This tool is used to hold the clutch boss
when removing or installing the clutch
boss nut.
Ignition checker
90890-06754
This instrument is necessary for check-
ing the ignition system components.
1-7
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ..................................................................... 2-1
MAINTENANCE SPECIFICATIONS ............................................................ 2-4

ENGINE ................................................................................................. 2-4
CHASSIS ............................................................................................. 2-12
ELECTRICAL ...................................................................................... 2-15
GENERAL TORQUE SPECIFICATIONS ................................................... 2-17
DEFINITION OF UNITS .............................................................................. 2-17
LUBRICATION POINTS AND LUBRICANT TYPE .................................... 2-18

ENGINE ............................................................................................... 2-18
CHASSIS ............................................................................................. 2-19
CABLE ROUTING ...................................................................................... 2-20

SPEC
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model SX-4
Model code number: 5BP1
Dimensions:
Overall length 2,020 mm
Overall width 770 mm
Overall height 1,090 mm
Seat height 770 mm
Wheelbase 1,295 mm
Minimum ground clearance 165 mm
Basic weight:
Weight oil and full fuel tank 131 kg
Minimum turning radius: 2,100 mm
Engine:
Engine type Air cooled 4-stroke gasoline, SOHC
Cylinder arrangement Forward inclined single cylinder
Displacement 223 cm3
Bore × stroke 70 × 58 mm
Compression ratio 9.5 : 1
Compression pressure 8.5 kg/cm2/370 r/min
Starting system Electric and kick starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil
SAE 20W40 type SE motor oil
(if temperature does not go below 5°C)
SAE 10W30 type SE motor oil
(if temperature does not go above 15°C)
Oil capacity:
Engine oil:
Periodic oil change 1.2 L
With oil filter replacement 1.3 L
Total amount 1.4 L
Air filter: Wet type element
Fuel:
Type Regular gasoline
Tank capacity:
Total 12 L
Reserve 3L
Carburetor:
Type/manufacturer BS30/MIKUNI
2-1
Model SX-4
Spark plug:
Type/manufacturer D8EA/NGK or X24ES-U/DENSO
Gap 0.6 ~ 0.7 mm
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 74/24 (3.083)
Secondary reduction system Chain drive
Secondary reduction ratio 44/15 (2.933)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio:
1st 36/14 (2.571)
2nd 32/19 (1.684)
3rd 28/22 (1.273)
4th 26/25 (1.040)
5th 23/27 (0.852)
Chassis:
Frame type Double-cradle
Caster angle 25.3°
Trail 85 mm
Tire:
Type With tube
Size (F) 80/100-18 M/C 47P
Size (R) 100/90-18 M/C 56P
Wear limit 0.8 mm
Tire pressure (cold tire):
Basic weight:
With oil and full fuel tank 131 kg
Maximum load * 180 kg
Cold tire pressure: FRONT REAR
2
Rider 2.00 kg/cm 2.00 kg/cm2
With passenger 2.00 kg/cm2 2.25 kg/cm2
* Load is the total weight of cargo, rider, pas-
senger, and accessories.
Brake:
Front Single disc brake
Operation Right hand operation
Rear Drum brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swing arm
2-2
Model SX-4
Shock absorber:
Front shock absorber Coil spring, oil damper
Rear shock absorber Coil spring, oil damper
Wheel travel:
Front wheel travel 140 mm
Rear wheel travel 100 mm
Electrical:
Ignition system CDI
Generator system A.C. magneto generator
Battery type or model GM7B-4B
Battery capacity 12 V 7 AH
Headlight type: Bulb type
Bulb wattage × quantity:
Headlight 12 V, 35 W/36.5 W × 1
Auxiliary light 12 V, 3.4 W × 1
Tail/brake light 12 V, 5 W/21 W × 1
Flasher light 12 V, 10 W × 4
Meter light 12 V, 1.7 W × 2
Indicator light:
“NEUTRAL” 12 V, 3.4 W × 1
“HIGH BEAM” 12 V, 3.4 W × 1
“TURN” 12 V, 3.4 W × 2
2-3
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Model SX-4
Cylinder head:
Warp limit
* <0.03 mm>
* Lines indicate straight edge measurement.
Cylinder:
Bore size/measuring point
* 70.000 ~ 70.018 mm
40 mm
Wear limit <0.01 mm>

Camshaft:
Drive method Chain drive (right)
Camshaft outside dia. 24.96 ~ 24.98 mm
Cam dimensions:
Intake:
“A” 36.52 ~ 36.62 mm
A
“B” 30.201 ~ 30.301 mm
Exhaust:
“A” 36.564 ~ 36.664 mm
“B” 30.216 ~ 30.316 mm
B
Camshaft runout limit <0.03 mm>
Rocker arm and rocker arm shaft:
Rocker arm inside diameter 14.992 ~ 15.000 mm
Shaft outside diameter 14.960 ~ 14.981 mm
Arm-to-shaft clearance 0.009 ~ 0.037 mm
Cam chain:
Cam chain type/no. of links DID SCR-0404SDH
Cam chain adjustment method Automatic
Valve, valve seat, valve guide:
Valve clearance (cold):
IN. 0.05 ~ 0.10 mm
EX. 0.10 ~ 0.15 mm
2-4
Model SX-4
Value dimensions:
B C
D
A
“A” head dia. IN. 33.9 ~ 34.1 mm

EX. 28.4 ~ 28.6 mm
“B” face width IN. 2.26 mm
EX. 2.26 mm
“C” seat width IN. 0.9 ~ 1.1 mm
EX. 0.9 ~ 1.1 mm
“D” margin thickness IN. 0.8 ~ 1.2 mm
EX. 0.8 ~ 1.2 mm
Stem outside dia. IN. 5.975 ~ 5.990 mm
EX. 5.960 ~ 5.975 mm
Guide inside dia. IN. 6.000 ~ 6.012 mm
EX. 6.000 ~ 6.012 mm
Stem-to-guide clearance IN. 0.010 ~ 0.037 mm
EX. 0.025 ~ 0.052 mm
Stem runout limit <0.03 mm>
Valve spring:
Free length lnner IN. 36.17 mm
EX. 36.17 mm
Outer IN 36.63 mm
EX. 36.63 mm
Set length (valve closed)
lnner IN. 30.5 mm
EX. 30.5 mm
Outer IN. 32 mm
EX. 32 mm
Compressed pressure (installed)
Inner IN. 7.65 ~ 9.35 kg
EX. 7.65 ~ 9.35 kg
Outer IN. 13.1 ~ 16.1 kg
EX. 13.1 ~ 16.1 kg
2-5
Model SX-4
Tilt limit
* IN.
EX.
<2.5°/1.6 mm>
<2.5°/1.6 mm>
Direction of winding
Inner IN. Counterclockwise
EX. Counterclockwise
Outer IN. Clockwise
EX. Clockwise
Piston:
Piston-to-cylinder clearance 0.020 ~ 0.025 mm
<Limit> <0.05 mm>
Piston size “D” 69.977 ~ 69.996 mm
Measuring point “H” 4 mm
H
D
Piston ring:
Top ring:
Type Barrel
Dimensions (B × T) 1.2 × 2.8 mm
B
End gap (installed) 0.15 ~ 0.30 mm
T
Side clearance (installed) 0.03 ~ 0.07 mm
2nd ring:
Type Taper
B
T
Side clearance 0.02 ~ 0.06 mm
Oil ring:
B
T
2-6
Model SX-4
Crankshaft:
B B
A
Crank width “A” 69.25 ~ 69.30 mm
Runout limit “B” <0.03 mm>
Big end side clearance “C” 0.35 ~ 0.85 mm
Clutch:
Friction plate: Thickness 2.9 ~ 3.1 mm
Quantity 6 pcs.
Wear limit <2.8 mm>
Clutch plate: Thickness 1.5 ~ 1.7 mm
Quantity 5 pcs.
Warp limit <0.2 mm>
Clutch spring: Free length 34.9 mm
Quantity 4 pc.
Minimum length <33.2 mm>
Push rod bending limit <0.5 mm>
Transmission:
Main axle deflection limit <0.08 mm>
Drive axle deflection limit <0.08 mm>
Shifter:
Shifter type Cam drum and guide bar
Guide bar bending limit <0.025 mm>
Carburetor:
I.D. mark 5BP1 00
Main jet (M.J.) #110
Main air jet (M.A.J.) #120
Jet needle (J.N.) 4EL10-2
Needle jet (N.J.) O-2
Pilot jet (P.J.) #17.5
Pilot air jet (P.A.J. #1) #65
(P.A.J. #2) 1.2
Pilot screw (P.S.) 3
Pilot outlet (P.O.) ø0.8
Bypass (B.P.1) ø0.9
(B.P.2) ø0.8
(B.P.3) ø0.8
Valve seat size (V.S.) ø2.0
Starter jet (G.S.1) #25
(G.S.2) 0.7
2-7
Model SX-4
Fuel level 2.7 ~ 4.7 mm below the float chamber line
Engine idling speed 1,350 ~ 1,450 r/min
Lubrication system:
Oil filter type Paper and wire mesh type
Oil pump type: Trochoid type
Tip clearance 0.15 mm
Side clearance 0.04 ~ 0.09 mm
2-8
Model SX-4
Lubrication chart:
OIL CLEANER
PIN WITH
HOLE CYLINDER HEAD
DRIVE AXLE MAIN AXLE OIL PUMP
CRANKSHAFT CAMSHAFT
OIL STRAINER
OIL PAN
2-9
Tightening torque
Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m·kg
Camshaft sprocket cover Bolt M6 2 10 1.0
Tappet cover Bolt M55 2 18 1.8
Cylinder head Flange bolt M8 4 22 2.2 E
Bolt M8 2 20 2.0
Cylinder head (exhaust pipe) Stud bolt M8 4 15 1.5
Cylinder head bearing plate Bolt M6 2 8 0.8
Cylinder head breather plate Bolt M6 3 8 0.8
Oil pressure checking screw Screw M6 1 7 0.7
Spark plug – M12 1 18 1.8
Rotor (CDI magneto) Flange bolt M10 1 60 6.0
Valve adjusting locknut Nut M6 2 14 1.4
Cam sprocket Bolt M10 2 60 6.0
Chain guide Bolt M6 2 8 0.8 LT
Chain tensioner Bolt M6 2 10 1.0

Bolt M8 1 8 0.8
Oil pump Screw M6 3 6 0.6
Oil filter cover Bolt M6 3 10 1.0
Oil delivery pipe (crankcase cover) Union bolt M10 1 20 2.0
(cylinder) Union bolt M8 1 18 1.8
Carburetor joint Bolt M6 2 10 1.0
Air filter case (lower) Bolt M6 2 6 0.6
(upper) Bolt M6 2 10 1.0
Exhaust pipe joint (lower) Flange bolt M8 2 20 2.0
Exhaust pipe Nut M8 2 18 1.8
Muffler Flange bolt M8 2 30 3.0
Crankcase Flange bolt M6 12 10 1.0
Crankcase cover (left) Flange bolt M6 9 10 1.0
Crankcase cover (right) Flange bolt M6 13 10 1.0
Magneto lead clamp Bolt M5 1 7 0.7 LT
Neutral switch lead clamp Screw M6 1 7 0.7

Drain bolt – M12 1 20 2.0
Starter clutch Bolt M8 3 30 3.0 State LT
Primary drive gear Nut M16 1 80 8.0 Use lock washer
Clutch boss Nut M14 1 70 7.0 Use lock washer
Clutch spring Screw M5 4 6 0.6
Clutch adjuster locknut Nut M6 1 8 0.8
Clutch push lever Screw M8 1 12 1.2
Drive sprocket Nut M18 1 110 11.0
Shiftcam stopper Bolt M6 1 10 1.0 LT
Shift arm Bolt M6 1 10 1.0

Neutral switch – M10 1 20 2.0
Stator Bolt M6 3 7 0.7
2 - 10
Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m·kg
Pickup coil Bolt M6 2 7 0.7
Starter motor Bolt M6 2 10 1.0
Kick crank Bolt M8 1 20 2.0
Kick racket wheel guide Bolt M6 2 10 1.0 Use lock washer
2 - 11
CHASSIS
Item SX-4
Steering system:
Steering bearing type Angular bearing
Front suspension:
Front fork travel 140 mm
Fork spring free length 391.5 mm
Spring rate: K1 0.75 kg/mm
K2 1.0 kg/mm
Stroke K1 0 ~ 95 mm
K2 95 ~ 140 mm
Optional spring No.
Oil capacity 252 cm3
Oil level 95 mm
From top of fully compressed inner tube without
fork spring
Oil grade Yamaha fork oil 10W or equivalent
Rear suspension:
Shock absorber travel 32 mm
Spring rate: K1 16.01 kg/mm
Stroke: K1 0 ~ 32 mm
Optional spring No.
Swingarm:
Swingarm free play limit: End <1 mm>
Swingarm free play limit: Side <1 mm>
Front wheel:
Type Spoke wheel
Rim size 1.85 × 1.60
Rim material Steel
Rim runout limit: Vertical <2 mm>
Lateral <2 mm>
Rear wheel:
Type Spoke wheel
Rim size 1.85 × 2.15
Rim material Steel
Rim runout limit: Vertical <2 mm>
Lateral <2 mm>
Drive chain:
Type/manufacturer 428 V/DAIDO
No. of links 118
Drive chain slack 20 ~ 30 mm
2 - 12
Item SX-4
Front disc brake:
Disc brake type Single
Disc outside diameter × thickness 267 × 4
<Limit> <3.5 mm>
Brake pad lining thickness 5.3 mm
<Limit> <0.8 mm>
Master cylinder inside diameter 11 mm
Caliper cylinder inside diameter 26.99 mm
22.22 mm
Recommended fluid DOT 3 or 4
Rear drum brake:
Type Leading and trailing
Drum inside diameter 130 mm
<Limit> <131 mm>
Lining thickness 4 mm
<Limit> <1 mm>
Shoe spring free length 50.5 mm
Brake lever and brake pedal:
Brake lever free play 2 ~ 5 mm
Brake pedal free play 20 ~ 30 mm
Clutch lever:
Clutch lever free play 10 ~ 15 mm
2 - 13
Tightening torque
Tightening
Part to be tightened Thread size torque Remarks
Nm m·kg
Handle crown and inner tube M8 × 1.25 23 2.3
Handle crown and steering stem M22 × 1.0 110 11.0
Steering stem and ring nut – 18 1.8 See NOTE
Handle crown and upper holder M8 × 1.25 19 1.9
Master cylinder M6 × 1.0 7 0.7
Engine stay and engine M10 × 1.25 58 5.8
Engine stay and frame M8 × 1.25 30 3.0
Engine mounting (rear-lower) and frame M10 × 1.25 79 7.9
Engine mounting (rear-upper) and frame M10 × 1.25 58 5.8
Engine mounting (front) and frame M10 × 1.25 58 5.8
Tension bar and swingarm M8 × 1.25 16 1.6
Kick starter and frame M10 × 1.25 52 5.2
Front wheel axle M14 × 1.5 58 5.8
Front brake disc M6 × 1.0 23 2.3
Front brake caliper M10 × 1.25 30 3.0
Brake hose union bolt M10 × 1.25 26 2.6
Brake caliper bleed screw M7 × 1.0 6 0.6
Rear wheel axle M14 × 1.5 85 8.5
Sprocket and wheel hub M8 × 1.25 30 3.0
Tension bar and rear brake shoe plate M8 × 1.25 16 1.6
Brake lever camshaft M6 × 1.0 10 1.0
Fuel sender and fuel tank M5 × 0.8 4 0.4
Footrest and footrest bracket M8 × 1.25 30 3.0
Footrest bracket and brake pedal M10 × 1.25 30 3.0
Footrest bracket and frame M8 × 1.25 30 3.0
Rear footrest bracket and frame M8 × 1.25 30 3.0
Pivot shaft M12 × 1.25 59 5.9
Rear shock absorber (upper) M12 × 1.25 59 5.9
Rear shock absorber (lower) M12 × 1.25 59 5.9
Relay arm and frame M12 × 1.25 59 5.9
Relay arm and connecting rod M12 × 1.25 59 5.9
Connecting rod and frame M12 × 1.25 59 5.9
Chain case and swingarm M6 × 1.0 7 0.7
Chain guide and swingarm M6 × 1.0 7 0.7
NOTE:
1. First, tighten the ring nut approximately 48 Nm (4.8 m • kg) by using the torque wrench, then
loosen the ring nut one turn.
2. Retighten the ring nut 18 Nm (1.8 m • kg).
2 - 14
ELECTRICAL
Item SX-4
Voltage: 12 V
Ignition system:
Ignition timing (B.T.D.C.) 5° at 1,450 r/min
Advancer type Electrical
CDI:
Pickup coil resistance (color) 248 ~ 372 Ω at 20°C
(Red - White)
Source coil resistance 688 ~ 1,032 Ω at 20°C
(Brown - Green)
CDI. unit-model/manufacturer 5BP/YAMAHA
Ignition coil:
Model/manufacturer 5BP/YAMAHA
Primary winding resistance 0.32 ~ 0.48 Ω at 20°C
Secondary winding resistance 5.68 ~ 8.52 kΩ at 20°C
Spark plug cap resistance 10 kΩ
Charging system/type: A.C. magneto generator
CDI magneto:
Model/manufacturer F5BP/YAMAHA
Nominal output 14 V, 100 W at 5,000 r/min
Lighting coil resistance 0.24 ~ 0.36 Ω at 20°C (Yellow/Red - Black)
Charging coil resistance 0.32 ~ 0.48 Ω at 20°C (White - Black)
Rectifier/regulator:
Model/manufacturer SH656-12/SHINDENGEN
No load regulated voltage (DC) 14.1 ~ 14.9 V
Capacity 8A
Battery:
Capacity: 12 V, 7AH
Specific gravity 1.280
Electric starter system:
Type Constant mesh type
Starter motor:
Model/manufacturer 5BP/YAMAHA
Output 0.4 kW
Brush
Overall length 10 mm
<Limit> <3.5 mm>
Spring pressure 560 ~ 840 g
Commutator:
Outside diameter 22 mm
<Wear limit> <21 mm>
Mica undercut 1.5 mm
2 - 15
Item SX-4
Horn:
Type/quantity Plain type × 2
Model/manufacturer 5BP/IMASEN
Maximum amperage 1.5 A
Flasher relay:
Type Condenser type
Model/manufacturer 3RS/DENSO
Self cancelling device No
Flasher frequency 75 ~ 95 cycle/min
Wattage 10 W × 2 + 3.4 W
Starting circuit cut-off relay:
Model/manufacturer ACA12115-3/MATSUSHITA
Diode Yes
Circuit breaker:
Type Fuse
Amperage for individual circuit × quantity:
Main 15 A × 1
Reserve 15 A × 1
2 - 16
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS SPEC
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten- General torque
ers with standard I.S.O. pitch threads. A B
specifications
Torque specifications for special components (Nut) (Bolt)
Nm m·kg ft·lb
or assemblies are included in the applicable 10 mm 6 mm 6 0.6 4.3
sections of this book. To avoid warpage, tighten 12 mm 8 mm 15 1.5 11
multifastener assemblies in a crisscross fash-
14 mm 10 mm 30 3.0 22
ion, in progressive stages, until full torque is
17 mm 12 mm 55 5.5 40
reached. Unless otherwise specified, torque
19 mm 14 mm 85 8.5 61
specifications call for clean, dry threads. Com-
ponents should be at room temperature. 22 mm 16 mm 130 13.0 94
A B
A: Distance across flats

B: Outside thread diameter
DEFINITION OF UNITS
Unit Read Definition Measure
-3
mm millimeter 10 meter Length
cm centimeter 10-2 meter Length
kg kilogram 103 gram Weight
N Newton 1 kg × m/sec 2
Force
Nm Newton meter N×m Torque
m • kg Meter kilogram m × kg Torque
Pa Pascal N/m2 Pressure
N/mn Newton per millimeter N/mn Spring rate
L Liter
– Volume or capacity
cm3 Cubic centimeter
r/min Rotation per minute – Engine speed
2 - 17
LUBRICATION POINTS AND LUBRICANT TYPE SPEC
LUBRICATION POINTS AND LUBRICANT TYPE
ENGINE
Lubrication Symbol Lubricant type
Oil seal lip LS Lithium-soap base grease
O-Ring LS Lithium-soap base grease
Bearing E Engine oil
Cylinder head bolt/washer E Engine oil
Rocker shaft M Molybdeum disulfide oil
Crankshaft pin E Engine oil
Connecting rod E Engine oil
Piston surface E Engine oil
Piston pin E Engine oil
Camshaft cam lobe/journal E Engine oil
Valve stem (IN, EX) M Molybdeum disulfide oil
Valve stem end (IN, EX) M Molybdeum disulfide oil
Cam chain/cam sprocket E Engine oil
Oil pump shaft, rotor (IN, OUT), housing E Engine oil
Kick shaft E Engine oil
Kick idle sprocket (inside) E Engine oil
Kick crank shaft LS Lithium-soap base grease
Kick idle gear/kick gear E Engine oil
Starter clutch E Engine oil
Primary driven gear E Engine oil
Push lever axle M Molybdeum disulfide oil
Transmission gear (wheel/pinion) M Molybdeum disulfide oil
Axle (main/drive) M Molybdeum disulfide oil
Shift cam M Molybdeum disulfide oil
Shift fork/guide bar E Engine oil
Crankcase mating surfaces Yamaha bond No.1215®
2 - 18
LUBRICATION POINTS AND LUBRICANT TYPE SPEC
CHASSIS
Lubrication Symbol Lubricant type
Steering bearing (upper/lower) LS Lithium-soap base grease
Wheel bearing/axle LS Lithium-soap base grease
Front wheel oil seal (right/left) LS Lithium-soap base grease
Rear wheel oil seal LS Lithium-soap base grease
Clutch hub oil seal LS Lithium-soap base grease
Clutch hub fitting area LS Lithium-soap base grease
Rear brake pedal shaft LS Lithium-soap base grease
Change pedal LS Lithium-soap base grease
Side/main stand sliding surface LS Lithium-soap base grease
Tube guide (throttle grip) inner surface LS Lithium-soap base grease
Brake lever bolt, sliding surface LS Lithium-soap base grease
Clutch lever collar, sliding surface LS Lithium-soap base grease
Swingarm pivot/bearing LS Lithium-soap base grease
Rear shock absorber bolt LS Lithium-soap base grease
Relay arm color/oil seal LS Lithium-soap base grease
Speedometer gear unit LS Lithium-soap base grease
Rear brake camshaft LS Lithium-soap base grease
Brake shoe plate pivot LS Lithium-soap base grease
2 - 19
CABLE ROUTING SPEC
CABLE ROUTING
1 Tachometer cable A Fuel sender lead È Clamp the wire harness.
2 Brake hose B Breather hose É Pass the cable holder through
3 Brake hose holder C Air vent hose the tachometer cable.
4 Wire harness D Throttle cable Ê Install the horn lead (short side)
5 Air vent hose E Clutch cable to the right side of the horn.
6 Starting motor lead F Magneto lead Ë Clamp the taillight lead.
7 Battery negative lead G Pick-up coil lead Ì Clamp the wire harness.
8 Battery positive lead H Wire harness Í Clamp the wire harness at the
9 Rear brake switch lead white tape portion.
0 Taillight lead
Ó F G
Ñ
H Ò
Ð
E
0 Ë C D
Ì Ï
Í A B
Î È
1
2
4
9 3
8
7
6 É
Ê
5
2 - 20
CABLE ROUTING SPEC
Î To fuel tank
Ï Clamp the throttle cable and clutch cable. Turn the clamp end to inside of motorcycle.
Ð Clamp the throttle cable and clutch cable.
Ñ Insert the air vent hose into the frame.
Ò Clamp the wire harness and turn the clamp end to inside of motorcycle.
Ó Clamp the magneto lead and pick-up coil lead and push the leads into holder.
Ó F G
Ñ
H Ò
Ð
E
0 Ë C D
Ì Ï
Í A B
Î È
1
2
4
9 3
8
7
6 É
Ê
5
2 - 21
CABLE ROUTING SPEC
1 Clutch cable B Fuel tank over flow hose Ë Clamp the magneto lead and
2 Breather hose pick-up coil lead.
3 Fuel tank over flow hose È Install the horn lead (long side) Ì Clamp the battery breather
4 Magneto lead to the left side of the horn hose.
5 Battery breather hose É Clamp the battery breather
6 Carburetor over flow hose hose, carburetor over flow
7 Fuel tank over flow hose hose and fuel tank over flow
8 Speedometer cable hose.
9 Wire harness Ê Pass the speedometer cable
0 Pick-up coil lead through the holder
A Magneto lead
0 A
Ë B
Ë
1 Ì
D
C A
È
2
3
9
5
6
Ê 7
2 - 22
CABLE ROUTING SPEC
1 Handlebar switch lead B Main switch lead Ì Clamp the handlebar switch
2 Clutch cable C Meter lead lead and front brake switch
3 Turn signal light lead lead.
4 Speedometer cable È Clamp the handlebar switch Í Clamp the wire harness at
5 Wire harness lead. white tape portion.
6 Tachometer cable É Pass the clutch cable through Î Clamp the wire harness.
7 Turn signal light lead the guide.
8 Throttle cable Ê Pass the wire harness through
9 Brake hose the guide.
0 Front brake switch lead Ë Clamp the brake hose.
A Handlebar switch lead
Î Í
A È
0
Ì 1
B C
9
2
8
É
7 3
Ë 6 Ê 5 4
2 - 23
INSP
ADJ
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION ........................................................................................... 3-1
PERIODIC MAINTENANCE/LUBRICATION ............................................... 3-1
SEAT ............................................................................................................. 3-3
SIDE COVER ................................................................................................ 3-3
FUEL TANK .................................................................................................. 3-3
ENGINE ........................................................................................................ 3-4

VALVE CLEARANCE ADJUSTMENT ................................................... 3-4
IDLING SPEED ADJUSTMENT ............................................................ 3-5
THROTTLE CABLE ADJUSTMENT ..................................................... 3-6
SPARK PLUG INSPECTION ................................................................ 3-8
COMPRESSION PRESSURE MEASUREMENT .................................. 3-8
ENGINE OIL LEVEL INSPECTION ....................................................... 3-9
ENGINE OIL REPLACEMENT ............................................................ 3-10
CLUTCH ADJUSTMENT ..................................................................... 3-12
AIR FILTER CLEANING ...................................................................... 3-13
CARBURETOR JOINT INSPECTION ................................................. 3-15
FUEL LINE INSPECTION ................................................................... 3-15
EXHAUST SYSTEM INSPECTION ..................................................... 3-16
CHASSIS .................................................................................................... 3-17

FRONT BRAKE ADJUSTMENT .......................................................... 3-17
BRAKE PAD INSPECTION ................................................................. 3-17
BRAKE FLUID LEVEL INSPECTION .................................................. 3-18
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) .............................. 3-18
BRAKE HOSE INSPECTION .............................................................. 3-19
REAR BRAKE ADJUSTMENT ............................................................ 3-20
BRAKE SHOE INSPECTION .............................................................. 3-21
BRAKE LIGHT SWITCH ADJUSTMENT ............................................ 3-21
DRIVE CHAIN SLACK ADJUSTMENT ............................................... 3-22
TIRE INSPECTION ............................................................................. 3-23
STEERING HEAD INSPECTION ........................................................ 3-23
REAR SHOCK ABSORBER INSPECTION ......................................... 3-25
WHEEL INSPECTION ......................................................................... 3-26
SPOKE INSPECTION AND TIGHTENING ......................................... 3-26
CABLE INSPECTION .......................................................................... 3-26
LUBRICATION .................................................................................... 3-27
INSP
ADJ
ELECTRICAL ............................................................................................. 3-28
BATTERY INSPECTION ..................................................................... 3-28
FUSE INSPECTION ............................................................................ 3-31
HEADLIGHT BEAM ADJUSTMENT ................................................... 3-32
HEADLIGHT BULB REPLACEMENT ................................................. 3-32
INTRODUCTION/PERIODIC MAINTENANCE/ INSP
LUBRICATION ADJ
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as new vehicles that are being prepared for
sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION
ODOMETER READING (× 1,000 km)
NO. ITEM CHECK OR MAINTENANCE JOB
0.5 2 4 8 12
1 * Fuel line • Check fuel hoses for cracks or damage.
2 * Fuel filter • Check condition. Replace if necessary.
• Check condition.
3 Spark plug • Clean and regap.
• Replace if necessary.
• Check valve clearance.
4 * Valves
• Adjust.
5 Air filter element • Clean. Replace if necessary.
• Check electrolyte level and specific gravity.
6 * Battery • Make sure that the breather hose is properly
routed.
• Check operation.
7 Clutch
• Adjust.
• Check operation, fluid level and vehicle for fluid
8 * Front brake leakage.
• Replace brake pads if necessary.
• Check operation and adjust brake pedal free
9 * Rear brake play.
• Replace brake shoes if necessary.
• Check runout, spoke tightness and for damage.
10 * Wheels
• Tighten spokes if necessary.
11 * Wheel bearings • Check bearing for looseness damage.
• Check operation and for excessive play.
12 * Swingarm
• Lubricate with lithium-soap based grease, every 24,000 km.
• Check chain slack.
Every 500 km and after washing the motorcycle
13 Drive chain • Make sure that the rear wheel is properly aligned.
or riding in the rain.
• Clean and lubricate.
• Check bearing play and steering for roughness.
14 * Steering bearings
• Lubricate with lithium-soap-based grease, every 12,000 km.
• Make sure that all nuts, bolts and screws are
15 * Chassis fasteners
properly tightened.
Sidestand/center- • Check operation.
16
stand • Lubricate.
17 * Front fork • Check operation and for oil leakage.
Shock absorber • Check operation and shock absorber for oil leak-
18 *
assembly age.
Rear suspension • Check operation.
relay arm and con-
19 *
necting arm pivoting • Lubricate with lithium-soap-base grease, every 24,000 km.
points
3-1
INSP
PERIODIC MAINTENANCE/LUBRICATION ADJ
ODOMETER READING (× 1,000 km)
NO. ITEM CHECK OR MAINTENANCE JOB
0.5 2 4 8 12
• Check starter (choke) operation.
20 * Carburetor
• Adjust engine idling speed.
21 Engine oil • Change.
Engine oil filter ele-
22 • Clean.
ment
23 * Engine oil strainer • Clean.
Front and rear brake
24 * • Check operation.
switches
Moving parts and
25 • Lubricate.
cables
Lights, signals and • Check operation.
26 *
switches • Adjust headlight beam.
*Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake systems
● After disassembling the brake master cylinder, and caliper cylinder, always change the fluid.
Regularly check the brake fluid levels and fill the reservoirs as required.
● Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every
two years.
● Replace the brake hose every four years or if cracked or damaged.
3-2
INSP
SEAT/SIDE COVER/FUEL TANK ADJ
SEAT
1.Install:
● Seat 1
NOTE:
Insert the projection a on the front of the seat
into the seat holder b as shown.
SIDE COVER
1.Remove:
● Seat
2.Remove:
● Side covers (left and right)
NOTE:
Remove screws a and knob b, and then pull
the side cover off as shown.
FUEL TANK
1.Remove:
● Air scoop (left and right)
● Bolt
● Washer
● Fuel sender coupler
● Breather hose
● Fuel hose
● Fuel tank 1
NOTE:
Turn the fuel cock to “OFF” position before
removing fuel hose.
3-3
INSP
VALVE CLEARANCE ADJUSTMENT ADJ
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
Valve clearance adjustment should be made
with the engine cool, at room temperature.
When the valve clearance is to be measured
or adjusted, the piston must be at Top Dead
Center (T.D.C) on the compression stroke.
1.Remove:
● Air scoop (left and right) 1
2.Remove:
● Spark plug
● Tappet cover (intake side) 1
● Tappet cover (exhaust side) 2
3.Remove:
● Timing mark accessing screw (with O-ring) 1
● Camshaft end cover (with O-ring) 2
4.Measure:
● Valve clearance
Out of specification → Adjust.
Valve clearance (cold):

Intake valve 0.05 ~ 0.10 mm
Exhaust valve 0.10 ~ 0.15 mm
*****************************************************
Measurement steps:
● Rotate the crankshaft counterclockwise to
align the slit a on the rotor with the slit b on
the crankcase cover when the piston is Top
Dead Center (TDC).
3-4
VALVE CLEARANCE ADJUSTMENT/ INSP
IDLING SPEED ADJUSTMENT ADJ
● Measure the valve clearance by using a
feeler gauge.
Out of specification → Adjust clearance.
*****************************************************
5.Adjust:
● Valve clearance
*****************************************************
Adjustment steps:
● Loosen the locknut 1.
● Turn the adjuster 2 in or out with the tappet
adjusting tool 3 until specified clearance is
obtained.
Valve clearance is
Turning in
decreased.
Valve clearance is
Turning out
increased.
Tappet adjusting tool:

90890-01311
● Hold the adjuster to prevent it from moving

and tighten the locknut.
14 Nm (1.4 m • kg)
T.
R.
● Measure the vale clearance.

● If the clearance is incorrect, repeat above
steps until specified clearance is obtained.
*****************************************************
6.Install:
● O-ring
● Tappet cover (intake side)
18 Nm (1.8 m • kg)
T.
R.
IDLING SPEED ADJUSTMENT

1.Start the engine and let it warm up for sev-
eral minutes.
2.Attach:
● Engine tachometer to the spark plug lead.
Engine tachometer:
90890-03113
3-5
IDLING SPEED ADJUSTMENT/ INSP
THROTTLE CABLE ADJUSTMENT ADJ
3.Check:
● Engine idling speed
Engine idling speed:

1,350 ~ 1,450 r/min.
4.Adjust:
● Engine idle speed
*****************************************************
Adjustment steps:
● Turn the pilot screw 1 until it is lightly
seated.
● Turn the pilot screw out by the specified
number of turns.
Pilot screw:
3 turns out
● Turn the throttle stop screw 2 in or out until

the specified idling speed is obtained.
Turning in Idling speed is increased.

Turning out Idling speed is decreased.
*****************************************************
5.Adjust:
● Throttle cable free play
Refer to the “THROTTLE CABLE ADJUST-

MENT” section.
THROTTLE CABLE ADJUSTMENT

NOTE:
Prior to adjusting the throttle cable free play,
the engine idling speed should be adjusted.
1.Check:
● Throttle cable free play a
Free play (throttle cable):

3 ~ 5 mm at throttle grip flange
3-6
INSP
THROTTLE CABLE ADJUSTMENT ADJ
2.Adjust:
*****************************************************
Adjustment steps:
Carburetor side
● Turn the adjusting nut 2 in or out until the
specified throttle cable free play is obtained.
Throttle cable free play is
Turn in
increased.
Turn out
decreased.
● Tighten the locknut.

NOTE:
If the specified throttle cable free play cannot
be obtained on the carburetor side of the
cable, use the adjusting nut on the handlebar
side.
Handlebar side
● Turn the adjusting nut 2 in or out until the
specified throttle cable free play is obtained.

Turn in
increased.
Turn out
decreased.
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
*****************************************************
3-7
SPARK PLUG INSPECTION/ INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
EB303040
SPARK PLUG INSPECTION
1.Check:
● Spark plug type
Incorrect → Replace.
Standard spark plug:

D8EA (NGK),
X24ES-U (DENSO)
2.Inspect:
● Electrode 1
Wear/damage → Replace.
● Insulator 2
Abnormal color → Replace.

Normal color is a medium-to-light tan color.
3.Clean:
● Spark plug
(with spark plug cleaner or wire brush)

4.Measure:
● Spark plug gap a
(with a wire gauge)

Out of specification → Adjust gap.
Spark plug gap:

0.6 ~ 0.7 mm
COMPRESSION PRESSURE
MEASUREMENT
NOTE:
Insufficient compression pressure will result in
performance loss.
1.Start the engine and let it warm up for sev-
eral minutes.
2.Turn off the engine.
3.Remove:
● Spark plug
4.Attach:
● Compression gauge 1
Compression gauge:
90890-03081
3-8
COMPRESSION PRESSURE MEASUREMENT/ INSP
ENGINE OIL LEVEL INSPECTION ADJ
5.Measure:
● Compression pressure
If it exceeds the maximum pressure allowed

→ Inspect the cylinder head, valve surfaces
and piston crown for carbon deposits.
If it is below the minimum pressure → Squirt
a few drops of oil into the affected cylinder
and measure again.
Follow the table below.
Compression pressure
(With oil applied into cylinder)
Reading Diagnosis
Higher than
Worn or damaged pistons
without oil
Possible defective ring(s),
Same as
valves, cylinder head gas-
without oil
ket or piston → Repair.
Compression pressure (at sea

level):
Standard:
1,200 kPa (12.0 Kg/cm2, 12.0 bar)
Minimum:
1,050 kPa (10.5 Kg/cm2, 10.5 bar)
*****************************************************
Measurement steps:
● Crank the engine with the throttle wide-open
until the reading on the compression gauge
stabilizes.
WARNING
Before cranking the engine, ground all
spark plug leads to prevent sparking.
*****************************************************
ENGINE OIL LEVEL INSPECTION

1.Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
2.Start the engine, warm it up for several min-
utes, and then turn it off.
3-9
ENGINE OIL LEVEL INSPECTION/ INSP
ENGINE OIL REPLACEMENT ADJ
3.Check:
● Engine oil level
The engine oil level should be between the

minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
Recommended oil:
Refer to the chart for the engine
oil grade
API standard
SE or higher grade
CAUTION:
Do not allow foreign materials to enter the
crankcase.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
ENGINE OIL REPLACEMENT

2.Place a container under the engine oil drain
bolt.
3.Remove:
● Engine oil filler bolt
● Engine oil drain bolt 1
(along with the gasket)

● Oil filter element drain bolt 2

4.Drain:
● Engine oil
(completely from the crankcase)
3 - 10
INSP
ENGINE OIL REPLACEMENT ADJ
5.If the oil filter element is also to be replaced,
perform the following procedure.
*****************************************************
Replacement steps:
● Remove the oil filter element cover 1 and oil
filter element 2.
● Check the O-rings 3 and replace them if
they are cracked or damaged.
● Install the new oil filter element and the oil fil-
ter element cover.
Oil filter element cover bolt:

10 Nm (1.0 m • kg)
T.
R.
È Outside
É Inside
*****************************************************
6.Check:
● Engine oil drain bolt gasket
● Oil filter element drain bolt gasket
Damage → Replace.
7.Install:
● Engine oil drain bolt

20 Nm (2.0 m • kg)
T.
R.
● Oil filter element drain bolt

(along with he gasket)
10 Nm (1.0 m • kg)
T.
R.
8.Fill:
● Crankcase
(With the specified amount of the recom-

mended engine oil)
Quantity:
Total amount:
1.4 L
Without oil filter element
replacement:
1.2 L
With oil filter element replace-
ment:
1.3 L
9.Install:
● Engine oil filler cap
3 - 11
ENGINE OIL REPLACEMENT/ INSP
CLUTCH ADJUSTMENT ADJ
11.Check:
● Engine
(for engine oil leaks)

12.Check:
● Engine oil level
Refer to the “ENGINE OIL LEVEL INSPEC-

TION” section.
13.Check:
● Engine oil pressure
*****************************************************
Checking steps:
● Slightly loosen the oil gallery bolt 1.
● Start the engine and keep it idling until engine
oil starts to seep from the oil gallery bolt. If no
engine oil comes out after one minute, turn
the engine off so that it will not seize.
● Check the engine oil passages and the oil
pump for damage or leakage. Refer to the
“OIL PUMP” section in CHAPTER 4.
● Start the engine after solving the problem(s)
and check the engine oil pressure again.
● Tighten the oil gallery bolt to specification.
Oil gallery bolt:

7 Nm (0.7 m • kg)
T.
R.
*****************************************************
CLUTCH ADJUSTMENT
1.Check:
● Clutch cable free play a
Clutch cable free play (at the end

of the clutch lever):
10 ~ 15 mm
3 - 12
CLUTCH ADJUSTMENT/ INSP
AIR FILTER CLEANING ADJ
2.Adjust:
● Clutch cable free play
*****************************************************
Adjustment steps:
Handlebar side
● Turn the adjusting bolt 2 in or out until the
specified clutch cable free play is obtained.
Clutch cable free play is
Turn in
increased.
Turn out
decreased.

NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable,
use the adjusting nut on the engine side.
Engine side
● Loosen the locknuts 1.
specified clutch cable free play is obtained.
Turn in
increased.
Turn out
decreased.
● Tighten the locknuts.

*****************************************************
AIR FILTER CLEANING
1.Check:
● Air filter check hoses 1
NOTE:
On the bottom of the air filter case is a check
hoses 1. If dust or water or both collects in
this hoses, clean the air filter element and air
filter case.
2.Remove:
● Side cover (left)
Refer to the “SIDE COVER” section.
3 - 13
INSP
AIR FILTER CLEANING ADJ
3.Remove:
● Air filter case cover 1
● Air filter element 2
4.Clean:
● Air filter element
(with solvent)
WARNING
Never use low flash point solvents, such as
gasoline, to clean the air filter element.
Such solvents may cause a fire or an explo-
sion.
NOTE:
After cleaning, gently squeeze the air filter ele-
ment to remove the excess solvent.
CAUTION:
Do not twist the air filter element when
squeezing it.
5.Check:
Damage → Replace.
6.Apply the recommended oil to the entire sur-
face of the air filter element and squeeze out
the excess oil. The air filter element should
be wet but not dripping.
Recommended oil:
Engine oil
3 - 14
AIR FILTER CLEANING/CARBURETOR JOINT INSP
INSPECTION/FUEL LINE INSPECTION ADJ
7.Install:
● Air filter case cover
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible overheat-
ing.
CARBURETOR JOINT INSPECTION

1.Inspect:
● Carburetor joint 1
Cracks/Damage → Replace.
FUEL LINE INSPECTION

1.Inspect:
● Fuse hose
Cracks/Damage → Replace.
3 - 15
INSP
EXHAUST SYSTEM INSPECTION ADJ
EXHAUST SYSTEM INSPECTION
1.Inspect:
● Exhaust pipe 1
● Muffler 2
Cracks/Damage/Leak → Repair or replace.

● Exhaust pipe Joint 3
● gasket 4
Damage/Leak → Repair or replace.

2.Tighten:
● Muffler and exhaust pipe
Nuts (exhaust pipe joint) 5:

18 Nm (1.8 m • kg)
T.
Bolt (exhaust pipe joint) 6:
R.
20 Nm (2.0 m • kg)
Bolts (muffler) 7:
30 Nm (3.0 m • kg)
3 - 16
FRONT BRAKE ADJUSTMENT/ INSP
BRAKE PAD INSPECTION ADJ
CHASSIS
FRONT BRAKE ADJUSTMENT
1.Check:
● Brake lever free play a
Free play (brake lever):

2 ~ 5 mm (at brake lever end)
2.Adjust:
● Brake lever free play
*****************************************************
Adjustment steps:
● Turn the adjuster 2 in or out until the speci-
fied free play is obtained.
brake lever free play is
Turning in
decreased.
brake lever free play is
Turning out
increased.
CAUTION:
After adjusting the front brake lever free
play, make sure that there is no brake drag.
*****************************************************
BRAKE PAD INSPECTION

1.Operate the brake lever.
2.Inspect:
● Brake pad
Wear indicators 1 almost touch the brake

disc → Replace the brake pads as set.
Refer to the “BRAKE PAD PEPLCEMENT”
section in CHPTER 6.
3 - 17
BRAKE FLUID LEVEL INSPECTION/ INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ADJ
BRAKE FLUID LEVEL INSPECTION
NOTE:
When inspecting the brake fluid level, make
sure the motorcycle is upright.
2.Inspect:
● Brake fluid level
Brake fluid level is below the “LOWER” level

line a → Fill to proper level.
Recommended brake fluid:

DOT 3 or 4
NOTE:
For a correct reading of the brake fluid level,
make sure the top of the handlebar brake fluid
reservoir is horizontal.
AIR BLEEDING (HYDRAULIC BRAKE

SYSTEM)
WARNING
Bleed the brake system whenever:
● The system is disassembled
● A brake hose is loosened or removed
● The brake fluid level is very low
● Brake operation is faulty
If the brake system is not properly bled, a

loss of braking performance may occur.
1.Bleed:
● Brake system
*****************************************************
Air bleeding steps:
a. Fill the reservoir with the proper brake fluid.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2.
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.
3 - 18
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP
BRAKE HOSE INSPECTION ADJ
i. Repeat steps (e) to (h) until all the air bub-
bles have disappeared from the bake fluid.
NOTE:
When bleeding the brake system, make sure
that there is always enough brake fluid in the
brake fluid reservoir, before applying the brake
lever. Ignoring this precaution could allow air
to enter the brake system, lengthening the
bleeding procedure, considerably.
j. Tighten the bleed screw.
Bleed screw:
6 Nm (0.6 m • kg)
T.
R.
NOTE:
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat the
bleeding procedure when the tiny bubbles in the
brake system have disappeared.
k. Fill the brake fluid reservoir to the proper
level.
Refer to the “BRAKE FLUID LEVEL
INSPECTION” section.
WARNING
After bleeding the brake system check the
brake operation.
*****************************************************
BRAKE HOSE INSPECTION

1.Inspect:
● Brake hose
Cracks/wear/damage → Replace.
2.Check:
● Brake hose clamp(s)
Loose → Tighten.
3.Hold the motorcycle upright and apply the
front brake.
4.Check:
● Brake hose
Activate the brake lever several times.

Brake fluid leakage → Replace the faulty
hose.
Refer to the “FRONT BRAKE” section in
CHAPTER 6.
3 - 19
INSP
REAR BRAKE ADJUSTMENT ADJ
REAR BRAKE ADJUSTMENT
1.Check:
● Brake pedal position
(distance a from the top of the rider footrest

to the top of the brake pedal)
Brake pedal position (below the

top of the rider footrest):
30 mm
2.Adjust:
● Brake pedal position
*****************************************************
Adjustment steps:
specified brake pedal position is obtained.
Turn in Brake pedal is raised.

Turn out Brake pedal is lowered.
● Tighten the locknut to specification.
Locknut:
10 Nm (1.0 m • kg)
T.
R.
*****************************************************
3.Check:
● Brake pedal free play a
Free play:
20 ~ 30 mm
3 - 20
REAR BRAKE ADJUSTMENT/BRAKE SHOE INSP
INSPECTION/BRAKE LIGHT SWITCH ADJUSTMENT ADJ
4.Adjust:
● Brake pedal free play
*****************************************************
Adjustment steps:
● Turn the adjuster 1 in or out until the speci-
fied free play is obtained.
Turning in Free play is decreased.

Turning out Free play is increased.
CAUTION:
Make sure that the brake does not drag
after adjusting it.
*****************************************************
5.Adjust:
● Brake light switch
Refer to the “BRAKE LIGHT SWITCH

ADJUSTMENT” section.
BRAKE SHOE INSPECTION

1.Operate the brake pedal.
2.Inspect:
● Brake shoes
Wear indicator 1 reaches the wear limit line

2 → Replace the brake shoes as a set.
Refer to the “REAR WHEEL AND REAR
BRAKE” section in CHAPTER 6.
BRAKE LIGHT SWITCH ADJUSTMENT

1.Check:
● Brake light operation timing
Incorrect → Adjust.
2.Adjust:
● Brake light operation timing
*****************************************************
Adjustment steps:
● Hold the main body 1 of the switch with your
hand so that it does not rotate, and turn the
adjuster 2 in or out until the proper opera-
tion timing is obtained.
Turning in Brake light comes on first.

Turning out Brake light comes on slow.
*****************************************************
3 - 21
INSP
DRIVE CHAIN SLACK ADJUSTMENT ADJ
DRIVE CHAIN SLACK ADJUSTMENT
WARNING
● Securely support the motorcycle so that
there is no danger of it falling over.
● Stand the motorcycle on its centerstand.
1.Check:
● Drive chain slack a
Drive chain slack:

20 ~ 30 mm
2.Adjust:
● Drive chain slack
*****************************************************
Adjustment steps:
● Loosen the each locknuts 1 and chain
adjuster nuts 2.
● Loosen the axle nut 3.
● Turn the chain adjustment nuts 2 clockwise
or counterclockwise until the specified drive
chain slack is obtained.
Drive chain slack is
Turning in
decreased.
Drive chain slack is
Turning out
increased.
NOTE:
● Turn each chain adjuster nuts exactly the
same amount to maintain correct axle align-

ment. (There are marks a on each chain
adjuster nuts. Use them when adjusting the
slack for proper alignment.)
● Before tightening the axle nut and locknuts to
specification, make sure that there is no

clearance at the adjuster nuts (or the swin-
garm end) on both sides by pushing the
wheel forward.
● Tighten the axle nut.
85 Nm (8.5 m • kg)
T.
R.

7 Nm (0.7 m • kg)
T.
R.
*****************************************************
3 - 22
TIRE INSPECTION/ INSP
STEERING HEAD INSPECTION ADJ
TIRE INSPECTION
1.Measure:
● Tire inflation pressure

Basic weight (with
oil and full fuel 131 kg
tank)
Maximum load* 180 kg
Cold tire pressure Front Rear
200 kPa 200 kPa
Up to 100 kg load* (2.0 kg/cm2) (2.0 kg/cm2)
100 kg ~ maximum. 200 kPa 225 kPa

Load* (2.0 kg/cm2) (2.25 kg/cm2)
* Load is the total weight of the cargo, rider, pas-

senger and accessories.
2.Inspect:
● Tire surfaces
Wear/Damage → Replace.
Minimum tire tread depth (front

and rear):
0.8 mm
1 Tread depth
2 Side wall
3 Wear indicator
3.After a tire repair or replacement, be sure to
tighten the valve stem locknut 1 to specifi-
cation.
STEERING HEAD INSPECTION

NOTE:
Stand the motorcycle on its centerstand.
2.Elevate the front wheel by placing a suitable
stand under the engine.
3 - 23
INSP
STEERING HEAD INSPECTION ADJ
3.Check:
● Handlebar assembly
Grasp the handlebar and gently rock the

steering.
Looseness → Adjust the handlebar.
● Steering assembly bearings
Grasp the bottom of the lower front fork

tubes and gently rock the fork assembly.
Looseness → Adjust the steering head.
4.Adjust:
● Steering head
5.Remove:
● Handlebar
● Pinch bolt
● Steering stem nut
● Handle crown
6.Adjust:
● Steering head
*****************************************************
Adjustment steps:
● Remove the lock washer 1, the upper ring
nut 2, and the rubber washer 3.
● Loosen the lower ring nut 4 and then tighten
it to specification with a ring nut wrench 5.
NOTE:
Set the torque wrench at a right angle to the
ring nut wrench.
Steering nut wrench:

90890-01403
Lower ring nut (initial tightening

torque):
T.
R.
48 Nm (4.8 m • kg)
● Loosen the lower ring nut 4 completely,

then tighten it to specification.
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening

torque):
T.
R.
18 Nm (1.8 • kg)
3 - 24
STEERING HEAD INSPECTION/ INSP
REAR SHOCK ABSORBER INSPECTION ADJ
● Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and inspect the upper and
lower bearings.
Refer to the “STEERING HEAD AND HAN-
DLEBAR” in section CHAPTER 6.
● Install the rubber washer 3.
● Install the upper ring nut 2.
● Finger tighten the upper ring nut 2, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
● Install the lock washer 1.
NOTE:
Make sure that the lock washer tabs a sit cor-
rectly in the ring nut slots b.
*****************************************************
7.Install:
● Handle crown
● Steering stem nut 110 Nm (11.0 m • kg)
T.
R.
● Pinch bolt 23 Nm (2.3 m • kg)
T.
R.
REAR SHOCK ABSORBER INSPECTION

1.Remove:
● Seat
● Side cover (right)

● Fuel tank
Refer to the “FUEL TANK” section.

2.Check:
● Rear shock absorber mount
Looseness → Tighten.
Bolt (upper) 1 59 Nm (5.9 m • kg)
T.
R.
Nut (lower) 2 59 Nm (5.9 m • kg)

T.
R.
Refer to the “REAR SHOCK ABSORBER

AND SWINGARM” section in CHAPTER 6.
3 - 25
WHEEL INSPECTION/SPOKE INSPECTION AND INSP
TIGHTENING/CABLE INSPECTION ADJ
WHEEL INSPECTION
1.Inspect:
● Wheels
Damage/Bends → Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
WARNING
● Never attempt even small repairs to the
wheel.
● Ride conservatively after installing a tire
to allow it to seat itself properly on the
rim.
SPOKE INSPECTION AND TIGHTENING

1.Inspect:
● Spokes 1
Bend/Damage → Replace.
Loose spoke → Retighten.
2.Tighten:
● Spokes
Nipple:
0.6 m • kg
T.
R.
CABLE INSPECTION
WARNING
Damage cable sheath may cause corrosion
and interfere with the cable movement. An
unsafe condition may result so replace
such cable as soon as possible.
1.Inspect:
● Cable sheath
● Cables (throttle, clutch and starter)
Damage → Replace.
3 - 26
INSP
LUBRICATION ADJ
LUBRICATION
Cables
1.Check:
● Cable operation
Unsmooth operation → Lubricate.
Recommended lubricant:
Engine oil
NOTE:
Hold cable end high and apply several drops of
lubricant to cable.
2.Apply the grease to the throttle cable end
and cable guide groove at inside of throttle
housing 1.
Lithium soap base grease
Level/pedal
1.Lubricate the pivoting parts of the each lever
and pedal.
Engine oil
Sidestand/centerstand
1.Lubricate the pivoting parts.
Engine oil
Rear suspension
1.Lubricate the pivoting parts.
Lithium-soap base grease
3 - 27
INSP
BATTERY INSPECTION ADJ
ELECTRICAL
BATTERY INSPECTION
WARNING
Battery electrolyte is dangerous. It con-
tains sulfuric acid which is poisonous and
highly caustic.
Always follow these preventive measures:
● Avoid bodily contact with electrolyte as it
can cause severe burns and permanent

eye injury.
● Wear protective eye gear when handling
or working near batteries.

● Antidote (EXTERNAL):
● SKIN - Flush with water.
● EYES - Flush with water for 15 minutes
and get immediate medical attention.

● Antidote (INTERNAL):
● Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg

or vegetable oil. Get immediate medical
attention.
● Batteries generate explosive hydrogen
gas.
● Always follow these preventive measures:
● Change batteries in a well - ventilated area.
● Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,

lighted cigarettes, etc.)
● DO NOT SMOKE when charging or han-
dling batteries.
● KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
1.Remove:

● battery band 1
2.Disconnect:
● battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative lead 2, then
the positive lead 3.
3.Remove:
● battery
3 - 28
INSP
4.Inspect:
● Electrolyte level
Electrolyte level should be between the

upper 1 and lower 2 level marks. Electro-
lyte level is too low → Add electrolyte to
proper level.
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.
5.Inspect:
● Breather hose
Obstruction → Remove.
Damage → Replace.
CAUTION:
When inspecting the battery, make sure
that the breather hose is routed correctly. If
the breather hose is positioned in such a
way as to allow battery electrolyte or gas to
come into contact with the frame, this
could damage the motorcycle and ruin its
finish.
6.Check:
● Specific gravity
Less than 1.280 → Recharge the battery.

Charging Current:
0.7 amps/10 hr
Specific Gravity:
1.280 at 20 °C
*****************************************************
Replace the battery if:
● Battery voltage will not rise to a specific
value or bubbles fail to rise during charging.
● Sulphation of one or more cells occurs, (as
indicated by the plates turning white, or
material accumulating in the bottom of the
cell).
3 - 29
INSP
● Specific gravity readings after a long, slow
charge indicate that one cell is charged lower
than the rest.
● Warpage or buckling of plates or insulators is
evident.
*****************************************************
7.Connect:
● Breather hose (battery)
Be sure the hose is properly attached and

routed.
CAUTION:
When inspecting the battery, be sure the
breather pipe is routed correctly. If the
breather pipe touches the frame or exits in
such a way as to cause battery electrolyte
or gas to exit onto the frame, structural and
cosmetic damage to the motorcycle can
occur.
8.Inspect:
● Battery terminals
Dirty → Clean with a wire brush.

Poor connection → Correct.
NOTE:
After cleaning the terminals, apply a light coat
of grease.
9.Install:
● Battery
10.Connect:
● Battery leads
CAUTION:
First, connect the positive lead 1, then
connect the negative lead 2.
11.Install:
● Battery band 3
3 - 30
INSP
FUSE INSPECTION ADJ
FUSE INSPECTION
1.Remove:

2.Remove:
● Fuse 1
3.Inspect:
● Fuse
Defective → Replace.
Blown fuse (new) → Inspect circuit.
NOTE:
Install new fuse of proper amperage.
Amperage: 10 A
4.Replace:
● Blown fuse
*****************************************************
Blown fuse replacement steps:
● Turn off ignition and the circuit.
● Install a new fuse of proper amperage.
● Turn on switches to verify operation of elec-
trical device.
● If fuse blows immediately again check circuit
in question.
*****************************************************
WARNING
Do not use fuse of higher amperage rating
than recommended. Extensive electrical
system damage and fire could result from
substitution of a fuse of improper amper-
age.
5.Install:
● Fuse
3 - 31
HEADLIGHT BEAM ADJUSTMENT/ INSP
HEADLIGHT BULB REPLACEMENT ADJ
HEADLIGHT BEAM ADJUSTMENT
1.Remove:
● Holding screw 1
● Headlight unit 2
2.Adjust:
● Headlight beam (vertical)
*****************************************************
Headlight beam adjustment steps:
● Loosen the bolt (headlight body).
● Position the headlight body up or down to
adjust the headlight beam.
*****************************************************
3.Install:
● Headlight unit
HEADLIGHT BULB REPLACEMENT

1.Remove:
● Holding screw 1
2.Remove:
● Cover 1
● Bulb (defective)
NOTE:
Turn the bulb holder 2 counterclockwise to
remove the bulb.
WARNING
Keep flammable products and your hands
away from the bulb while it is on, it will be
hot. Do not touch the bulb until it cools
down.
3 - 32
INSP
HEADLIGHT BULB REPLACEMENT ADJ
3.Install:
● Bulb (new)
Secure the new bulb with the bulb holder.
CAUTION:
Avoid touching glass part of bulb. Also
keep it free from oil otherwise, transpar-
ency of glass, bulb life and illuminous flux
will be adversely affected. If oil gets on
bulb, clean it with a cloth moistened thor-
oughly with alcohol or lacquer thinner.
4.Install:
● Cover
● Headlight unit
3 - 33
ENG
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL ...................................................................................... 4-1

ENGINE OIL .......................................................................................... 4-1
EXHAUST PIPE ASSEMBLY ................................................................ 4-1
LEFT FOOTREST BRACKET ............................................................... 4-2
DRIVE CHAIN ........................................................................................ 4-2
CARBURETOR ...................................................................................... 4-3
WIRE, CABLE AND TUBE .................................................................... 4-3
STARTER MOTOR ................................................................................ 4-4
ENGINE ................................................................................................. 4-4
ENGINE INSTALLATION ............................................................................. 4-5

ENGINE ASSEMBLY ............................................................................. 4-5
STARTER MOTOR ................................................................................ 4-5
WIRE AND CABLES .............................................................................. 4-5
CARBURETOR ...................................................................................... 4-6
DRIVE CHAIN ........................................................................................ 4-6
LEFT FOOTREST BRACKET ............................................................... 4-6
EXHAUST ASSEMBLY ......................................................................... 4-7
FUEL TANK AND SEAT ........................................................................ 4-7
CYLINDER HEAD ......................................................................................... 4-9

CYLINDER HEAD REMOVAL ............................................................. 4-10
CYLINDER HEAD INSPECTION ......................................................... 4-12
TIMING CHAIN TENSIONER INSPECTION ....................................... 4-13
CYLINDER HEAD INSTALATION ....................................................... 4-14
CAMSHAFT AND ROCKER ARMS .......................................................... 4-16

ROCKER ARM AND CAMSHAFT REMOVAL .................................... 4-17
CAMSHAFT INSPECTION .................................................................. 4-18
ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION .......... 4-18
CAMSHAFT AND ROCKER ARM INSTALLATION ............................ 4-19
VALVES AND VALVE SPRINGS ............................................................... 4-21

VALVE AND VALVE SPRINGS REMOVAL ........................................ 4-22
VALVES AND VALVE SPRINGS INSPECTION ................................. 4-24
VALVE SEATS INSPECTION ............................................................. 4-25
VALVES AND VALVE SPRINGS INSTALLATION .............................. 4-27
CYLINDER AND PISTON ........................................................................... 4-29

PISTON REMOVAL ............................................................................. 4-30
CYLINDER INSPECTION .................................................................... 4-31
PISTON AND PISTON PIN INSPECTION .......................................... 4-32
PISTON RINGS INSPECTION ............................................................ 4-33
PISTON RINGS, PISTON AND CYLINDER INSTALLATION ............. 4-34
ENG
GENERATOR ............................................................................................. 4-36
CRANKCASE COVER (LEFT) REMOVAL .......................................... 4-37
GENERATOR ROTOR REMOVAL ..................................................... 4-38
STARTER CLUTCH INSPECTION ..................................................... 4-39
GENERATOR INSTALLATION ........................................................... 4-39
CRANKCASE COVER (LEFT) INSTALLATION .................................. 4-40
CLUTCH ...................................................................................................... 4-42

CRANKCASE COVER (RIGHT) REMOVAL ....................................... 4-43
CLUTCH REMOVAL ............................................................................ 4-44
CLUTCH INSPECTION ....................................................................... 4-45
CLUTCH INSTALLATION .................................................................... 4-47
KICK STARTER AND SHIFT SHAFT ......................................................... 4-50

KICK SHAFT AND SHIFT SHAFT REMOVAL .................................... 4-51
KICK STARTER INSPECTION ............................................................ 4-51
SHIFT SHAFT INSPECTION ............................................................... 4-52
KICK SHAFT ASSEMBLING ............................................................... 4-53
SHIFT SHAFT AND KICK STARTER INSTALLATION ....................... 4-53
OIL PUMP ................................................................................................... 4-54

OIL PUMP REMOVAL ......................................................................... 4-55
OIL PUMP INSPECTION ..................................................................... 4-55
OIL PUMP INSTALLATION ................................................................. 4-56
CRANKCASE AND CRANKSHAFT ........................................................... 4-57

CRANKCASE SEPARATING .............................................................. 4-58
CRANKSHAFT INSPECTION ............................................................. 4-59
BEARINGS AND OIL SEALS INSPECTION ....................................... 4-60
TIMING CHAIN, TIMING CHAIN DRIVE SPROCKET
AND TIMING CHAIN GUIDES INSPECTION .................................. 4-60
CRANKSHAFT INSTALLATION .......................................................... 4-61
CRANKCASE ASSEMBLING .............................................................. 4-61
TRANSMISSION ......................................................................................... 4-63

TRANSMISSION REMOVAL ............................................................... 4-64
SHIFT FORK SHIFT CAM INSPECTION ............................................ 4-64
TRANSMISSION INSPECTION .......................................................... 4-65
TRANSMISSION INSTALLATION ....................................................... 4-67
ENGINE REMOVAL ENG
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE:
It is not necessary to remove the engine in
order to remove the following components.
● Cylinder head
● Cylinder
● Piston
● Clutch
● Kickstarter shaft and shift shaft
● Oil pump
● Generator
1.Remove:
● Seat
● Fuel tank
Refer to the “SEAT, FUEL TANK” section in

CHAPTER 3.
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
ENGINE OIL
1.Remove:
● Drain plug
Refer to the “ENGINE OIL REPLACEMENT”

section in CHAPTER 3.
EXHAUST PIPE ASSEMBLY

1.Remove:
● Bolts (right footrest bracket)
● Right footrest bracket 1
4-1
ENGINE REMOVAL ENG
2.Loosen:
● Bolt 1 (exhaust pipe joint)
3.Remove:
● Nuts 1 (exhaust pipe)
4.Remove:
● Exhaust pipe assembly
5.Remove:
● Bolts (muffler)
● Nut (muffler)
● Muffler 1
LEFT FOOTREST BRACKET

1.Remove:
● Bolt (shift pedal)
● Bolts (left footrest bracket)
● Left footrest bracket 1
NOTE:
When removing shift pedal, shift the transmis-
sion into 1st gear.
DRIVE CHAIN
1.Remove:
● Drive chain case 1
4-2
ENGINE REMOVAL ENG
2.Remove:
● Lock washer 1
● Drive sprocket 2
3.Loosen:
● Rear wheel axle nut
● Locknuts
● Drive chain adjuster nuts
CARBURETOR
1.Remove:
● Carburetor
Refer to the “CARBURETOR” section in

CHAPTER 5.
WIRE, CABLE AND TUBE

1.Remove:
● Spark plug lead cap 1
● Ignition coil 2
2.Straighten:
● Stopper
3.Remove:
● Clutch cable 1
4.Remove:
● Breather hose 1
● Tachometer cable 2
4-3
ENGINE REMOVAL ENG
5.Remove:
● Neutral switch lead 1
● Generator lead coupler 2
● Generator leads 3
STARTER MOTOR
1.Remove:
● Starter motor
Refer to the “ELECTRIC STARTING SYS-

TEM” in CHAPTER 7.
ENGINE
1.Remove:
● Engine mounting bracket 1
2.Remove:
● Rear upper mounting bolt 1
● Front mounting bolt 2
● Rear lower mounting bolt 3
4-4
ENGINE INSTALLATION ENG
ENGINE INSTALLATION
ENGINE ASSEMBLY
WARNING
is no danger of it falling over when install-
ing engine.
1.Install:
● Engine assembly
● Rear lower mounting bolt
● Rear upper mounting bolt
Rear lower mounting bolt:

79 Nm (7.9 m • kg)
T.
R.
Rear upper mounting bolt:
58 Nm (5.8 m • kg)
2.Install:
● Front mounting bolt
Front mounting bolt:

58 Nm (5.8 m • kg)
T.
R.
3.Install:
● Engine mounting bracket
● Bolt (engine mounting bracket-frame)
● Bolt (engine mounting bracket-engine)
Bolt (engine mounting bracket-

frame):
T.
R.
30 Nm (3.0 m • kg)
Bolt (engine mounting bracket-
engine):
58 Nm (5.8 m • kg)
STARTER MOTOR
1.Install:
● Starter motor
Refer to the “ELECTRIC STARTING SYS-

TEM” in CHAPTER 7.
WIRE AND CABLES

1.Install:
● Generator leads 1
● Generator lead coupler 2
4-5
2.Install:
● Tachometer cable
● Breather hose
3.Install:
● Clutch cable
4.Install:
● Ignition coil
● Spark plug lead cap
CARBURETOR
1.Install:
● Carburetor

CHAPTER 5.
DRIVE CHAIN
1.Install:
● Drive chain
● Drive sprocket
● Lock washer
Nut (drive chain):

110 Nm (11.0 m • kg)
T.
R.
2.Install:
● Drive chain case
LEFT FOOTREST BRACKET

1.Install:
● Left footrest bracket
Bolt (shift arm):

10 Nm (1.0 m • kg)
T.
R.
Bolt (footrest bracket):

30 Nm (3.0 m • kg)
4-6
EXHAUST ASSEMBLY
1.Install:
● Muffler
● Nut (muffler)
● Bolts (muffler)
2.Install:
● Exhaust pipe
3.Tighten:
● Bolt (exhaust pipe joint)
4.Tighten:
● Nuts
● Bolts
Nuts (exhaust pipe):

18 Nm (1.8 m • kg)
T.
R.
Bolt (exhaust pipe joint):
20 Nm (2.0 m • kg)
Bolts (muffler)
30 Nm (3.0 m • kg)
5.Install:
● Right footrest bracket
● Bolts (right footrest bracket)
FUEL TANK AND SEAT

1.Install:
● Fuel tank
● Seat
Refer to the “SEAT, FUEL TANK REMOVAL

AND INSTALLATION” section in CHAPTER
3.
2.Fill:
● Engine oil
Into crankcase
Refer to the “ENGINE OIL REPLACEMENT”
4-7
3.Adjust:
● Clutch lever free play

MENT”, “CLUTCH ADJUSTMENT” section in
CHAPTER 3.
Throttle cable free play:

3 ~ 5 mm
Clutch lever free play:
10 ~ 15 mm
4.Adjust:
Refer to the “DRIVE CHAIN SLACK

ADJUSTMENT” section in CHAPTER 3.
Drive chain slack:

20 ~ 30 mm
4-8
CYLINDER HEAD ENG
CYLINDER HEAD
1 O-ring 7 Gasket
2 Tappet cover 8 Camshaft sprocket
3 O-ring 9 Gasket
4 Camshaft sprocket cover 0 Dowel pin
5 Plate A Cylinder head
6 Cam chain tensioner B Spark plug
C Timing chain guide (exhaust side)
4-9
CYLINDER HEAD ENG
CYLINDER HEAD REMOVAL
NOTE:
Prior to remove the cylinder head, remove the
seat, fuel tank and air scoop, and drain the
engine oil.
1.Remove:
● Exhaust pipe assembly
Refer to the “ENGINE REMOVAL” section in

CHAPTER 3.
2.Remove:
● Carburetor

CHAPTER 5.
3.Remove:
● Carburetor joint 1
● Spark plug 2
4.Remove:
● Tappet cover 1
● Camshaft sprocket cover 3
5.Remove:
● Timing mark accessing screw (with O-ring) 1
● Camshaft end cover (with O-ring) 2
6.Align:
● Camshaft sprocket “I” mark
With the stationary pointer on the cylinder

head.
***********************************************
TDC alignment steps:
● Turn the crankshaft counter clockwise with a
wrench.
● Align the camshaft sprocket “I” mark 1 with
the stationary pointer 2 on the cylinder
head. When the “I” mark is aligned with the
stationary pointer, the piston is at Top Dead
Center (TDC).
4 - 10
CYLINDER HEAD ENG
NOTE:
TDC on compression stroke check:
● Both rocker arms must have a valve clearance
when the “l” mark a on the flywheel is aligned

with the slit b on the crankcase cover.
● If not, give the crankshaft one counter clock-
wise turn to meet above condition.
***********************************************
7.Loosen:
● Bolt (camshaft sprocket) 1
NOTE:
Hold the crankshaft end with a wrench 2.
8.Remove:
● Cam chain tensioner 1
9.Remove:
● Camshaft sprocket
NOTE:
Fasten a safety wire to the cam chain.
10.Remove:
● Engine mounting bracket
Refer to the “ENGINE REMOVAL” section.

11.Remove:
● Cylinder head 1
NOTE:
Loosen the bolts in this stage, using a criss-
cross pattern.
4 - 11
CYLINDER HEAD ENG
12.Remove:
● Dowel pins 1
● Gasket (cylinder head) 2
● Timing chain guide (exhaust side) 3
CYLINDER HEAD INSPECTION

1.Eliminate:
● Carbon deposits
(from combustion chambers)

Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
● Spark plug threads
● Valve seats
2.Inspect:
● Cylinder head
Scratches/damage → Replace.
3.Measure:
● Cylinder head warpage
Out of specification → Resurface.
Cylinder head warpage:

Less than 0.03 mm
***********************************************
Warpage measurement and resurfacement
steps:
● Place a straightedge and feeler gauge
across the cylinder head.
● Measure the warpage.
● If the warpage is out of specification, resur-
face the cylinder head.
● Place a 400 ~ 600 grit wet abrasive paper on
the surface plate, and resurface the head
using a figure-eight sanding pattern.
NOTE:
Rotate the cylinder head several times for an
even resurfacement.
***********************************************
4 - 12
CYLINDER HEAD ENG
TIMING CHAIN TENSIONER INSPECTION
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 it clockwise with stopper 1 until it stops.
b. Remove your finger and slowly release the
timing chain tensioner rod.
c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.
***********************************************
4 - 13
CYLINDER HEAD ENG
CYLINDER HEAD INSTALATION
1.Install:
● Cylinder
Bolt:
22 Nm (2.2 m • kg)
T.
R.
Bolt:
20 Nm (2.0m • kg)
2.Install:
● Camshaft sprocket
● Timing chain
● Washer
● Bolt (camshaft sprocket)
***********************************************
Camshaft sprocket installing steps (rear
cylinder):
● Turn the crankshaft counter clockwise with
wrench.
● Align the mark “l” on the flywheel with the slit
on the crankcase cover.
● Install the camshaft sprocket with the “I”
mark facing outward.
● Force the camshaft counter clockwise to
remove the cam chain slack.
● Insert your finger into the cam chain ten-
sioner hole, and push the cam chain damper
inward.
● While pushing the cam chain damper be
sure the camshaft sprocket “I” mark 1 aligns
with the stationary pointer 2 on the cylinder
head at TDC.
● If marks are aligned, tighten the camshaft
sprocket bolt temporary.
● If marks do not align, change the meshing
position of sprocket and chain.
***********************************************
3.Install:
● Gasket (new)
● Timing chain tensioner
NOTE:
Use the gasket (new).
4 - 14
CYLINDER HEAD ENG
***********************************************
Timing chain tension installation steps:
● Turn the stopper clockwise.
● Hold the stopper with the bolt 1.
● Install the tensioner with a new gasket into
the cylinder.
Bolt (tensioner-cylinder):
10 Nm (1.0 m • kg)
T.
R.
***********************************************
4.Tighten:
● Bolt (camshaft sprocket)
Bolt (camshaft sprocket):

60 Nm (6.0 m • kg)
5.Check:
● Alignment marks
If the marks do not align → Adjust.

6.Adjust:
● Valve clearance
Refer to the “VALVE CLEARANCE ADJUST-

MENT” section in CHAPTER 3.
Intake valve (cold):

0.05 ~ 0.10 mm
Exhaust valve (cold):
0.10 ~ 0.15 mm
7.Install:
● Tappet cover
● Camshaft sprocket cover
Tappet cover:
18 Nm (1.8 m • kg)
T.
R.
Camshaft sprocket cover:

10 Nm (1.0 m • kg)
8.Install:
● Spark plug
● Carburetor joint
Spark plug:
18 Nm (1.8 m • kg)
T.
R.
Carburetor joint:
10 Nm (1.0 m • kg)
4 - 15
CAMSHAFT AND ROCKER ARMS ENG
CAMSHAFT AND ROCKER ARMS
1 Locknut
2 Valve adjuster
3 Rocker arm
4 Rocker arm shaft (exhaust)
5 Rocker arm shaft (intake)
6 O-ring
7 Bearing
8 Camshaft
9 Plate
4 - 16
ROCKER ARM AND CAMSHAFT REMOVAL
NOTE:
Prior to remove the rocker arm and camshaft,
remove the cylinder head.
1.Loosen:
● Locknut 1
● Valve adjuster 2
2.Remove
● Stopper plate 3
3.Remove:
● Camshaft 1
● Bearing 2
NOTE:
Remove the camshaft and collar by using 10
mm bolt 3.
4.Attach:
● Slide hammer set 1
Slide hammer bolt:

90890-01085
Weight:
90890-01084
5.Remove:
● Rocker arm shaft
● Rocker arm (intake/exhaust)
4 - 17
YP402052
CAMSHAFT INSPECTION
1.Inspect:
● Cam lobes
Pitting/Scratches/Blue discoloration →
Replace.
2.Measure:
● Cam lobes length a and b.
Out of specification → Replace.
Cam lobes length:

Intake:
a 36.52 ~ 36.62 mm
<Limit: 36.42 mm>
b 30.201 ~ 30.301 mm
<Limit: 30.1 mm>
Exhaust:
a 36.564 ~ 36.664 mm
<Limit: 36.46 mm>
b 30.216 ~ 30.316 mm
<Limit: 30.12 mm>
3.Inspect:
● Camshaft oil passage
Stuffed → Blow out oil passage with com-

pressed the air.
YP402060
ROCKER ARMS AND ROCKER ARM
SHAFTS INSPECTION
1.Inspect:
● Cam lobe contact surface 1
● Adjuster surface 2
Wear/Pitting/Scratches/Blue discoloration →
Replace.
***********************************************
Inspection steps:
● Inspect the two contact areas on the rocker
arms for signs of unusual wear.
● Rocker arm shaft hole.
● Cam-lobe contact surface.
● Excessive wear → Replace.
4 - 18
● Inspect the surface condition of the rocker
arm shafts.
● Pitting/scratches/blue discoloration →
Replace or check lubrication.
● Measure the inside diameter of the rocker
arm holes.
Inside diameter (rocker arm):

14.992 ~ 15.000 mm
<Limit: 15.02 mm>
● Measure the outside diameter of the rocker

arm shafts.
Outside diameter
(rocker arm shaft):
14.960 ~ 14.981 mm
<Limit 14.94 mm>
***********************************************
YP******
CAMSHAFT AND ROCKER ARM
INSTALLATION
1.Lubricate:
● Rocker arm shaft
● Rocker arm inner surface
Rocker arm shaft:

Engine oil
Rocker arm inner surface:
Molybdenum disulfide grease
2.Install:
● Rocker arm 1
● Rocker arm shaft 2
NOTE:
Install the rocker arm shaft (exhaust) com-
pletely pushed in.
4 - 19
3.Lubricate:
● Camshaft 1
Camshaft:
Molybdenum disulfide grease
Camshaft bearing:
Engine oil
4.Install:
● Plate 1
● Bolts 2 8 Nm (0.8 m • kg)
T.
R.
4 - 20
VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS
1 Valve cotter
2 Upper spring seat
3 Lower spring seat
4 Oil seal
5 Inner valve spring
6 Outer valve spring
7 Valve
4 - 21
VALVE AND VALVE SPRINGS REMOVAL
NOTE:
● Prior to remove the valves, remove the cylin-
der head, rocker arm and camshaft.

● Before removing the internal parts (Valve,
valve spring, valve seat etc.) of the cylinder

head, the valve sealing should be checked.
1.Check:
● Valve sealing
Leakage at valve seat → Inspect the valve

face, valve seat and valve seat width.
Refer to the “VALVE SEATS INSPECTION”
section.
***********************************************
Valve seat checking steps:
● Pour a clean solvent 1 into the intake and
exhaust ports.
● Check the valve seating.
There should be no leakage at the valve seat
2.
***********************************************
4 - 22
2.Attach:
● Valve spring compressor 1
Valve spring compressor:

90890-04019
3.Remove:
● Valve cotters 1
● Upper spring seat 2
● Outer valve spring 3
● Inner valve spring 4
● Oil seal 5
● Lower spring seat 6
● Valve 7
NOTE:
● Identify each part position very carefully so
that it can be reinstalled in its original place.

● Deburr any deformed valve stem end. Use
an oil stone to smooth the stem end.

1 Deburr
2 Valve stem
4.Eliminate:
● Carbon deposit
From the combustion chamber.

Use a rounded scraper.
NOTE:
Do not use a sharp instrument and avoid dam-
aging or scratching:
● Spark plug threads
● Valve seat
● Cylinder head
4 - 23
YP******
INSPECTION
1.Measure:
● Valve stem diameter a
Valve stem diameter:

Intake:
5.975 ~ 5.990 mm
<Limit: 5.95 mm>
Exhaust:
5.960 ~ 5.975 mm
<Limit: 5.935 mm>
YP402010
2.Measure:
● Runout (valve stem)
Runout limit
0.03 mm
YP402030
3.Measure:
● Free length (valve spring) a
Valve spring free length:

Inner valve spring:
36.17 mm
<Limit: 34.47 mm>
Outer valve spring:
36.63 mm
<Limit: 34.63 mm>
4.Measure:
● Compressed valve spring force a

b Installed length
Inner valve spring

30.5 mm at 7.65 ~ 9.35 kg
Outer valve spring
32 mm at 13.1 ~ 16.1 kg
YP402030
5.Measure:
● Valve spring tilt a
Spring tilt limit:

2.5°/16 mm
4 - 24
6.Inspect:
● Spring contact face
Wear/Pitting/Scratches → Replace.
7.Measure:
● Valve guide inside diameter
Valve guide inside diameter:

Intake:
6.000 ~ 6.012 mm
<Limit: 6.042 mm>
Exhaust:
6.000 ~ 6.012 mm
<Limit: 6.042 mm>
YP402010
8.Measure:
Stem-to-guide clearance =
Valve guide inside diameter a –
Valve stem diameter
Out of specification → Replace the valve

guide.
Stem-to-guide clearance limit:

Intake:
0.08 mm
Exhaust:
0.1 mm
EB402020
VALVE SEATS INSPECTION
1.Eliminate:
● Carbon deposits
(from the valve face and valve seat)

2.Inspect:
● Valve seats
Pitting/wear → Reface the valve seat.
4 - 25
3.Measure:
● Valve seat width a
Out of specification → Reface the valve seat.
Valve seat width:

Intake:
0.9 ~ 1.1 mm
<Limit: 1.6 mm>
Exhaust:
0.9 ~ 1.1 mm
<Limit: 1.6 mm>
***********************************************
Measurement steps:
● Apply Mechanic’s blueing dye (Dykem) 1 to
the valve face.
● Install the valve into the cylinder head.
● Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
● Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
● If the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat must
be replaced.
***********************************************
EB402020
4.Lap:
● Valve face
● Valve seat
NOTE:
After replacing the valve seat, valve and valve
guide, the valve seat and valve face should be
lapped.
***********************************************
Lapping steps:
● Apply a coarse lapping compound a to the
valve face.
CAUTION:
Do not let compound enter the gap
between the valve stem and the guide.
● Apply molybdenum disulfide oil to the valve
stem.
4 - 26
● Install
the valve into the cylinder head.
● Turn the valve unit the valve face and valve
seat are evenly polished, then clean off all
compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hand.
● Apply a fine lapping compound to the valve
face and repeat the above steps.
NOTE:
Make sure to clean off all compound from the
valve face and valve seat after every lapping
operation.
● Apply Mechanic’s blueing dye (Dykem) b to
the valve face.
● Install the valve into the cylinder head.
● Press the valve through the valve guide and
onto the valve seat to make a clean pattern.
● Measure the valve seat width c again.
***********************************************
EB404032
INSTALLATION
1.Deburr:
● Valve stem end
Use an oil stone to smooth the stem end.

2.Apply:
● Molybdenum disulfide oil
(onto the valve stem 3 and seal 2)
Molybdenum disulfide oil
3.Install:
● Lower spring seat 1
● Oil seal 2 New
● Valve 3
(into the cylinder head)

● Inner valve spring 4
● Outer valve spring 5
● Upper spring seat 6
NOTE:
Install the valve spring with the larger pitch a
facing upwards.
b Smaller pitch
4 - 27
4.Install:
● Valve cotters 1
NOTE:
Install the valve cotters while compressing the
valve spring with a valve spring compressor
2.
Valve spring compressor:

90890-04019
5.Secure the valve cotters onto the valve stem

by tapping lightly with a piece of wood.
CAUTION:
Do not hit so much as to damage the valve.
4 - 28
CYLINDER AND PISTON ENG
CYLINDER AND PISTON
1 Oil delivery pipe
2 Cylinder
3 O-ring
4 Gasket
5 O-ring
6 Dowel pin
7 Piston
8 Piston rings
9 Piston pin clip
0 Piston pin
4 - 29
PISTON REMOVAL
NOTE:
Prior to remove the cylinder, remove the cylin-
der head, carburetor joint and exhaust pipe.
1.Remove:
● Oil delivery pipe 1
2.Remove:
● Cylinder 1
● O-ring 2
● Dowel pin 3
● Gasket 4 (cylinder)
● O-ring 5
3.Remove:
● Piston pin clip 1
NOTE:
Before removing the piston pin clip cover the
crankcase with a clean rag 2 so you will not
accidentally drop the clip into the crankcase.
4.Remove:
● Piston pin 1
● Piston 2
NOTE:
Before removing the piston pin, deburr the clip
grooved and pin hole area. If the piston pin
groove is deburred and piston pin is still diffi-
cult to remove use the piston pin puller.
CAUTION:
Do not use a hammer to drive the piston
pin out.
4 - 30
5.Remove:
● Piston rings 1
NOTE:
When removing a piston rings, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
YP402100
CYLINDER INSPECTION
1.Measure:
● Cylinder bore
Out of specification → Rebore or replace.

NOTE:
● Measure the cylinder bore with a cylinder
bore gauge.
● Measure the cylinder bore in parallel to and
at right angles to the crankshaft. Then, find

the average of the measurements.
Cylinder bore:
70.000 ~ 70.018 mm
<Limit: 70.1 mm>
<Difference limit between A, B
and C: 0.03 mm>
2.Measure:
● Warpage
Cylinder warpage limit:

0.01 mm
4 - 31
YP******
PISTON AND PISTON PIN INSPECTION
1.Measure:
● Piston skirt diameter

a 4.0 mm form the piston bottom edge
Piston skirt diameter:

69.977 ~ 69.996 mm
Oversize (2) 70.50 mm
Oversize (4) 71.00 mm
2.Calculate:
● Piston-to cylinder-clearance
Piston-to-cylinder clearance =
Cylinder bore – Piston skirt diameter
Refer to the “CYLINDER” section for cylinder

bore measurement.
Out of specification → Replace the piston
and piston rings as a set.
Piston-to-cylinder clearance:
0.020 ~ 0.025 mm
<Limit: 0.05 mm>
3.Measure:
● Piston pin bore diameter
Piston pin bore diameter:

16.002 ~ 16.013 mm
<Limit: 16.043 mm>
4.Measure:
● Piston pin outside diameter
Piston pin outside diameter:

15.996 ~ 16.000 mm
<Limit 15.97 mm>
5.Inspect:
● Piston pin
Blue discoloration/groove → Clean or
replace.
4 - 32
YP402111
PISTON RINGS INSPECTION
1.Measure:
● Side clearance
Out of specification → Replace the piston

and the piston rings as a set.
NOTE:
Eliminate the carbon deposits from the piston
ring grooves and piston rings before measur-
ing the side clearance.
Side clearance (piston ring):

Top ring:
0.03 ~ 0.07 mm
<Limit 0.1 mm>
2 nd ring:
0.02 ~ 0.06 mm
<Limit: 0.1 mm>
2.Position:
● Piston rings
(into the cylinder)

NOTE:
Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
3.Measure:
End gap
NOTE:
You cannot measure the end gap on the
expander spacer of the oil ring. If the oil ring
rails show excessive gap, replace all three
rings.
a 40.0 mm
End gap:
Top ring
0.15 ~ 0.30 mm
<Limit: 0.6 mm>
2 nd ring:
0.15 ~ 0.30 mm
<Limit: 0.6 mm>
Oil ring:
0.3 ~ 0.9 mm
4 - 33
EB404184
PISTON RINGS, PISTON AND CYLINDER
INSTALLATION
1.Install:
● Top ring 1
● 2nd ring 2
● Oil ring 3
NOTE:
● Make sure to install the piston rings so that
the manufacture’s marks or numbers are

located on the upper side of the rings.
● Lubricate the pistons and piston rings liber-
ally with engine oil.
2.Install:
● Piston 1
● Piston pin 2
● Piston pin clip 3 New
NOTE:
● Apply engine oil onto the piston pins.
The “→” mark a on the piston must face the

exhaust side of the cylinder.
● Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre-

vent the piston pin clip from falling into the
crankcase.
● Make sure to install each piston in its respec-
tive cylinder.
3.Install:
● O-ring
● Gasket (cylinder) New

● Dowel pins
4.Position:
● Piston rings
NOTE:
Offset the piston ring end gaps as shown.
a Top ring end
b Oil ring end (lower)
c Oil ring end (upper)
d 2 nd ring end
4 - 34
5.Lubricate:
● Piston outer surface
● Piston ring
● Cylinder inner surface
Engine oil
6.Install:
● Cylinder 1
NOTE:
● Install the cylinder with one hand while com-
pressing the piston rings with the other hand.

● Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cav-

ity.
7.Install:
4 - 35
GENERATOR ENG
GENERATOR
1 Drive sprocket cover 8 Pickup coil

2 Cover 9 Generator rotor
3 O-ring 0 Starter clutch
4 Crankcase cover (left) A Starter clutch gear
5 Gasket B Bearing
6 Dowel pin C Starter clutch idle gear #2
7 Stator assembly D Starter clutch idle gear #1
4 - 36
GENERATOR ENG
CRANKCASE COVER (LEFT) REMOVAL
NOTE:
Prior to remove the crankcase cover (left),
remove the shift pedal and drain the engine oil.
1.Remove:
● Fuel tank
Refer to the “FUEL TANK” section in CHAP-

TER 3.
2.Remove:
Refer to the “LEFT FOOTREST BRACKET”

section.
3.Remove:
● Drive sprocket cover 1
● Cover 2
4.Remove:
● Starter idle gear #1 1
● Bearing 2
● Shaft 3
5.Remove:
● Neutral switch leads 1
● Crankcase cover (left)
NOTE:
Working in a crisscross, loosen the bolts 1/4
turn each. Remove them after all are loos-
ened.
M6 × 40 mm bolts: 1 ~ 6
M6 × 30 mm bolts: 7 ~ 9
6.Remove:
● Gasket
● Dowel pin
4 - 37
GENERATOR ENG
GENERATOR ROTOR REMOVAL
1.Remove:
● Bolt 1
NOTE:
● Do not touch the projection a when install-
ing the sheave holder.

● Loosen the nut while holding the generator
rotor with sheave holder 2.
2.Remove:
● Generator rotor 1
Use a flywheel puller 2
Sheave holder:
90890-01701
Flywheel puller:
90890-01362
3.Remove
● Woodruff key 1
4.Remove:
● Washer 1
● Starter clutch idle gear #2 2
● Washer 3
● Starter clutch gear 4
● Bearing 5
● Washer 6
4 - 38
GENERATOR ENG
EAS00351
STARTER CLUTCH INSPECTION
1.Check:
Burrs/chips/roughness/wear → Replace the

defective part(-s).
2.Check:
● Starter clutch gear’s contacting surfaces a
Damage/pitting/wear → Replace the starter

clutch gear.
3.Check:
● Starter clutch operation
***********************************************
a. Install the starter clutch gear 1 onto the
starter clutch 2 and hold the starter clutch.
b. When turning the starter clutch gear clock-
wise È, the starter clutch and the starter
clutch gear should engage.
If the starter clutch gear and starter clutch do
not engage, the starter clutch is faulty and
must be replaced.
c. When turning the starter clutch gear coun-
terclockwise É, it should turn freely.
If the starter clutch gear does not turn freely,
the starter clutch is faulty and must be
replaced.
***********************************************
GENERATOR INSTALLATION
1.Install
● Washer 1
● Bearing 2
● Washer 4
● Washer 6
4 - 39
GENERATOR ENG
2.Install:
● Woodruff key 1
● Generator rotor 2
● Washer 3
● Bolt 4
Use the sheave holder 5
Sheave holder:
90890-01701
NOTE:
● Before installing the generator rotor, clean
the outside of the crankshaft and inside of

the generator rotor.
● When installing the generator rotor, make
sure the woodruff key is properly seated in

the key way of the crankshaft.
NOTE:
Do not allow the special tool to touch the pro-
jection a on the generator rotor.
Nut (rotor):
60 Nm (6.0 m • kg)
T.
R.
CRANKCASE COVER (LEFT)

INSTALLATION
1.Install:
● Stator coil 1
● Pickup coil 2
Bolts (starter coil):

7 Nm (0.7 m • kg)
T.
R.
Screws (pickup coil):

7 Nm (0.7 m • kg)
2.Install:
● Dowel pin
● Gasket New
4 - 40
GENERATOR ENG
3.Install:
● Crankcase cover (left)
NOTE:
Tighten the bolts (crankcase cover-left) in a
crisscross pattern.
M6 × 40 mm bolts: 1 ~ 6
M6 × 30 mm bolts: 7 ~ 9
Bolts (crankcase cover-left):

7 Nm (0.7 m • kg)
T.
R.
4.Install:
5.Install:
● Starter clutch idle gear #1
● Cover 1
● Drive sprocket cover 2
6.Install:

section.
7.Install:
● Fuel tank
Refer to the “FUEL TANK” section in CHAP-

TER 3.
4 - 41
CLUTCH ENG
CLUTCH
1 Crankcase cover (right) 7 Push rod #1 D Clutch housing

2 Gasket 8 Clutch plate E Ball
3 Dowel pin 9 Friction plate (#1) F Push rod #2
4 Compression spring 0 Cushion spring G Push lever assembly
5 Pressure plate A Friction plate (#2) H Primary drive gear
6 Push plate B Clutch boss I Collar
C Thrust washer J Straight key
4 - 42
CLUTCH ENG
CRANKCASE COVER (RIGHT) REMOVAL
NOTE:
Prior to remove the crankcase cover (right),
drain the engine oil.
1.Remove:
● Oil filter cover 1
● Oil filter 2
● O-ring 3 (filter cover)
● O-ring 4
2.Remove:
3.Remove:
● Kick starter 1
4.Remove:
● Crankcase cover (right)
NOTE:
● Working in a crisscross pattern, loosen
screw 1/4 turn each. Remove them after all
are loosened.
● Be sure not to give damages to the mating
surface.
M6 × 55 mm bolt: 1
M6 × 50 mm bolts: 2 ~ 4
M6 × 35 mm bolt: 5
M6 × 25 mm bolts: 6 ~ C
5.Remove:
● Gasket
● Dowel pin
4 - 43
CLUTCH ENG
CLUTCH REMOVAL
1.Remove:
● Bolts (clutch springs)
● Clutch springs
2.Remove:
● Pressure plate 1
● Friction plate (#1) 2 (5 pcs)
● Clutch plate 4 (5 pcs)
● Cushion spring 5
● Push plate 6
● Push rod (#1) 7
● Ball 8
● Push rod (#2) 9
3.Straighten:
● Lock washer tab.
NOTE:
Slide the right side of crankcase to remove ball
and push rod (#1).
4.Loosen:
● Nut (clutch boss)
● Nut (primary drive gear)
NOTE:
Loosen the nut (clutch boss) while holding the
clutch boss with universal clutch holder 1.
Universal clutch holder:

90890-04086
4 - 44
CLUTCH ENG
5.Remove:
● Nut 1 (clutch boss)
● Lock washer 2
● Clutch boss 3
● Thrust washer 4
● Clutch housing 5
6.Remove:
● Nut 1 (primary drive gear)
● Lock washer 2
● Crow washer 3
● Primary drive gear 4
● Collar 5
● Straight key 6
T402181
CLUTCH INSPECTION
1.Inspect:
● Friction plate (#1, #2)
Damage/wear → Replace the friction plates

as a set.
2.Measure:
● Friction plate thickness
Out of specification → Replace the friction

plates as a set.
Measure at four places.
Thickness (friction plate #1, #2):

2.9 ~ 3.1 mm
<Limit: 2.8 mm>
3.Inspect:
● Clutch plates
Damage → Replace the clutch plates as a

set.
4.Measure:
● Clutch plate warpage
Out of specification → Replace the clutch

plates as a set.
Use a surface plate and a feeler gauge 1.
Warp; limit (clutch plate):

Less than 0.2 mm
4 - 45
CLUTCH ENG
5.Inspect:
● Compression springs
Damage → Replace the compression

springs as a set.
6.Measure:
● Free length (compression spring) a
Out of specification → Replace the clutch

springs as a set.
Free length (clutch spring):

34.9 mm
<Limit: 33.2 mm>
7.Inspect:
● Push rod (#2)
Wear/crack/damage → Replace.
8.Measure:
● Push rod (#2)
Bending limit (push rod #2):

0.5 mm
9.Inspect:
● Dogs on the housing
Cracks/wear/damage → Deburr or replace.
10.Inspect:
● Clutch housing bearing 1
Cracks/wear/damage → Replace.
4 - 46
CLUTCH ENG
11.Inspect:
● Clutch boss splines
Scoring/wear/damage → Replace clutch

boss assembly.
12.Inspect:
● Oil filter
Cracks/damage → Replace.
Contamination → Clean the flushing oil.
T******
CLUTCH INSTALLATION
1.Install:
● Straight key
● Collar 1
● Primary drive gear 2
● Crow washer 3
● Lock washer 4 New

● Nut (primary drive gear) 5
80 Nm (8.0 m • kg)
T.
R.
2.Install:
● Clutch housing
● Thrust washer
● Clutch bass
● Lock washer 1 New

● Nut 2 (clutch boss) 70 Nm (7.0 m • kg)
T.
R.
NOTE:
Install the primary drive gear and clutch boss
nut 2 while holding the clutch boss with a
clutch holding tool 3.
Universal clutch holder:

90890-04086
3.Bend:
● Lock washer tab 1 (primary drive gear and
clutch boss)
(along a flat side of the end)
4 - 47
CLUTCH ENG
4.Install:
● Cushion spring 3
● Friction plate (#2) 4
● Push rod (#2) 7
● Ball 8
● Push rod (#1) 9
● Push plate 0
NOTE:
Install the clutch plates and friction plates alter-
nately on the clutch boss, starting with a fric-
tion plate and ending with a friction plate.
5.Install:
● Pressure plate 1
● Compression springs
● Bolts 2 (compression springs)
T.
R.
6 Nm (0.6 m • kg)
NOTE:
Tighten the bolts in a crisscross pattern.
6.Adjust:
● Clutch mechanism free play
***********************************************
Clutch mechanism free play adjustment
steps:
● Loosen the locknut 1
● Push the push lever toward the front of the
engine with your finger to align the push
lever tab with the alignment mark on the
crankcase.
● With the push lever in this position, turn the
screw 2 either in or out until the push lever
mark 3 and crankcase match mark are
aligned.
Locknut:
8 Nm (0.8 m • kg)
T.
R.
***********************************************
4 - 48
CLUTCH ENG
7.Tighten
● Screw (push lever axle)
Screw:
12 Nm (1.2 m • kg)
T.
R.
8.Install:
● Dowel pins 1
● Gasket 2 New
9.Install:
● Crankcase cover (right)
Bolts (crankcase cover-right):

10 Nm (1.0 m • kg)
T.
R.
M6 × 55 mm bolt: 1
M6 × 50 mm bolts: 2 ~ 4
M6 × 35 mm bolt: 5
M6 × 25 mm bolts: 6 ~ C
10.Install:
● Kick crank 1
NOTE:
Align the lip a of kick crank boss with the bolt
b as shown.
4 - 49
KICK STARTER AND SHIFT SHAFT ENG
KICK STARTER AND SHIFT SHAFT
1 Kick shaft
2 Kick segment gear
3 Kick pinion gear
4 Kick spring
5 Kick crank
6 Shift shaft assembly
7 Stopper lever
4 - 50
KICK SHAFT AND SHIFT SHAFT REMOVAL
NOTE:
Prior to remove the kick shaft, remove the
clutch assembly.
1.Remove:
● Clutch housing
Refer to the “CLUTCH REMOVAL” section.

2.Remove:
● Shift pedal

section.
3.Remove:
● Circlip 1
● Washer 2
● Kick pinion gear 3
● Washer 4
● Circlip 5
4.Remove:
● Kick shaft assembly 1
● Shift shaft assembly 2
5.Remove:
● Stopper lever assembly 1
T******
KICK STARTER INSPECTION
1.Inspect:
● Kick segment gear 1
● Ratchet gear teeth 2
4 - 51
2.Inspect:
● Kick spring
Wear/crack → Replace.
T402200
SHIFT SHAFT INSPECTION
1.Inspect:
● Stopper lever
Roller turns roughly → Replace.

Bends/damage → Replace.
2.Inspect:
● Stopper lever spring
3.Inspect:
● Shift shaft assembly
● Shift shaft spring
Bends/wear damage → Replace.
4 - 52
KICK SHAFT ASSEMBLING
1.Install:
● Kick shaft 1
● Kick segment gear 2
● Ratchet gear 3
NOTE:
Align the punch mark of kick shaft a to the
kick segment gear b.
SHIFT SHAFT AND KICK STARTER

INSTALLATION
1.Install:
● Stopper lever assembly 1
Bolt (stopper):
10 Nm (1.0 m • kg)
T.
R.
LOCTITE®
2.Install:
● Shift shaft assembly 1
● Kick shaft assembly 2
NOTE:
Hook the kick spring onto the crankcase stop-
per.
3.Install:
● Circlip 1
● Washer 2
● Kick pinion gear 3
● Washer 4
● Circlip 5
4.Bend:
● Lock washer
4 - 53
OIL PUMP ENG
OIL PUMP
1 Oil pump assembly

2 Oil pump gear
3 Circlip
4 Gasket
5 Oil strainer
4 - 54
OIL PUMP ENG
OIL PUMP REMOVAL
NOTE:
Prior to remove the oil pump, remove the
clutch assembly.
1.Remove:
● Oil strainer 1
● Circlip 2
● Oil pump gear 3
● Oil pump assembly 4
● Gasket 5
NOTE:
Do not remove the screw, to avoid disassem-
bling oil pump.
T402140
OIL PUMP INSPECTION
1.Measure:
● Tip clearance È
(between the inner rotor 1 and the outer

rotor 2)
● Side clearance É
(between the outer rotor 2 and the pump

housing 3)
Out of specification → Replace the oil pump
assembly.
● Housing and rotor clearance Ê
(between the pump housing 3 and the

rotors 1 2)
Out of specification → Replace the oil pump
assembly.
Tip clearance È:
0.15 mm <Limit: 0.20 mm>
Side clearance É
0.04 ~ 0.09 mm
<Limit: 0.15 mm>
Housing and rotor clearance Ê:
0.03 ~ 0.09 mm
<Limit: 0.15 mm>
4 - 55
OIL PUMP ENG
2.Inspect:
● Oil stainer
Contamination → Clean the flushing oil.
OIL PUMP INSTALLATION

1.Install:
● Gasket 1
● Oil pump assembly 2
● Oil pump gear 3
● Circlip 4
● Oil strainer 5
Bolt (oil pump):

6 Nm (0.6 m • kg)
T.
R.
4 - 56
CRANKCASE AND CRANKSHAFT ENG
CRANKCASE AND CRANKSHAFT
1 Crankcase (left)
2 Crankcase (right)
3 Dowel pin
4 Crank shaft assembly
5 Bearing
6 Timing chain drive sprocket
7 Timing chain
8 Timing chain guide (intake side)
9 Drain bolt
0 Gasket
4 - 57
CRANKCASE SEPARATING
NOTE:
Prior to separate the crankcase, remove the
engine and remove the cylinder head, cylinder,
generator, clutch, kick axle, shift shaft and oil
pump.
1.Remove:
● Timing chain 1
● Timing chain guide (intake side) 2
● Timing chain drive sprocket 3
● Push lever (clutch)
2.Remove:
● Neutral switch 1
● 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.
M6 × 70 mm bolts: 2 ~ 4
M6 × 60 mm bolts: 5, 6
M6 × 55 mm bolts: 7 ~ 9
M6 × 45 mm bolts: 0 ~ C
3.Remove:
● Circlip 1
● Crankcase (right)
NOTE:
Align the shift drum 2 projections with the
slots on the right crankcase before removing
right crankcase.
CAUTION:
Use soft hammer to tap on the case half,
tap only on reinforced portions of case.
The slot for separating the crankcase is
provided. Using the screwdriver, separate
the case with even force applied to both
side. Do not damage the crankcase mating
surface.
4 - 58
4.Remove:
● Crankshaft 1
Use a crankcase separating tool 2.
Crankcase separating tool:

90890-01135
T******
CRANKSHAFT INSPECTION
1.Measure:
● Crankshaft runout 1
Out of specification → Replace crankshaft

and/or bearing.
NOTE:
Measure the crankshaft runout with the crank-
shaft assembly turning slowly.
Runout limit:
0.03 mm
2.Measure:
● Big end side clearance 2
Out of specification → Replace big end bear-

ing, crank pin and/or connecting rod.
Big end side clearance:

0.35 ~ 0.85 mm
3.Measure:
● Crank width 3
Out of specification → Replace crankshaft.
Crank width
69.25 ~ 69.30 mm
4.Inspect:
● Bearing 1
Wear/crack/damage → Replace crankshaft.
4 - 59
5.Inspect:
● Crankshaft journal
Clogged → Blow out the journal with com-

pressed air.
EAS00401
BEARINGS AND OIL SEALS INSPECTION
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.
EAS00207
TIMING CHAIN, TIMING CHAIN DRIVE
SPROCKET AND TIMING CHAIN GUIDES
INSPECTION
1.Check:
● Timing chain
Damage/stiffness → Replace the timing

chain and camshaft sprocket as a set.
2.Check:
● Timing chain drive sprocket
More than 1/4 tooth a wear → Replace the

camshaft sprocket and the timing chain as a
set.
a 1/4 tooth
b Correct
1 Timing chain roller
2 Timing chain drive sprocket
4 - 60
3.Check:
● Timing chain guide (exhaust side)
● Timing chain guide (intake side)
Damage/wear → Replace the defective

part(-s).
CRANKSHAFT INSTALLATION
1.Install:
● Crankshaft
Into the crankcase (right)

NOTE:
Hold the connecting rod 1 at top dead center
with one hand while turning the nut of the
installing tool with the other. Operate the
installing tool unit the crankshaft bottoms
against the bearing.
Crankshaft installer pot 2:

90890-01274
Crankshaft installer bolt 3:
90890-01275
Adaptor (M10) 4:
90890-01383
spacer 5:
90890-01288
CRANKCASE ASSEMBLING
1.Apply:
● Sealant
To the mating surface of both case halves

1.
Yamaha bond No. 1215

90890-85505
2.Install:
● Dowel pins 2
3.Fit the right crankcase onto the left case.

Tap lightly on the case with a soft hammer.
CAUTION:
Before installing and torquing the crank-
case holding bolts, be sure to check
whether the transmission is functioning
properly by manually rotating the shift cam
either way.
4 - 61
4.Tighten:
● Crankcase bolts
NOTE:
● Tighten the crankcase bolts in stages and in
a crisscross pattern.
● Install a copper washer on bolts 1, 2, 3.
M6 × 70 mm bolts: 1 ~ 3
M6 × 60 mm bolts: 4, 5
M6 × 55 mm bolts: 6 ~ 8
M6 × 45 mm bolts: 9 ~ B
Bolt (left crankcase):

10 Nm (1.0 m • kg)
T.
R.
5.Install:
● Neutral switch C
6.Install:
● Push lever (clutch)
● Timing chain drive sprocket 1
● Timing chain guide (intake side) 2
● Timing chain 3
4 - 62
TRANSMISSION ENG
TRANSMISSION
1 Main axle/1st pinion gear 8 4th wheel gear
2 3rd/4th pinion gear 9 5th wheel gear
3 5th pinion gear 0 2nd wheel gear
4 2nd pinion gear A Drive sprocket
5 Drive axle B Shift drum assembly
6 1st wheel gear C Shift fork “L”
7 3rd wheel gear D Shift fork “C”
E Shift fork “R”
4 - 63
TRANSMISSION ENG
TRANSMISSION REMOVAL
NOTE:
Prior to remove the transmission, separate the
crankcase.
1.Remove:
● Dowel pin
● Guide bar 1
● Shift fork “R” 2
● Shift fork “C”
● Shift fork “L” 3
● Shift drum assembly 4
NOTE:
Note the position of each part. Pay particular
attention to the location and direction of shift
forks.
2.Remove:
● Transmission gear assembly 1
T402190
SHIFT FORK SHIFT CAM INSPECTION
1.Inspect:
● Shift fork cam follower 1
● Shift fork pawl 2
Scoring/bends/wear/damage → Replace.
2.Inspect:
● Shift drum grooves 1
Wear/damage/scratches → Replace.
● Shift drum segment 2
4 - 64
TRANSMISSION ENG
3.Inspect:
● Shift fork “C” 2
● Shift fork guide bar 4
● Pin 6
Roll the shift fork guide bar on a flat surface.

Bends → Replace.
WARNING
Do not attempt to straighten a bent shift
fork guide bar.
4.Check:
● Shift fork movement
(along the shift fork guide bar)

Unsmooth operation → Replace the shift fork
and the shift fork guide bar.
NOTE:
When damaged the shift fork and mission
gear, replace the facing each gear as set.
EAS00424
TRANSMISSION INSPECTION
1.Measure:
● Main axle runout
(with a centering device and dial gauge 1)

Out of specification → Replace the main
axle.
Main axle runout limit

0.08 mm
2.Measure:
● Drive axle runout
(with a centering device and dial gauge 1)

Out of specification → Replace the drive
axle.
Drive axle runout limit

0.08 mm
4 - 65
TRANSMISSION ENG
3.Check:
● Transmission gears
Blue discoloration/pitting/wear → Replace

the defective gear(s).
● Transmission gear dogs

Cracks/damage/rounded edges → Replace
the defective gear(s).
4.Check:
● Transmission gear engagement
(each pinion gear to its respective wheel

gear)
Incorrect → Reassemble the transmission
axle assemblies.
NOTE:
When reassembling the main axle, press the
2nd pinion gear 1 onto it 2 as shown.
5.Check:
● Transmission gear movement
Rough movement → Replace the defective
part(s).
6.Check:
● Circlips
Damage/bends/looseness → Replace.
4 - 66
TRANSMISSION ENG
TRANSMISSION INSTALLATION
1.Install:
● Transmission gears assembly 1
● Shift fork “C”
Into the crankcase (right)

● Guide bar 5
NOTE:
Facing the mark on shift fork down ward.
2.Check:
● Shifter operation
Unsmooth operation → Repair.

NOTE:
● Oil each gear and bearing thoroughly.
● Before assembling the crankcase, be sure
that the transmission is in neutral and that

the gears turn freely.
4 - 67
CARB
CHAPTER 5.
CARBURETION
CARBURETOR ............................................................................................. 5-1

REMOVAL ............................................................................................. 5-2
DISASSEMBLY ..................................................................................... 5-3
INSPECTION ........................................................................................ 5-5
ASSEMBLY ........................................................................................... 5-7
INSTALLATION ..................................................................................... 5-9
FUEL LEVEL ADJUSTMENT .............................................................. 5-10
CARB
CARBURETOR CARB
CARBURETION
CARBURETOR
1 Vacuum chamber cover 7 Needle jet D Drain hose
2 Piston valve spring 8 Pilot jet E Float pivot pin
3 Jet needle set 9 Throttle stop screw set F Float
4 Pilot screw set 0 Gasket G Drain screw
5 Piston valve A Main jet H Pilot air jet
6 Starter plunger assembly B Needle valve assembly I Coasting enricher
C Needle valve holder J Coasting enricher spring
5-1
CARBURETOR CARB
REMOVAL
WARNING
Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.
1.Remove:
● Fuel tank
Refer to the “FUEL TANK” section in

CHAPTER 3.
2.Remove:
● Battery
Refer to the “BATTERY INSPECTION” sec-

tion in CHAPTER 3.
3.Remove:
● Drive chain guard 1
4.Remove:
● Battery case 1
5.Remove:
● CDI unit 1
● Starter relay 2
● Fuse 3
5-2
CARBURETOR CARB
6.Remove:
● Air filter case 1
7.Drain:
● Loosen the drain screw 1 and drain the gas-
oline
8.Loosen:
● Lock nut 2 (throttle cable)
9.Remove:
● Throttle cable 3
10.Loosen:
● Screw 1 (carburetor joint)
11.Remove:
● Carburetor 1
DISASSEMBLY
1.Remove:
● Vacuum chamber cover 1
2.Remove:
● Piston valve spring 2
● Piston valve 3
5-3
CARBURETOR CARB
3.Remove:
● Jet needle set 1
4.Remove:
● Pilot screw set 1
5.Remove:
● Float chamber cover 1
● Gasket
6.Remove:
● Float pivot pin 1
● Float 2
● Needle valve 3
7.Remove:
● Needle valve holder 1
5-4
CARBURETOR CARB
8.Remove:
● Main jet 1
● Washer 2
● Needle jet 3
● Pilot jet 4
9.Remove:
● Starter plunger assembly 1
INSPECTION
1.Inspect:
● Carburetor body
● Fuel passage
Contamination → Clean as indicated.
*****************************************************
Carburetor cleaning steps:
● Wash carburetor in petroleum based solvent.
(Do not use any caustic carburetor cleaning
solution.)
● Blow out all passages and jets with a com-
pressed air.
*****************************************************
2.Inspect:
● Float
Damage → Replace.
3.Inspect:
● Needle valve assembly 1
Damage/wear/contamination → Replace as
a set.
5-5
CARBURETOR CARB
4.Inspect:
● Piston valve 1
Cracks → Replace.
● Rubber diaphragm 2
Tears → Replace.
● Jet needle 3
Bend → Replace.
NOTE:
If you suspect the piston valve has been dam-
aged, check the component for cracks by
pouring gasoline into the valve. If it leaks,
replace with a new piston valve.
5.Check:
● Free movement
Insert the throttle valve into the carburetor

body, and check for free movement.
Stick → Replace.
6.Inspect:
● Main jet 1
● Needle jet 2
● Pilot jet 3
● Pilot screw 4
● Pilot air jet 5
Bends/wear/damage → Replace.
Contamination → Blow out jets with a com-
pressed air.
7.Inspect:
● Starter plunger assembly 1
5-6
CARBURETOR CARB
ASSEMBLY
To assemble the carburetor reverse the disas-
sembly procedures. Note the following points.
NOTE:
● Before reassembling wash all parts in clean
gasoline.
● Always use a new gasket.
1.Install:
● Jet needle set
To piston valve assembly

NOTE:
Be sure to install the jet needle plate so that
the projection a is located toward the hole b
in the piston valve.
2.Install:
● Pilot screw set 1
*****************************************************
Note the following installation points:
● Screw in the pilot screw 4 until it is lightly
seated.
● Back out by the specified number of turns.
Pilot screw (turn out):

2-1/2
*****************************************************
5-7
CARBURETOR CARB
3.Install:
● Needle jet
To carburetor
NOTE:
Be sure to insert the slot a onto the projection
b.
4.Install:
● Needle valve holder
Screw (float valve holder):

2 Nm (0.2 m • kg)
T.
R.
5.Install:
● Float chamber cover 1
Screw (float chamber cover):

5 Nm (0.5 m • kg)
T.
R.
6.Install:
● Piston valve assembly 1
● Piston valve spring 2
● Vacuum chamber cover 3
Screw (vacuum chamber cover):

4 Nm (0.4 m • kg)
T.
R.
NOTE:
Match the tab a on the rubber diaphragm to
the matching recess b in the piston valve.
5-8
CARBURETOR CARB
INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points:
1.Install:
● Carburetor
NOTE:
Be sure to insert the projection a into the slot
b of carburetor joint.
2.Adjust:
● Engine idle speed
Refer to the “IDLING SPEED ADJUST-

Engine idle speed:

1,350 ~ 1,450 r/min
3.Adjust:
● Throttle cable free play a (throttle grip)


3 ~ 5 mm
5-9
CARBURETOR CARB
FUEL LEVEL ADJUSTMENT
1.Measure:
● Fuel level a
Fuel level:
2.7 ~ 4.7 mm below the float
chamber line
*****************************************************
Fuel level measurement and adjustment
steps:
● Place the motorcycle on a level surface.
● Use centerstand to ensure that the carbure-
tor is positioned vertically.
● Connect the fuel level gauge 1 to the drain
pipe 2 using a level gauge adapter.
Fuel level gauge:

90890-01312
● Loosen the drain screw 3.

● Measure the fuel level a with the gauge.
● If the fuel level in incorrect, adjust the fuel
level.
● Remove the carburetor.
● Inspect the needle valve.
● If it is worn, replace it.
● If it is fine, adjust float level by bending the
float tang b slightly.
● Install the carburetor.
● Recheck the fuel level.
*****************************************************
5 - 10
CHAS
CHAPTER 6.
CHASSIS
FRONT WHEEL AND BRAKE DISC ............................................................ 6-1

FRONT WHEEL REMOVAL .................................................................. 6-2
FRONT WHEEL DISASSEMBLY .......................................................... 6-2
FRONT WHEEL INSPECTION ............................................................. 6-3
BRAKE DISC INSPECTION .................................................................. 6-4
FRONT WHEEL ASSEMBLY ................................................................ 6-5
FRONT WHEEL INSTALLATION .......................................................... 6-5
REAR WHEEL AND REAR BRAKE ............................................................ 6-7

REAR WHEEL REMOVAL .................................................................... 6-8
REAR WHEEL DISASSEMBLY ............................................................ 6-8
REAR WHEEL INSPECTION ................................................................ 6-8
REAR BRAKE INSPECTION ................................................................ 6-9
BRAKE SHOE PLATE ASSEMBLY .................................................... 6-10
REAR WHEEL ASSEMBLY ................................................................ 6-10
REAR WHEEL INSTALLATION .......................................................... 6-11
FRONT BRAKE .......................................................................................... 6-12

FRONT BRAKE CALIPER .................................................................. 6-12
MASTER CYLINDER .......................................................................... 6-13
BRAKE PAD REPLACEMENT ............................................................ 6-14
FRONT BRAKE CALIPER REMOVAL ................................................ 6-16
FRONT BRAKE CALIPER INSPECTION ........................................... 6-17
FRONT BRAKE CALIPER INSTALLATION ........................................ 6-17
MASTER CYLINDER REMOVAL ........................................................ 6-20
MASTER CYLINDER INSPECTION ................................................... 6-20
MASTER CYLINDER INSTALLATION ................................................ 6-21
FRONT FORK ............................................................................................. 6-24

FRONT FORK REMOVAL .................................................................. 6-25
FRONT FORK DISASSEMBLY ........................................................... 6-25
FRONT FORK INSPECTION .............................................................. 6-27
FRONT FORK ASSEMBLY ................................................................. 6-27
FRONT FORK INSTALLATION .......................................................... 6-30
STEERING HEAD AND HANDLEBAR ...................................................... 6-32

HANDLEBAR ...................................................................................... 6-32
STEERING HEAD ............................................................................... 6-33
HANDLEBAR REMOVAL .................................................................... 6-34
STEERING HEAD REMOVAL ............................................................ 6-35
STEERING HEAD AND HANDLEBAR INSPECTION ........................ 6-36
STEERING HEAD INSTALLATION .................................................... 6-37
HANDLEBAR INSTALLATION ............................................................ 6-39
CHAS
REAR SHOCK ABSORBER AND SWINGARM ........................................ 6-41
REAR SHOCK ABSORBER AND SWINGARM REMOVAL ............... 6-42
REAR SHOCK ABSORBER INSPECTION ......................................... 6-43
SWINGARM INSPECTION ................................................................. 6-43
RELAY ARM INSPECTION ................................................................. 6-44
CONNECTING ARM INSPECTION .................................................... 6-44
DRIVE CHAIN INSPECTION .............................................................. 6-44
REAR WHEEL CLUTCH HUB INSPECTION ..................................... 6-46
DRIVEN SPROCKET ASSEMBLY ...................................................... 6-46
REAR SHOCK ABSORBER AND SWINGARM INSTALLATION ....... 6-46
FRONT WHEEL AND BRAKE DISC CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC
1 Front wheel axle
2 Collar
3 Oil seal
4 Bearing
5 Spacer
6 Meter clutch
7 Speedometer gear unit
8 Brake disc
6-1
FRONT WHEEL REMOVAL
WARNING
is no danger of it falling over.
1.Place the motorcycle on level place.
2.Remove:
● Speedometer cable 1
● Front wheel axle nut 2
3.Remove:
● Front wheel axle 1
● Collar 2
● Speedometer gear unit 3
● Front wheel 4
T******
FRONT WHEEL DISASSEMBLY
1.Remove:
● Bearings 1
● Spacer 2
Remove the bearings using a general bear-

ing puller 3.
6-2
T700021
FRONT WHEEL INSPECTION
1.Inspect:
● Front wheel axle
(by rolling it on a flat surface)

Bends → Replace.
WARNING
Do not attempt to straighten a bent axle.
Wheel axle bending limit:

0.25 mm
2.Inspect:
● Front tire
Refer to the “TIRE INSPECTION” section in
CHAPTER 3.
● Front wheel
Refer to the “WHEEL INSPECTION” section

in CHAPTER 3.
3.Check:
● Spokes
Loose spokes → Retighten.
Turn the wheel and tap the spokes with a
screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
4.Tighten:
● Loose spokes
● Nipple
NOTE:
Check the front wheel runout after tightening
the spokes.
6-3
5.Measure:
● Front wheel runout
Over the specified limits → Replace.
Front wheel runout limits:

Radial: 2.0 mm
Lateral: 2.0 mm
6.Inspect:
● Front wheel bearings
Bearings allow free play in the wheel hub or
the wheel does not turn smoothly →
Replace.
● Oil seals
7.Inspect:
● Collar
Grooved wear → Replace the collar and the

oil seal as a set.
BRAKE DISC INSPECTION

1.Inspect:
● Brake disc
Galling/damage → Replace.
2.Measure:
● Brake disc deflection a
Out of specification → Inspect the wheel

runout.
If wheel runout is within the limits, replace
the brake disc.
Brake disc maximum deflection:

0.15 mm
Measuring point 2 mm
● Brake disc thickness b
Brake disc minimum thickness:

3.5 mm
6-4
FRONT WHEEL ASSEMBLY
1.Install:
● Bearing 1
● Spacer
● Bearing
● Oil seal
NOTE:
● Apply the lithium soap base grease on the
bearing and oil seal lip when installing.

● Use a socket that matches the outside diam-
eter of the race of the bearing.

● Always use a new oil seal.
● Install the oil seal with its manufacturer’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of balls of the
bearing. Contact should be made only with
the outer race.
FRONT WHEEL INSTALLATION

1.Install:
● Brake disc 1 23 Nm (2.3 m • kg)
T.
R.
NOTE:
®
● Apply LOCTITE to the threads of the brake
disc bolts.
● Tighten the brake disc bolts in stages using a
crisscross pattern.
2.Install:
● Speedometer gear unit 1
NOTE:
Be sure that projections a inside the wheel
hub mesh with the slots b in the gear unit
assembly.
6-5
3.Tighten:
● Front wheel axle nut
58 Nm (5.8 m • kg)
T.
R.
NOTE:
Be sure that the projection (torque stopper) a
of the gear unit housing is positioned correctly.
4.Connect:
● Speedometer cable
6-6
REAR WHEEL AND REAR BRAKE CHAS
REAR WHEEL AND REAR BRAKE
1 Drive chain puller 8 Oil seal
2 Brake camshaft lever 9 Bearing
3 Brake shoe wear indicator 0 Spacer
4 Spacer A Rear wheel clutch hub damper
5 Brake shoe plate B Rear wheel clutch hub
6 Brake camshaft C Driven sprocket
7 Brake shoe D Collar
E Rear wheel axle
6-7
REAR WHEEL REMOVAL
1.Remove:
● Adjuster 1
● Brake rod 2
● Tension bar 3
NOTE:
Depress the brake pedal to remove the brake
rod.
2.Loosen:
● Rear wheel axle nut 1
● Locknuts
● Drive chain adjuster nuts
3.Remove:
● Rear wheel axle nut 1
● Rear wheel axle 2
● Washers
● Spacer 3
● Rear wheel 4
4.Remove:
● Brake shoe plate
T******
REAR WHEEL DISASSEMBLY
1.Remove:
● Bearings 1
● Spacer 2
Refer to the “FRONT WHEEL AND BRAKE

DISC” section.
T701020
REAR WHEEL INSPECTION
1.Inspect:
● Rear wheel axle
● Rear wheel
● Rear wheel bearings
● Oil seals

DISC” section.
2.Check:
● Spokes

DISC” section.
3.Measure:
● Rear wheel runout

DISC” section.
6-8
4.Inspect:
● Rear wheel clutch hub damper
REAR BRAKE INSPECTION

1.Inspect:
● Brake shoes
Glazed parts → Sand with coarse sandpa-

per.
NOTE:
After using the sandpaper, clean of the pol-
ished particles with a cloth.
2.Measure:
● Brake shoe thickness a
Brake shoe thickness (limit):

1.0 mm
b Measure point
3.Inspect:
● Brake shoe spring
4.Inspect:
● Brake drum inner surface
Oil/scratches → Remove.
Use a rag soaked in lacquer

Oil
thinner or solvent.
Use an emery cloth (lightly

Scratch
and evenly polishing).
5.Measure:
● Brake drum inside diameter a
Standard 130 mm
Wear limit 131 mm
6-9
6.Inspect:
● Brake shoe plate 1
● Brake camshaft 2
● Camshaft hole 3
Scratches/excessive wear → Replace.
T******
BRAKE SHOE PLATE ASSEMBLY
1.Install:
● Brake camshaft 1
● Brake shoe wear indicator 2
***********************************************
Installation steps:
● Set the camshaft with its punched mark a
facing the direction as shown.
● Align the projection b on the indicator with
the camshaft notch and install.
● Check the proper position of the brake shoe.
***********************************************
2.Install:
● Brake camshaft lever 1
Install the camshaft lever with its slit and the

indicator at right angle as shown.
T******
REAR WHEEL ASSEMBLY
1.Install:
● Bearing 1
● Spacer 2

DISC” section.
6 - 10
T701032
REAR WHEEL INSTALLATION
Note the following points.
1.Install:
● Brake shoe plate assembly
● Rear wheel assembly
NOTE:
Make sure that the slot in the rear wheel clutch
hub damper fits over the tab on the rear wheel
clutch hub assembly.
2.Install:
● Rear wheel
● Spacer
● Rear wheel axle
● Rear wheel axle nut T.

85 Nm (8.5 m • kg)
R.
3.Install:
● Tension bar 16 Nm (1.6 m • kg)
T.
R.
4.Adjust:
● Brake pedal free play
Brake pedal free play:

20 ~ 30 mm
5.Adjust:
Refer to the “DRIVE CHAIN SLACK

ADJUSTMENT” section in CHAPTER 3.
Drive chain slack:

20 ~ 30 mm
6 - 11
FRONT BRAKE CHAS
FRONT BRAKE
FRONT BRAKE CALIPER
1 Brake caliper
2 Brake pad
3 Brake pad spring
4 Retaining bolt
5 Brake caliper piston
6 Brake caliper piston seal
7 Bleed screw kit
8 Brake caliper bolt
6 - 12
FRONT BRAKE CHAS
MASTER CYLINDER
1 Brake master cylinder
2 Brake master cylinder kit
3 Reservoir diaphragm
4 Reservoir cap
5 Master cylinder holder
6 Brake hose
7 Union bolt
8 Copper washer
6 - 13
FRONT BRAKE CHAS
CAUTION:
Disc brake components rarely require dis-
assembly. DO NOT:
● Disassemble components unless abso-
lutely necessary;
● Use solvents on internal brake compo-
nents;
● Use spent brake fluid for cleaning; (use
only clean brake fluid)

● Allow brake fluid to come in contact with
the eyes, as this may cause eye injury;

● Splash brake fluid onto painted surfaces
or plastic parts, as this may cause dam-

age;
● Disconnect any hydraulic connection, as
this would require the entire brake sys-

tem to be disassembled, drained,
cleaned, properly filled and bled after
reassembly.
BRAKE PAD REPLACEMENT
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1.Loosen:
● Retaining bolts
2.Remove:
● Brake caliper bolts
● Brake caliper
3.Remove:
● Retaining bolts 1
● Brake pads 2
NOTE:
● Install new brake pad springs when the
brake pads have to be replaced.

● Replace the brake pads as a set if either is
found to be worn to the wear limit.

4.Measure:
● Brake pad wear limit a
Out of specification → Replace the brake

pads as a set.
Brake pad wear limit:

0.8 mm
6 - 14
FRONT BRAKE CHAS
5.Install:
● Brake pads
● Brake pads springs
***********************************************
Installation steps:
● Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
● Loosen the brake caliper bleed screw and
using a finger push the caliper pistons into
the brake caliper.
● Tighten the brake caliper bleed screw.
Brake caliper bleed screw:

6 Nm (0.6 m • kg)
T.
R.
● Install new brake pad springs and a new
brake pads.
● Install the brake caliper 3 and retaining bolts
4/brake caliper bolts 5.
Retaining bolt:
27 Nm (2.7m • kg)
T.
R.
Brake caliper bolt:

30 Nm (3.0 m • kg)
***********************************************
6.Inspect:

INSPECTION” section in CHAPTER 3.
a “LOWER” level line
7.Check:
● Brake lever operation
Soft or spongy feeling → Bleed the brake

system.
Refer to the “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
6 - 15
FRONT BRAKE CHAS
EAS00619
FRONT BRAKE CALIPER REMOVAL
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1.Remove:
● Union bolt 1
● Copper washers 2
● Brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2.Remove:
● Retaining bolts 1
● Brake caliper 2
3.Remove:
● Brake caliper pistons 1
● Brake caliper piston seals 2
***********************************************
a.Blow compressed air into the brake hose
joint opening to force out the pistons from the
brake caliper.
WARNING
● Cover the brake caliper pistons with a
rag.
Be careful not to get injured when the pis-
tons are expelled from the brake caliper.
● Never try to pry out the brake caliper pis-
tons.
b.Remove the brake caliper piston seals.
***********************************************
6 - 16
FRONT BRAKE CHAS
EAS00633
FRONT BRAKE CALIPER INSPECTION
Recommended brake component
replacement schedule:
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Replace when
Brake fluid brakes are disas-
sembled.
1.Check:
● Brake caliper pistons 1
Rust/scratches/wear → Replace the brake

caliper. Piston assembly.
● Brake caliper cylinders 2
Scratches/wear → Replace the brake cali-

per.
● Brake caliper 3
Cracks/damage → Replace
● Brake fluid delivery passages
(brake caliper body)

Obstruction → Blow out with compressed air.
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
FRONT BRAKE CALIPER INSTALLATION
WARNING
● Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
● Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
● Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.

DOT 3 or 4
6 - 17
FRONT BRAKE CHAS
1.Install:
● Brake caliper 1
(temporarily)
● Copper washers New 2
● Brake hose 3
● Union bolt 4 26 Nm (2.6 m • kg)
T.
R.
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
the “CABLE ROUTING” section.
CAUTION:
When installing the brake hose onto the
brake caliper 1, make sure that the brake
pipe a touches the projection b on the
brake caliper.
2.Install:
● Brake pad springs
● Brake pads
● Brake caliper
● Brake caliper retaining bolt
27 Nm (2.7 m • kg)
T.
R.
3.Fill:
● Brake master cylinder reservoir
(with the specified amount of the recom-

mended brake fluid)

DOT 3 or 4
WARNING
● Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
● Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
6 - 18
FRONT BRAKE CHAS
● When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4.Bleed:
● Brake system

5.Check:
Below the minimum level mark a → Add the

recommended brake fluid to the proper level.
6.Check:
● Brake level operation
Soft or spongy feeling → Bleed the brake

system.
6 - 19
FRONT BRAKE CHAS
EAS00588
MASTER CYLINDER REMOVAL
NOTE:
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake
system.
1.Remove:
● Brake lever/compression spring
● Brake switch 1
2.Remove:
● Union bolt 2
● Copper washers
● Brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
3.Remove:
● Master cylinder holder
● Brake master cylinder
EAS00592
MASTER CYLINDER INSPECTION
The following procedure applies to the both of
the brake master cylinders.
1.Check:
● Brake master cylinder 1
Damage/scratches/wear → Replace.
● Brake fluid delivery passages 2
(brake master cylinder body)

Obstruction → Blow out with compressed air.
2.Check:
● Brake master cylinder kit 1
Damage/scratches/wear → Replace.
6 - 20
FRONT BRAKE CHAS
3.Check:
● Brake fluid reservoir 1
● Reservoir diaphragm 2
4.Check:
● Brake hose 1
Cracks/damage/wear → Replace.
EAS00598
MASTER CYLINDER INSTALLATION
WARNING
● Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
● Never use solvents on internal brake
components.

DOT 3 or 4
1.Install
● Brake master cylinder 1
● Master cylinder holder
7 Nm (0.7 m • kg)
T.
R.
● Brake lever/compression spring

NOTE:
● Install the master cylinder bracket with the
“UP” mark facing up.

● Adjust the brake master cylinder to the
proper angle, as shown.

● First, tighten the upper bolt, then the lower
bolt.
6 - 21
FRONT BRAKE CHAS
2.Install:
● Copper washers New 1
● Brake hose 2
● Union bolt 3 26 Nm (2.6 m • kg)
T.
R.
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
the “CABLE ROUTING” section.
NOTE:
● While holding the brake hose, tighten the
union bolt as shown.

● Turn the handlebar to the left and to the right
to make sure that the brake hose does not

touch other parts (e.g., wire harness, cables,
leads). Correct if necessary.
3.Fill:
● Brake master cylinder reservoir
(with the specified amount of the recom-

mended brake fluid)

DOT 3 or 4
WARNING
● Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
● Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
● When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
6 - 22
FRONT BRAKE CHAS
4.Bleed:
● Brake system

5.Check:
Below the minimum level mark a → Add the

recommended brake fluid to the proper level.
6.Check:
● Brake lever operation
Soft of spongy feeling → Bleed the brake

system.
6 - 23
FRONT FORK CHAS
FRONT FORK
1 Cap bolt 7 Damper rod
2 O-ring 8 Oil lock piece
3 Spacer 9 Inner tube
4 Spring seat 0 Dust seal
5 Fork spring A Oil seal clip
6 Rebound spring B Oil seal
C Outer tube
6 - 24
FRONT FORK CHAS
EAS00649
FRONT FORK REMOVAL
The following procedure applies to both of the
front fork legs.
WARNING
Securely support the motorcycle so that
2.Remove:
● Front wheel

DISC” section.
3.Remove:
● Bolts 1 (front fender)
● Collars 2
● Front fender 3
4.Loosen:
● Cap bolt 1
● Handle crown pinch bolt 2
● Lower bracket pinch bolt 3
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
5.Remove:
● Front fork leg
FRONT FORK DISASSEMBLY

front fork legs.
1.Remove:
● Cap bolt
● O-ring
● Spacer
● Spring seat
● Fork spring
6 - 25
FRONT FORK CHAS
2.Drain:
● Fork oil
3.Remove:
● Dust seal 1
● Oil seal clip 2 (with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
4.Remove:
● Damper rob bolt
● Copper washer
NOTE:
While holding the damper rod with the damper
rod holder 1 and T-handle 2, loosen the
damper rod bolt 3.
Damper rod holder (19mm):

90890-04084
T-Handle:
90890-01326
5.Remove:
● Inner tube
● Damper rod
Pull out the inner tube with damper rod.
6.Remove:
● Oil seal 1
CAUTION:
Never reuse the oil seal.
2 Rag
6 - 26
FRONT FORK CHAS
EAS00657
FRONT FORK INSPECTION
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:
● Spring free length a
Over the specified limit → Replace.
Spring free length limit:

384 mm
3.Check:
● Damper rod 1
Obstruction → Blow out all of the oil pas-
sages with compressed air.
● Oil lock piece 2
Damage → Replace.
CAUTION:
When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
4.Check:
● Cap bolt O-ring
EAS00659
FRONT FORK ASSEMBLY
front fork legs.
WARNING
● Make sure that the oil levels in both front
fork legs are equal.
● Uneven oil level can result in poor han-
dling and a loss of stability.
6 - 27
FRONT FORK CHAS
NOTE:
● When assembling the front fork leg, be sure
to replace the following parts:

-oil seal
-dust seal
● Before assembling the front fork leg, make
sure that all of the components are clean.
1.Install:
● Damper rod 1
● Oil lock piece 2
CAUTION:
Allow the damper rod to slide slowly down
the inner tube until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
2.Lubricate:
● Inner tube’s outer surface
Fork oil 10 W or equivalent
3.Tighten:
● Damper rod bolt 1 30 Nm (3.0 m • kg)
T.
R.
NOTE:
While holding the damper rod with the damper
rod holder 2 and T-handle 3, tighten the
damper rod bolt 1.
Damper rod holder (19 mm):

90890-04084
T-handle:
90890-01326
4.Install:
● Oil seal 1
(with the fork seal driver weight and adapter)
Fork seal driver weight 2:

90890-01367
Fork seal driver attachment (ø33)
3:
90890-01368
6 - 28
FRONT FORK CHAS
CAUTION:
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.

● Apply fork oil onto the outer surface of the
inner tube.
● Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 1 to pro-

tect the oil seal during installation.
5.Install:
● Oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the
outer tube’s groove.
6.Install:
● Dust seal 1
(with the fork seal driver weight)
Fork seal driver weight:

90890-01367
Front fork seal driver attachment
(ø33):
90890-01368
7.Fill
● Front fork leg
(with the specified amount of the recommend

fork oil)
Quantity (each front fork leg):

252 cm3
Yamaha fork and shock oil
10 W or equivalent.
6 - 29
FRONT FORK CHAS
Front fork leg oil level a (from
the top of the inner tube, with the
inner tube fully compressed and
without the fork spring):
95 mm
NOTE:
● While filling the front fork leg, keep it upright.
● After filling, slowly pump the front fork leg up
and down to distribute the fork oil.

● Be sure to stroke the inner tube slowly
because the for oil may spurt out.

8.Install:
● Spring 1
● Spring seat 2
● Spacer 3
● Cap bolt 4
NOTE:
● Install the spring with the smaller pitch facing
up.
● Before installing the cap bolt, apply grease
onto the O-ring.

● Temporarily tighten the cap bolt.
EAS00662
FRONT FORK INSTALLATION
front fork legs.
1.Install:
● Front fork leg
Temporarily tighten the handle crown pinch

bolt and lower bracket pinch bolt.
NOTE:
Make sure that the inner fork tube is flush with
the top of the handlebar holder.
6 - 30
FRONT FORK CHAS
2.Tighten:
● Lower bracket pinch bolt 1
30 Nm (3.0 m • kg)
T.
R.
● Handle crown pinch bolt 2
23 Nm (2.3 m • kg)
T.
R.
● Cap bolt 3 23 Nm (2.3 m • kg)
T.
R.
WARNING
Make sure that the brake hoses are routed
properly.
3.Install:
● Front fender
● Collars
● Bolts (front fender) 7 Nm (0.7 m • kg)
T.
R.
4.Install:
● Front wheel

DISC” section.
6 - 31
STEERING HEAD AND HANDLEBAR CHAS
STEERING HEAD AND HANDLEBAR
HANDLEBAR
1 Grip end
2 Throttle grip
3 Handlebar
4 Throttle cable
5 Clutch cable
6 - 32
STEERING HEAD
1 Handlebar holder 6 Lower ring nut
2 Bolt cap 7 Ball race cover
3 Lock washer 8 Bearing
4 Upper ring nut 9 Bearing
5 Rubber washer 0 Bearing race
A Lower bracket
6 - 33
HANDLEBAR REMOVAL
1.Remove:
● Handlebar switch 1 (left)
2.Remove:
● Grip end 1 (left)
● Handlebar grip 2 (left)
● Clutch cable 3
● Clutch lever holder 4
NOTE:
Before removing the clutch lever holder 4,
remove the clutch switch leads and clutch
cable.
3.Remove:
● Handlebar switch 1 (right)
4.Remove:
5.Remove:
● Grip end 1 (right)
● Throttle grip 2
● Brake lever holder 3
6 - 34
6.Remove:
● Bolt cap 1
● Handlebar holders 2
7.Remove:
● Handlebar
STEERING HEAD REMOVAL
WARNING
is no danger of its falling over.
1.Place the motorcycle on the centerstand and
place a suitable stand under the engine to
elevate the front wheel.
2.Remove:
● Handlebar
3.Remove:
● Leads 1
● Headlight body 2
● Speedometer cable 3
● Speedometer assembly 5
● Holder 6
6 - 35
4.Remove:
● Front wheel
● Front fork
Refer to the “FRONT WHEEL AND FRONT

FORK REMOVAL” section.
NOTE:
It is not necessary to remove the cap bolts
when removing front fork.
5.Remove:
● Handle crown 1
● Upper ring nut 2
● Rubber washer
● Lower ring nut 3
Use the steering nut wrench to remove the

upper ring nut and lower ring nut.
Steering nut wrench:

90890-01403
● Lower bracket
WARNING
Support the lower bracket so that it may
not fall down.
STEERING HEAD AND HANDLEBAR

INSPECTION
1.Wash the bearing race and ball with solvent.
2.Inspect:
● Lower bracket 1
● Bearings 2
● Bearing races 3
● Inner surface 4 (handle crown)
Scratches/damage → Replace.
6 - 36
3.Remove:
● Ball race cover 1
● Bearing race 2
● Bearing 3
***********************************************
Bearing race replacement steps:
● Remove the bearing race on the lower
bracket using the floor chisel 4 and the
hammer as shown.
● Install the new bearing races.
***********************************************
NOTE:
Always replace bearings and races as a set.
4.Inspect:
● Handlebar
STEERING HEAD INSTALLATION

Reverse the “REMOVAL” procedures.
Note the following points:
1.Lubricate:
● Bearing (upper/lower)
● Bearing race
Lithium-soap base grease
6 - 37
2.Install:
● Bearing (lower)
Onto the bearing race.

● Lower bracket
WARNING
Support the lower bracket until it is
secured.
● Bearing (upper)
● Bearing race (upper)
● Bearing race cover
● Ring nuts
3.Tighten:
● Ring nut
Refer to the “STEERING HEAD INSPEC-

TION” section in CHAPTER 3.
4.Install:
● Holder
Pass the brake cable and wire harness

through the holder.
5.Install:
● Front fork leg
Temporarily tighten the upper and lower

bracket pinch bolts.
6.Install:
● Handle crown
Nut (steering stem):

110 Nm (11.0 m • kg)
T.
R.
7.Install:
● Front fork
Refer to the “FRONT FORK” section.
Pinch bolt (lower bracket):

30 Nm (3.0 m • kg)
T.
R.
Pinch bolt (handle crown):

23 Nm (2.3 m • kg)
8.Install:
● Front wheel

DISC” section.
Nut (front wheel axle):

58 Nm (5.8 m • kg)
T.
R.
6 - 38
HANDLEBAR INSTALLATION
1.Install:
● Speedometer assembly
● Handlebar 1
● Handlebar holders 2
● Bolt cap 3
NOTE:
● Punch mark 1 should be flush with upper
bracket when installing the handlebar.

● Arrow marks 2 should be pointed toward
when installing handlebar holder.
Bolt (handlebar holder):

19 Nm (1.9 m • kg)
T.
R.
2.Install:
● Clutch lever 1
● Grip 2 (left)
● Grip end 3 (left)
● Handlebar switch 4 (left)
NOTE:
● Align the handlebar switch projection with the
hole on the handlebar.

● Apply lithium-soap base grease to clutch
cable end when installing left handlebar

switch.
3.Install:
● Brake lever holder 1
● Throttle grip 2 (right)
● Throttle grip end 3
● Handlebar switch 4 (right)
NOTE:
● Align the handlebar switch projection with the
hole on the handlebar.

● Apply lithium-soap base grease to throttle
cable end when installing right handlebar

switch.
6 - 39
WARNING
It should have 1 ~ 3 mm when installing
throttle grip end.
Bolt (throttle grip end):

23 Nm (2.3 m • kg)
T.
R.
4.Adjust:
Refer to the “THROTTLE CABLE FREE

PLAY ADJUSTMENT” section in CHAPTER
3.

3 ~ 5 mm
6 - 40
REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARM
1 Rear shock absorber 8 Relay arm
2 Bush 9 Bush
3 Swingarm 0 Oil seal
4 Bearing A Collar
5 Dust cover B Connecting arm
6 Bush C Bush
7 Drive chain guide D Oil seal
E Collar
6 - 41
EAS00703
REAR SHOCK ABSORBER AND
SWINGARM REMOVAL
WARNING
Securely support the motorcycle so that
2.Remove:
● Air filter case

CHAPTER 5.
3.Remove:
● Bolt (rear shock absorber) 1
NOTE:
When removing the rear shock absorber lower
bolt, hold the swingarm so that it does not drop
down.
4.Remove:
● Bolt (rear shock absorber) 1
● Rear shock absorber
5.Check:
● Swingarm side play È
● Swingarm vertical movement É
***********************************************
a.Check the tightening torque of the pivot shaft
nut.
Pivot shaft nut:

59 Nm (5.9 m • kg)
T.
R.
b.Check the swingarm side play È by moving

the swingarm from side to side.
c.If the swingarm side play is large, check the
spacers, bearings, washers, and dust cov-
ers.
d.Check the swingarm vertical movement É
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
6 - 42 ***********************************************
EAS00696
REAR SHOCK ABSORBER INSPECTION
1.Inspect:
● Rear shock absorber rod
Bends/damage → Replace the rear shock

absorber assembly.
● Rear shock absorber
Gas leaks/oil leaks → replace the rear shock

absorber assembly.
● Spring
Damage/wear → Replace the rear shock

absorber assembly.
● Bushings
● Dust seals
● Bolts
Bends/damage/wear → Replace.
EAS00707
SWINGARM INSPECTION
1.Inspect:
● Swingarm
Bends/cracks/damage → Replace.
2.Inspect:
● Pivot shaft
Roll the pivot shaft on a flat surface.

Bends → Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
3.Wash:
● Pivot shaft
● Dust covers
● Collars
● Washers
● Bearings
● Bushes
Recommended cleaning solvent

Kerosine
6 - 43
4.Inspect:
● Dust covers 1
● Bush 2
● Bearings 3
Damage/pitting → Replace.
EC574210
RELAY ARM INSPECTION
1.Inspect:
● Bushs 1
● Collar 2
Free play exists/unsmooth revolution/rust →

Replace bush and collar as a set.
2.Inspect:
● Oil seals 3
Damage → Replace.
EC574310
CONNECTING ARM INSPECTION
1.Inspect:
● Bushs 1
● Collars 2
Free play exists/unsmooth revolution/rust →

Replace bush and collar as a set.
2.Inspect:
● Oil seals 3
Damage → Replace.
T701020
DRIVE CHAIN INSPECTION
1.Inspect:
● Drive chain stiffness
Stiffness → Clean and lubricate or replace.
2.Inspect:
● Drive chain 1
● Driven sprocket 2
More than 1/2 tooth a wear → Replace the

drive chain.
Use new driven sprocket.
6 - 44
3.Measure:
● 10 link length a (drive chain)
Out of specification → Replace the drive

chain.
10 link length limit:

119.5 mm
NOTE:
● Tighten the drive chain with a finger before
measuring.
● 10 link length is the distance between the
inside edge of roller 1 and A as shown.

● 10 link length measurement should be done
at two or three different places.
4.Clean:
● Drive chain
Put it in kerosene, and brush off as much dirt

as possible. Then remove the drive chain
from the kerosene and dry it.
Drive chain lubricant:

Engine oil or chain lubricant for
O-ring chain
CAUTION:
This motorcycle has a drive chain with
small rubber O-rings 1 between the drive
chain side plates. Never use high-pressure
water or air, steam, gasoline, certain sol-
vents (e.g., benzene), or a coarse brush to
clean the drive chain.
Don’t soak drive drain in kerosine for more
than ten minutes. O-ring is damage by ker-
osine.
5.Check:
● O-rings 1
Damage → Replace the drive chain.

● Drive chain rollers 2
Damage/wear → Replace the drive chain.

● Drive chain side plates 3
Cracks/damage/wear → Replace the drive

chain.
6 - 45
T*****
REAR WHEEL CLUTCH HUB INSPECTION
1.Inspect:
● Rear wheel clutch hub
Wear/damage/cracks → Replace.
T******
DRIVEN SPROCKET ASSEMBLY
1.Install:
● Driven sprocket 1
● Lock washers 2 New

● Bolts 3 30 Nm (3.0 m • kg)
T.
R.
NOTE:
Tighten the bolts in a crisscross pattern.
2.Bend:
● Lock washer tab 1
(along a flat side of the end)
EAS00711
REAR SHOCK ABSORBER AND
SWINGARM INSTALLATION
1.Lubricate:
● Bearings
● Collars
● Dust covers
● Pivot shaft
● Bushes
Recommended lubricant
Lithium soap-base grease
6 - 46
2.Install:
● Bush 1
● Bearings 2
● Chain guide 3
● Collar (chain guide) 4
● Bolt (chain guide) 5
● Dust covers 6
(to the swingarm).
3.Install:
● Collar 1
● Bushes 2
● Oil seals 3
(to the relay arm).
4.Install:
● Collars 1
● Bushes 2
● Oil seals 3
(to the connecting arm).
5.Install:
● Connecting arm 1
● Bolt (connecting arm-relay arm) 2
● Washer 3
● Nut (connecting arm-relay arm) 4
59 Nm (5.9 m • kg)
T.
R.
NOTE:
● Apply the lithium soap-base grease on the
bolt.
● Install the nut on the right side of the chassis.
6 - 47
6.Install:
● Connecting arm 1
● Bolt (connecting arm-swingarm) 2
● Washer 3
● Nut (connecting arm-swingarm) 4
59 Nm (5.9 m • kg)
T.
R.
NOTE:
Apply the lithium soap-base grease on the
bolt.
7.Install:
● Swingarm 1
● Pivot shaft 2
● Washer
● Nut 59 Nm (5.9 m • kg)
T.
R.
NOTE:
pivot shaft.
● Insert the pivot shaft from right side
8.Install:
● Bolt (relay arm-frame) 1
● Washer 2
● Nut (relay arm-frame) 3
T.
R.
59 Nm (5.9 m • kg)
NOTE:
bolt.
9.Install:
● Bolt (rear shock absorber-frame) 1
59 Nm (5.9 m • kg)
T.
R.
NOTE:
bolt.
10.Install:
● Bolt (rear shock absorber-relay arm) 1
● Washer 2
● Nut (rear shock absorber-relay arm) 3
59 Nm (5.9 m • kg)
T.
R.
NOTE:
bolt.
● Insert the bolt from left side.
6 - 48
– +
ELEC
CHAPTER 7.
ELECTRICAL
ELECTRICAL COMPONENTS ..................................................................... 7-1
SWITCHES ................................................................................................... 7-3

CHECKING SWITCH CONTINUITY ..................................................... 7-3
CHECKING THE SWITCHES ....................................................................... 7-4
CHECKING OF BULBS ................................................................................ 7-6

KINDS OF BULBS ................................................................................. 7-6
CHECKING BULB CONDITION ............................................................ 7-6
IGNITION SYSTEM ...................................................................................... 7-8

CIRCUIT DIAGRAM .............................................................................. 7-8
TROUBLESHOOTING .......................................................................... 7-9
ELECTRIC STARTING SYSTEM ............................................................... 7-13

CIRCUIT DIAGRAM ............................................................................ 7-13
STARTING CIRCUIT OPERATION .................................................... 7-14
TROUBLESHOOTING ........................................................................ 7-15
STARTER MOTOR ............................................................................. 7-19
CHARGING SYSTEM ................................................................................. 7-25

CIRCUIT DIAGRAM ............................................................................ 7-25
LIGHTING SYSTEM ................................................................................... 7-28

CIRCUIT DIAGRAM ............................................................................ 7-28
LIGHTING SYSTEM CHECK .............................................................. 7-31
SIGNALING SYSTEM ................................................................................ 7-34

CIRCUIT DIAGRAM ............................................................................ 7-34
SIGNAL SYSTEM CHECK .................................................................. 7-38
– +
ELEC
– +
ELECTRICAL COMPONENTS ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1 Fuel sender
2 Starting circuit cut-off relay
3 Rectifier/regulator
4 Rear brake switch
5 Starter relay
6 Battery
7 Main switch
7-1
– +
ELECTRICAL COMPONENTS ELEC
1 Ignition coil
2 Flasher relay
3 CDI unit
4 Neutral switch
5 Horn
7-2
– +
SWITCHES ELEC
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.
CAUTION:
Never insert the tester probes into the cou-
pler terminal slots 1. Always insert the
probes from the opposite end of the cou-
pler, taking care not to loosen or damage
the leads.
Pocket tester
90890-03112
NOTE:
● Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.

● When checking for continuity, switch back
and forth between the switch positions a few

times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
NOTE:
“ ” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity between black/white and
black when the switch is set to “OFF” or
“LOCK”.
There is continuity between brown and red
when the switch is set to “ON”.
7-3
– +
CHECKING THE SWITCHES ELEC
EAS00731
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the ter-
minals. Refer to the “CHECKING SWITCH CONTINUITY” section.
Damage/wear → Repair or replace the switch.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
6 Br R B B/W = 9 8
LOCK Br
L/W B B/W
OFF
OFF OFF G/Y
ON
ON RUN
Br B
B/W R
3 1
P B L/Y
OFF
B/Y
ON
5
Dg Br/W Ch P Br/W Ch
R
L/Y B Br
N
L B/Y Dg L
7
Br L
OFF
PO
ON
2
Br Y
OFF
ON
4
Y G
HI
LO
B A C
10A
Sb
7-4
– +
CHECKING THE SWITCHES ELEC
1 Clutch switch
2 Pass switch
3 Horn switch
4 Dimmer switch
5 Turn switch
6 Main switch
7 Lights switch
8 Front brake switch
9 Engine stop switch
0 Start switch
A Fuse
B Rear brake switch
C Neutral switch
7-5
– +
CHECKING OF BULBS ELEC
CHECKING OF BULBS
(FOR HEADLIGHT, TAIL/BLAKE
LIGHT, FLASHER LIGHT, METER
LIGHT, ETC.)
To determine the condition of a bulb check for

continuity at the bulb terminal.
KINDS OF BULBS
The bulbs used in motorcycles can be classi-
fied by shape of socket and use.
A and B are the main types used in head-

lights.
C is mainly used for the flasher light and tail/

brake light.
D and E are mainly used for meter lights and

other indicator lights.
CHECKING BULB CONDITION

1.Remove the bulb.
NOTE:
● Bulbs of the A and B type uses a bulb
holder. Remove the bulb holder before

removing the bulb itself. Most of the bulb
holders for this type can be removed by turn-
ing counterclockwise.
● Most of the bulbs of C and D type can be
removed from the bulb sockets by pushing

and turning them counterclockwise.
● Bulbs of the E type can just be pulled out.
CAUTION:
Be sure to hold the socket firmly when
removing the bulb. Never pull the lead. Oth-
erwise, the lead may be pulled off the termi-
nal in the coupler.
WARNING
Headlight bulbs become very hot even after
a short time. Keep flammable products
away from a hot headlight bulb and be
careful never to touch it, before it had time
to cool down.
7-6
– +
CHECKING OF BULBS ELEC
2.Check for continuity at the bulb terminals.
*****************************************************
Checking steps:
● Set the pocket tester selector to “Ω × 1”.
● Connect the tester leads to the respective
bulb terminals. Take for example a 3-termi-
nal bulb as shown left. First check the conti-
nuity between the terminals 1 and 2 by
connecting the tester (+) lead to the terminal
1 and the tester (–) lead to the terminal 2.
Then check the continuity between the termi-
nals 1 and 3 by connecting the tester (+)
lead still to the terminal 1 and the tester (–)
lead to the terminal 3. If the tester shows “∞”
in either case, replace the bulb.
*****************************************************
3.Check the bulb socket by installing a proven

bulb to it. As in the checking of bulbs, con-
nect the pocket tester leads to the respective
leads of the socket and check for continuity
in the same manner as mentioned above.
7-7
1 B/W
LOCK Br B B Br W B W W O O
OFF R R R Y/R R R
W W
ON Br Br 4 B
(GREEN) Y/R Y
B/W B/W
G G
B B 6
5
Br R B B/W R W W
O Br B/W G
2 Y/R Y/R
3 B R W
CIRCUIT DIAGRAM
B B B
IGNITION SYSTEM
Br
10A
Br
L/W B/W
Br
R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
Y/R R/W ON RUN (BLACK) (BLACK)
B L/W
R/W Sb L/Y
R
R/W G/Y
X Y
L/W
B
B
B Z
B B
Br Br
Br/W
Br
7-8
W P P
B
9 9 Br 0 Br/W
B
P Y/R L Br/W L/Y
Y C
Br L Dg Ch
D E F G H I
OFF OFF OFF HI R P Br/W Ch Ch Br/W P
L/Y L/Y
Q Dg Dg ON PO ON LO N L/Y B Br Y/R B L/Y
B/Y B/Y
Ch Ch ON L B/Y Dg L L Dg B
(BLUE) (BLUE) (BLACK) (BLACK)
R S T U V W
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
IGNITION SYSTEM
G B Sb Y Y G Ch Dg
Sb L Dg Ch L Y
4 CDI unit
P L L K O J B L L B
L L N M
Sb Y Y
G G
B B
6 Spark plug
ELEC
5 Ignition coil
B B Ch Dg Dg Ch
1 Main switch
B B
Sb
3 CDI magneto
(GREEN) (GREEN)
–
O B B
B B B B

+
– +
IGNITION SYSTEM ELEC
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE

(NO SPARK OR INTERMITTENT SPARK)
Procedure
Check;
1.Spark plug 6.Engine stop switch
2.Ignition spark gap 7.Source coil resistance
3.Spark plug cap resistance 8.Pickup coil resistance
4.Ignition coil resistance 9.Wiring connection (ignition system)
5.Main switch
NOTE:
● Remove the following parts before troubleshooting.
1)Headlight unit
2)Seat
3)Fuel tank
● Use the following special tools in this troubleshooting.
Pocket tester: Ignition checker:

90890-03112 90890-06754
1.Spark plug
● Check the spark plug type, condition and
gap.
Refer to the “SPARK PLUG INSPECTION”
Standard spark plug:
D8EA (NGK) or X24ES-U (DENSO)
Spark plug gap:
0.6 ~ 0.7 mm INCORRECT
CORRECT
Repair or replace spark plug.

*
7-9
– +
* C0NTINUITY
2.Ignition spark gap

● Disconnect the spark plug cap from the
spark plug.
● Connect the ignition checker 1 between
cylinder head and spark plug cap 2, and
set the specified spark gap 3.
● Turn the main switch to “ON”, then apply

clutch lever or shift the transmission into
neutral. SPARK
● Push the start switch or kick the kick crank.
● Check the ignition spark condition.
Minimum spark gap:
6 mm Ignition circuit is good.
OUT OF
SPECIFICATION
3.Spark plug cap resistance

● Remove the spark plug cap.
● Connect the pocket tester (Ω × 1k) to the
spark plug cap.
● Checking the spark plug cap for the speci- OUT OF SPECIFICATION
fied resistance.
Spark plug cap resistance:
10 kΩ at 20°C Replace spark plug cap.
MEETS
SPECIFICATION
*
7 - 10
– +
* C0NTINUITY
4.Ignition coil resistance

● Disconnect the ignition coil lead (Orange)
from the wire harness.
● Connect the pocket tester to the ignition
coil.
Primary coil: (Ω × 1)
Tester (+) lead → Orange 1 terminal
Tester (–) lead → Ignition coil base 2
Secondary coil: (Ω × 1k)
Tester (+) lead → Spark plug lead 3
Tester (–) lead → Ignition coil base 2
● Measure the primary and secondary coil

resistances. OUT OF SPECIFICATIONS
Primary coil resistance È:
0.32 ~ 0.48 Ω at 20°C
Secondary coil resistance É:
5.68 ~ 8.52 kΩ at 20°C Replace ignition coil.
BOTH MEETS
SPECIFICATIONS
5.Main switch INCORRECT
● Check the main switch for continuity.

Refer to the “CHECKING THE
SWITCHES” section. Replace main switch.
CORRECT
INCORRECT
6.Engine stop switch
● Check the engine stop switch for continuity.
SWITCHES” section. Replace handlebar switch (right).
CORRECT
7 - 11
– +
* C0NTINUITY
7.Source coil resistance

● Disconnect the CDI magneto coupler from
the wire harness.
● Connect the pocket tester (Ω × 100) to the
source coil.
Tester (+) lead → Brown 1 terminal
Tester (–) lead → Green 2 terminal
3 CDI magneto OUT OF SPECIFICATION

● Measure the source coil resistance.
Source coil resistance:
688 ~ 1,032 Ω at 20°C
Replace source coil.
MEETS
SPECIFICATION
8.Pickup coil resistance

the wire harness.
pickup coil.
Tester (+) lead → Red 1 terminal
Tester (–) lead → White 2 terminal
OUT OF SPECIFICATION
3 CDI magneto
● Measure the pickup coil resistance.
Pickup coil resistance:
248 ~ 372 Ω at 20°C Replace pickup coil.
MEETS
SPECIFICATION
9.Wiring connection POOR CONNECTION
● Check the entire ignitions system for con-

nections.
Refer to the “WIRING DIAGRAM” section. Correct.
CORRECT
CDI unit is faulty. Replace it.
7 - 12
1 B/W
OFF
Y Fuse
R R R Y/R R R
W W
ON Br Br 4 B
X Battery
(GREEN) Y/R Y
B/W B/W
G G
B B 6
5
Br R B B/W R W W
7 Start switch
1 Main switch
Z Starter relay
O Br B/W G
2
W Starter motor
I Clutch switch
Y/R Y/R
3 B R W
O Neutral switch
CIRCUIT DIAGRAM
B B B 8 Engine stop switch
Br
10A
Br
L/W B/W
Br
[ Starting circuit cut-off relay

R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
B L/W
R/W Sb L/Y
R
R/W G/Y
Y
ELECTRIC STARTING SYSTEM
X L/W
B
B
B Z
B B
Br Br
Br/W
W Br
7 - 13
9 P 9 P
B Br 0 Br/W
B
P Y/R L Br/W L/Y
Y C
Br L Dg Ch
D E F G H I
L/Y L/Y
B/Y B/Y
R S T U VW
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
ELECTRIC STARTING SYSTEM
G B Sb Y Y G Ch Dg
Sb L Dg Ch L Y
P L L K O J B L L B
L L N M
Sb Y Y
G G
B B
ELEC
B B Ch Dg Dg Ch
B B
Sb
(GREEN) (GREEN)
–
O B B
B B B B
+
– +
ELECTRIC STARTING SYSTEM ELEC
STARTING CIRCUIT OPERATION
The starting circuit on this model consist of the
starter motor, starter relay, and the relay unit
(starting circuit cut-off relay). If the engine stop
switch and the main switch are both closed,
the starter motor can operate only if:
The transmission is in neutral (the neutral

switch is closed).
or if
The clutch lever is pulled to the handlebar

(the clutch switch is closed).
The starting circuit cut-off relay prevents the

starter from operating when neither of these
conditions has been met. In this instance, the
starting circuit cut-off relay is open so current
cannot reach the starter motor.
When one of both of the above conditions

have been met, however, the starting circuit
cut-off relay is closed, and the engine can be
started by pressing the starter switch.
WHEN THE TRANSMISSION IS

IN NEUTRAL
WHEN THE CLUTCH LEVER IS
PULLED IN
1 Battery
2 Starter relay
3 Starter motor
4 Main switch
5 Starting circuit cut-off relay (relay assembly)
6 Clutch switch
7 Neutral switch
8 Start switch
7 - 14
– +
TROUBLESHOOTING
STARTER MOTOR DOES NOT OPERATE.
Procedure
Check;
1.Fuse 6.Main switch
2.Battery 7.Engine stop switch
3.Starter motor 8.Neutral switch
4.Starter relay 9.Clutch switch
5.Starting circuit cut-off relay (relay assembly) 10.Start switch
11.Wiring connection (electric starting system)
NOTE:
1)Side cover (right)

2)Headlight unit
3)Seat
4)Fuel tank
● Use the following special tool in this troubleshooting.
Pocket tester:
90890-03112
1.Fuse
INCORRECT
● Connect the pocket tester “Ω × 1” to the
fuse.
● Check the fuse for continuity.
CONTINUITY Replace fuse.
2.Battery
● Check the battery condition. INCORRECT
● Check the battery fluid level, battery termi-
nals and specific gravity.
Specific gravity:
● Refill battery fluid.
1.280 at 20°C
● Clean battery terminals.
● Recharge or replace battery.
CORRECT
7 - 15
– +
* C0NTINUITY
3.Starter motor *
● Connect the battery positive terminal 1 WARNING
and starter motor cable 2 using the jumper ● A wire for the jumper lead must have the
lead 3 . equivalent capacity as that of the battery
●
*
Check the starter motor operation. lead or more, otherwise it may cause the
jumper lead to be burned.
● This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
in the vicinity.
INOPERATIVE
Repair or replace starter motor.

C0NTINUITY
4.Starter relay
Disconnect the starter relay coupler from
*
● WARNING
the wire harness. ● A wire for the jumper lead must have the
● Connect the battery (12 V) to the starter equivalent capacity as that of the battery
relay terminals, using the jumper leads .
Battery (+) lead → Yellow/Red 1 terminal
* lead or more, otherwise it may cause the
jumper lead to be burned.
Battery (–) lead → Black 2 terminal ● This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
the vicinity.
DOES NOT MOVES
● Check the starter motor for operation. Replace starter relay.
MOVES
7 - 16
– +
* C0NTINUITY
5.Starting circuit cut-off relay

● Disconnect the relay lead coupler from the
wire harness.
● Connect the pocket tester (Ω × 1) and bat-
tery (12 V) to relay.
Step 1:
Battery (+) lead → Brown terminal 1
Battery (–) lead → Sky blue terminal 2
Tester (+) lead → Brown terminal 1
Tester (–) lead → Red/White terminal 4
Step 2:
Battery (+) lead → Brown terminal 1
Battery (–) lead →
Blue/Yellow terminal 3
Tester (+) lead → Brown terminal 1
Tester (–) lead → Red/White terminal 4
NO CONTINUITY
● Check the relay for continuity. Replace relay.
CONTINUITY
6.Main switch INCORRECT

SWITCHES” section. Replace main switch.
CORRECT
7.Engine stop switch INCORRECT
● Check the engine stop switch for continuity.

SWITCHES” section. Replace handlebar switch (right).
CORRECT
*
7 - 17
– +
* C0NTINUITY
8.Neutral switch INCORRECT
● Check the neutral switch for continuity.

SWITCHES” section. Replace neutral switch.
CORRECT
9.Clutch switch INCORRECT
● Check the clutch switch for continuity.

SWITCHES” section. Replace clutch switch.
CORRECT
10.Start switch
INCORRECT
● Check the start switch for continuity.
SWITCHES” section.
Replace handlebar switch (right).
CORRECT

● Check the entire ignition system for conti-
nections.
Refer to the “WIRING DIAGRAM” section.
Correct.
7 - 18
– +
STARTER MOTOR
1 Brush
2 Armature
3 O-ring
4 O-ring
BRUSH LENGTH LIMIT:

A
3.5 mm
COMMUTATOR WEAR LIMIT:
B
21 mm
MICA UNDER CUT:
C
1.5 mm
ARMATURE COIL RESISTANCE:
D
0 Ω at 20°C
7 - 19
– +
Removal
1.Remove:
● Carburetor

CHAPTER 5.
2.Remove:
● Clutch cable
Refer to the “WIRE, CABLE AND TUBE”

3.Disconnect:
● Starter motor lead 1
4.Remove:
● Starter motor 2
5.Remove:
● Bolts (starter motor front cover)
6.Remove:
● Starter motor yoke 1
● O-ring 2
7.Remove:
● Armature 1
Inspection and repair

1.Inspect:
● Commutator
Dirty → Clean it with #600 grit sandpaper.

2.Measure:
● Commutator diameter a
Out of specification → Replace starter motor.
Commutator wear limit:

21 mm
7 - 20
– +
3.Measure:
● Mica undercut b
Out of specification → Scrape the mica to

proper value use a hacksaw blade can be
ground to fit.
Mica undercut:
1.5 mm
NOTE:
the mica insulation of the commutator must be
undercut to ensure proper operation of com-
mutator.
4.Inspect:
● Armature coil (continuity/insulation)
Defects (s) → Replace starter motor.

*****************************************************
Inspecting steps:
● Connect the pocket tester for continuity
check 1 and insulation check 2.
Pocket tester:
90890-03112
● Measure the armature coil resistances.
Armature coil resistance:

Continuity check 1: (Ω × 1)
0 Ω at 20°C
Insulation check 2: (Ω × 1k)
More than 1 MΩ at 20°C
● If the resistance is incorrect, replace the

starter motor.
*****************************************************
5.Measure:
● Brush length a
Brush length limit:

3.5 mm
7 - 21
– +
6.Measure:
● Brush spring pressure
Fatigue/out of specification → Replace as a

set.
Brush spring pressure:

560 ~ 840 g
7.Inspect
● Bearing
● Oil seal
● O-ring
Assembly
Reverse the “Removal” procedure.
1.Install:
● Brush
● Brush spring
Using a thin screw driver.
7 - 22
– +
2.Install
● Armature 1
3.Install:
● O-ring 1
● Starter motor yoke 2
4.Install
● Starter motor assembly
NOTE:
Align the groove a on the starter motor
assembly with the groove b on the housing.
5.Install:
● O-ring 1 New
● Screw
WARNING
Always use a new O-ring.
6.Install:
● O-ring 2
WARNING
Always use a new O-ring.
NOTE:
Apply a lightly grease to the O-ring 2.
7 - 23
– +
Installation
1.Install:
● Starter motor 1
● Starter motor lead 2
Bolt (starter motor):

10 Nm (1.0 m • kg)
T.
R.
7 - 24
1 B/W
OFF R R R Y/R R R
W W
ON Br Br 4 B
(GREEN) Y/R Y
B/W B/W
G G
B B 6
5
CIRCUIT DIAGRAM
Br R B B/W R W W
O Br B/W G
2 Y/R Y/R
3 B R W
B B B
CHARGING SYSTEM
Br
10A
Br
L/W B/W
Br
R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
B L/W
R/W Sb L/Y
R
R/W G/Y
X Y
L/W
B
B
B Z
7 - 25
B B
Br Br
Br/W
W Br
9 P 9 P
B Br Br/W
B
0
P Y/R L Br/W L/Y
Y CD
Br L Dg Ch
E F G H I
L/Y L/Y
B/Y B/Y

CHARGING SYSTEM
R S T U V W
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
Y Fuse
G B Sb Y Y G Ch Dg
X Battery
Sb L Dg Ch L Y
ELEC
3 CDI magneto
P L L K O J B L L B
–
L L N M
Sb Y Y
G G
B B
B B Ch Dg Dg Ch
B B
Sb
+
(GREEN) (GREEN)
O B B
B B B B
– +
CHARGING SYSTEM ELEC
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED.
Procedure
Check;
1.Fuse 4.Charging coil resistance
2.Battery 5.Wiring connection (charging system)
3.Charging voltage
NOTE:

2)Seat
3)Fuel tank
● Use the following special tools in this troubleshooting.
Pocket tester: Inductive tachometer:

90890-03112 90890-03113
1.Fuse
NO CONTINUITY
fuse.
CORRECT Replace fuse.
2.Battery
● Check the battery condition. INCORRECT
● Check the battery fluid level, battery termi-
nals and specific gravity.
Refer to the “BATTERY INSPECTION”
section in CHAPTER 3. ● Refill battery fluid.
Specific gravity: ● Clean battery terminals.
1.280 at 20°C ● Recharge or replace battery.
CORRECT
7 - 26
– +
CHARGING SYSTEM ELEC
* C0NTINUITY
3.Charging voltage
● Connect the Indicative tachometer to the
spark plug lead.
● Connect the pocket tester (DC 20 V) to the
battery.
Tester (+) lead → Battery (+) terminal 1
Tester (–) lead → Battery (–) terminal 2
● Start the engine. MEETS SPECIFICATION

● Measure the charging voltage.
Charging voltage:
12 V or more at 3,000 r/min
14.5 V or less at 8,000 r/min Replace battery.
OUT OF
SPECIFICATION
4.Charging coil resistance

the wire harness.
stator coil.
Battery (+) lead → White 1 terminal
Battery (–) lead → Black 2 terminal
● Measure the charging coil resistance.
Charging coil resistance:
0.32 ~ 0.48 Ω at 20°C
(White - Black) Replace stator assembly.
MEETS
SPECIFICATION
POOR CONNECTION
5.Wiring connection
● Check the entire charging system for con-
nections.
CORRECT
Replace rectifier/regulator.
7 - 27
1 B/W
OFF R R R Y/R R R
W W
ON Br Br 4 B
(GREEN) Y/R Y
B/W B/W
G G
B B 6
M Headlight
5
S Meter light
Br R B B/W R W W
F Pass switch
O Br B/W G
E Lights switch
2
N Auxiliary light
Y/R Y/R
3 B R W
3 CDI magneto
J Tail/black light
G Dimmer switch
CIRCUIT DIAGRAM
B B B
Br
LIGHTING SYSTEM
T High beam indicator light
10A
Br
L/W B/W
Br
R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
B L/W
R/W Sb L/Y
R
R/W G/Y
X Y
L/W
B
B
B Z
B B
Br Br
Br/W
W Br
7 - 28
9 P 9 P
B Br 0 Br/W
B
P Y/R L Br/W L/Y
Y CD
Br L Dg Ch
E F G H I
L/Y L/Y
B/Y B/Y
R S T U V W
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
LIGHTING SYSTEM
G B Sb Y Y G Ch Dg
Sb L Dg Ch L Y
P L L K O J B L L B
L L N M
Sb Y Y
G G
B B
ELEC
B B Ch Dg Dg Ch
B B
Sb
(GREEN) (GREEN)
–
O B B
B B B B
+
– +
LIGHTING SYSTEM ELEC
TROUBLESHOOTING
HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT AND/OR METER LIGHT DO NOT
COME ON.
Procedure
Check;
1.Lighting coil resistance 4.Pass switch
2.Lights switch 5.Wiring connection (entire lighting system)
3.Dimmer switch
NOTE:

2)Headlight unit
3)Seat
● Use the following special tool (s) in this troubleshooting.
Pocket tester:
90890-03112
1.Lighting coil resistance

the wire harness.
stator coil.
Tester (+) lead → Yellow 1 terminal
Tester (–) lead → Black 2 terminal
● Measure the lighting coil resistance. OUT OF SPECIFICATION
Lighting coil resistance.

0.24 ~ 0.36 Ω at 20°C
(Yellow - Black)
Replace stator assembly.
MEETS
SPECIFICATION
2.Lights switch INCORRECT
● Check the lights switch for continuity.

SWITCHES” section. Lights switch is faulty, replace handlebar
switch (right).
CORRECT
*
7 - 29
– +
* C0NTINUITY
INCORRECT
3.Dimmer switch
● Check the dimmer switch for continuity.
SWITCHES” section. Dimmer switch is faulty, replace handlebar
switch (left).
CORRECT
INCORRECT
4.Pass switch
● Check the pass switch for continuity.
SWITCHES” section. Pass switch is faulty, replace handlebar
switch (left).
CORRECT
● Check the entire lighting system for con-

nections.
CORRECT
Check condition of each circuit for lighting

system.
Refer to the “LIGHTING SYSTEM CHECK”
section.
7 - 30
– +
LIGHTING SYSTEM CHECK
1.Headlight and high beam indicator light do not come on.
1.Bulb and bulb socket NO CONTINUITY

● Check the bulb and bulb socket for continu-
ity.
Refer to the “CHECKING OF BULBS” sec-
tion. Bulb and/or bulb socket are faulty, replace.
CONTINUITY
2.Voltage Headlight
headlight and high beam indicator light
leads.
Headlight:
Tester (+) lead →
Yellow 2 or Green 1 lead
Tester (–) lead → Black 3 lead
High beam indicator light:
Tester (+) lead → Yellow 4 lead High beam indicator light
È When dimmer switch is “LO” position.
É When dimmer switch is “HI” position.
● Start the engine.
● Turn the lights switch to “ON”.
● Turn the dimmer switch to “LO” or “HI” posi-
tion.
● Check for voltage (12 V) on the “Green”
and “Yellow” lead at bulb socket connector.
MEETS SPECIFI-
CATION (12 V)
Wiring circuit from main switch to bulb socket
This circuit is good. connector is faulty, repair.
7 - 31
– +
2.Meter light does not come on.
1.Bulb and bulb socket

● Check the bulb and bulb socket for continu- NO CONTINUITY
ity.
tion.
Bulb and/or bulb socket are faulty, replace.
CONTINUITY
2.Voltage
bulb socket leads.
Tester (+) lead → Blue 1 terminal

● Turn the lights switch to “ON” or “PO”.
● Check for voltage (12 V) on the “Blue” lead Wiring circuit from main switch to bulb socket
at the bulb socket connector. connector is faulty, repair.
MEETS SPECIFI-
CATION (12 V)
This circuit is good.
7 - 32
– +
3.Taillight does not come on

NO CONTINUITY
ity.
Bulb and/or bulb socket are faulty, replace.
CONTINUITY
2.Voltage
bulb socket leads.
Tester (+) lead → Blue 1 terminal

● Turn the lights switch to “ON” or “PO”.
● Check for voltage (12 V) on the “Blue” lead Wiring circuit from main switch to bulb socket
at the bulb socket connector. connector is faulty, repair.
MEETS SPECIFI-
CATION (12 V)
7 - 33
1 B/W
OFF R R R Y/R R R
W W
ON Br Br 4 B
(GREEN) Y/R Y
B/W B/W
G G
B B 6
5
Br R B B/W R W W
O Br B/W G
2 Y/R Y/R
3 B R W
CIRCUIT DIAGRAM
B B B
Br
10A
Br
L/W B/W
SIGNALING SYSTEM
Br
R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
B L/W
R/W Sb L/Y
R
R/W G/Y
X Y
L/W
B
B
B Z
B B
Br Br
Br/W
W Br
7 - 34
9 P 9 P
B Br 0 Br/W
B
P Y/R L Br/W L/Y
Y CD
Br L Dg Ch
E F G H I
L/Y L/Y
B/Y B/Y
R S T U VW
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
SIGNALING SYSTEM
G B Sb Y Y G Ch Dg
Sb L Dg Ch L Y
P L L K O J B L L B
L L N M
Sb Y Y
G G
B B
ELEC
B B Ch Dg Dg Ch
B B
Sb
(GREEN) (GREEN)
–
O B B
B B B B
+
– +
SIGNALING SYSTEM ELEC
1 Main switch
9 Horn
0 Flasher relay
A Front brake switch
B Rear brake switch
D Horn switch
H Turn signal switch
J Tail/black light
K Rear turn signal light
L Front turn signal light
O Neutral switch
P Fuel sender
R Fuel gauge
U Neutral indicator light
V Turn indicator light
X Battery
Y Fuse
7 - 35
– +
TROUBLESHOOTING
● FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT DO NOT COME ON.
● HORN DOES NOT SOUND.
● FUEL GAUGE DOES NOT OPERATED.
Procedure
Check;
1.Fuse
2.Battery
3.Main switch
4.Wiring connection (entire signal system)
NOTE:

2)Headlight unit
3)Seat
4)Fuel tank
● Use the following special tool (s) in this troubleshooting
Pocket tester:
90890-03112
1.Fuse
● Remove the fuse.
● Connect the pocket tester (Ω × 1) to the NO CONTINUITY
fuse.
Refer to the “FUSE INSPECTION” section
in CHAPTER 3. Fuse is faulty, replace it.
CONTINUITY
2.Battery INCORRECT
● Check the battery condition.

Refer to the “BATTERY INSPECTION”
section in CHAPTER 3. ● Refill battery fluid.
Specific gravity: ● Clean battery terminals.
1.280 at 20°C ● Recharge or replace battery.
CORRECT
*
7 - 36
– +
* C0NTINUITY
INCORRECT
3.Main switch
SWITCHES” section. Main switch is faulty, replace it.
CORRECT
4.Wiring connection
POOR CONNECTION
● Check the entire signal system for connec-
tions.
Correct.
CORRECT
Check condition of each circuit for signal sys-

tem.
Refer to the “SIGNAL SYSTEM CHECK”
section.
7 - 37
– +
SIGNAL SYSTEM CHECK
1.Horn does not sound.
1.Horn switch INCORRECT

● Check the horn switch for continuity.
Horn switch is faulty, replace handlebar
CORRECT switch (left).
2.Voltage
horn lead.
Tester (+) lead → Brown 1 lead
Tester (–) lead → Frame ground
● Turn the main switch to “ON”.

● Check for voltage (12 V) on the “Brown” Wiring circuit from main switch to horn termi-
lead at the horn terminal. nal is faulty, repair.
MEETS SPECIFI-
CATION (12 V)
7 - 38
– +
* C0NTINUITY
3.Horn
● Disconnect the “Pink” lead at the horn ter-
minal.
● Connect a jumper lead 1 to the horn termi-
nal and ground the jumper lead.
HORN IS SOUNDED
Horn is good.
HORN IS NOT
SOUNDED
4.Voltage
horn at the Pink terminal.
Tester (+) lead → Pink 1 lead

● Check for voltage (12 V) on the “Pink” lead
at the horn terminal. Horn is faulty, replace it.
MEETS SPECIFI-
CATION (12 V)
Adjust or replace horn.
7 - 39
– +
2.Brake light does not come on.

NO CONTINUITY
ity.
CONTINUITY
2.Brake switch
INCORRECT
● Check the brake switches for continuity.
CORRECT Brake switch is faulty, replace it.
3.Voltage
bulb socket connector.
Tester (+) lead → Yellow 1 terminal
● The brake level is pulled in or brake pedal
is stopped down.
● Check for voltage (12 V) on the “Yellow” Wiring circuit from main switch to bulb socket
lead at the bulb socket connector. connector is faulty, repair.
MEETS SPECIFI-
CATION (12 V)
7 - 40
– +
3.Flasher light and/or turn indicator light do not blink.

NO CONTINUITY
ity.
CONTINUITY
2.Turn signal switch INCORRECT

● Check the turn signal switch for continuity.
Turn signal switch is faulty, replace handle-
CORRECT bar switch (left).
3.Voltage
flasher relay.
● Check for voltage (12 V) on the “Brown”
lead at the flasher relay terminal.
MEETS SPECIFI-
CATION (12 V)
Wiring circuit from main switch to flasher
* relay connector is faulty, repair.
7 - 41
– +
* C0NTINUITY
4.Voltage
flasher relay.
Tester (+) lead → Brown/White 1 terminal

● Check for voltage (12 V) on the “Brown/
White” lead at the flasher relay terminal. Flasher relay is faulty, replace it.
MEETS SPECIFI-
CATION (12 V)
5.Voltage
At flasher light (left):
Tester (+) lead → Chocolate 1 lead
At flasher light (right):
Tester (+) lead → Dark green 2 lead
● Turn the turn signal switch to “L” or “R”.
● Check for voltage (12 V) on the “Chocolate”
lead or “Dark green” lead at the bulb socket
connector.
Wiring circuit from turn signal switch to bulb
MEETS SPECIFI- socket connector is faulty, repair.
CATION (12 V)
7 - 42
– +
4.Natural indicator light does not come on.
NO CONTINUITY
ity.
Refer to the “CHECKING OF BULBS” sec- Bulb and/or bulb socket are faulty, replace.
tion.
CONTINUITY
INCORRECT
2.Neutral switch
● Check the neutral switch for continuity.
SWITCHES” section. Neutral switch is faulty, replace it.
CORRECT
3.Voltage

● Check for voltage (12 V) on the “Brown” Wiring circuit from main switch to bulb socket
lead at bulb socket connector. connector is faulty, repair.
MEETS SPECIFI-
CATION (12 V)
7 - 43
– +
5.Fuel meter does not operate.
1.Fuel sender
● Remove the fuel sender 1 from the fuel
tank.
● Connect the pocket tester to the fuel
sender coupler.
Tester (+) lead → Green 2 terminal
● Check the fuel sender for the specified

resistance.
Fuel sender resistance (Up 4): OUT OF SPECIFICATION
(Ω × 1)
4 ~ 10 Ω at 20°C
Fuel sender resistance (Down 5):
(Ω × 10)
90 ~ 100 Ω at 20°C Replace fuel sender.
BOTH MEET
SPECIFICATION
2.Voltage
fuel meter coupler.
● Turn the main switch to “ON”. OUT OF SPECIFICATION

● Check for voltage (12 V) on the “Brown”
lead at the fuel meter coupler.
MEETS SPECIFI- Check the entire signal system for connec-

CATION (12 V) tions.
7 - 44
– +
* C0NTINUITY
3.Fuel meter
● Move the float to “UP 1” or “DOWN 2”.
NOTE:
Before reading the meter, stay put the float for
more than three minutes respectively at “UP”
or “DOWN”.
DOES NOT MOVE

● Check the fuel meter needle moves “FULL”
or “EMPTY”. Replace fuel meter.
MOVES
4.Wiring connection
● Check the entire signal system for connec-
tion.
7 - 45
TRBL
SHTG
CHAPTER 8.
TROUBLESHOOTING
TROUBLESHOOTING .................................................................................. 8-1

ELECTRICAL SYSTEM ........................................................................ 8-1
COMPRESSION SYSTEM .................................................................... 8-2
INTAKE AND EXHAUST SYSTEM ....................................................... 8-3
TRBL
SHTG
TRBL
TROUBLESHOOTING SHTG
TROUBLESHOOTING
TROUBLESHOOTING
ELECTRICAL SYSTEM
8-1
TRBL
COMPRESSION SYSTEM
8-2
TRBL
INTAKE AND EXHAUST SYSTEM
8-3
SX-4 WIRING DIAGRAM
1 B/W 1 Main switch
OFF R R R Y/R R R 6 3 CDI magneto
ON
(GREEN)
W
Y/R
W
Y
Br Br 4 B 4 CDI unit
B/W B/W
G G 5 Ignition coil
B B
5 6 Spark plug
Br R B B/W
7 Start switch
R W W
2 3 O Br B/W G
Y/R Y/R B R W
R
9 Horn
B B B 0 Flasher relay
A Front brake switch
Br
B Rear brake switch
C Handlebar switch (left)
10A
Br
Br
[
L/W B/W
D Horn switch
R
A B E Lights switch
Y L/Y R/W
Sb Br
7 8 Br B F Pass switch
R
R R
OFF OFF
G/Y B G Dimmer switch
Y/R R/W ON RUN (BLACK) (BLACK) H Turn signal switch
I Clutch switch
R
B L/W
R/W Sb L/Y
R
R/W G/Y
J Tail/brake light
X Y K Rear flasher light
L/W
B
L Front flasher light
B
B Z M Headlight
B B
N Auxiliary light
Br Br
Br/W
O Neutral switch
W Br P Fuel sender
9 P 9 P
Q Meter
B Br 0 Br/w
B R Fuel gauge
S Meter light
T High beam indicatior light
U Neutral indicator light
P Y/R L Br/w L/Y
Y C V Turn indicator light

D E F G H I
Br L Dg Ch
OFF OFF OFF HI R W Starter motor
X Battery
P Br/W Ch Ch Br/W P
Q Dg Dg ON PO ON LO N L/Y L/Y
L/Y B Br Y/R B L/Y
Ch Ch ON L B/Y B/Y
B/Y Dg L L Dg B Y Fuse
(BLUE) (BLUE) (BLACK) (BLACK) Z Starter relay
R S T U V W [ Starting circuit cut-off relay
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
G B Sb Y Y G Ch Dg
Sb L Dg Ch L Y
P L L K O J
Sb
L L N M B L
Y
L B
Y
G G
B B
B B Ch Dg Dg Ch
B B
Sb
(GREEN) (GREEN)
O B B
B B B B
COLOR CODE
B ............Black R ............Red Br/W.......Brown/White R/W ....... Red/White
Br ...........Brown Sb ..........Sky blue Ch ..........Chocolate Y/R ........ Yellow/Red
G............Green W ...........White Dg ..........Dark green
L.............Blue Y ............Yellow G/Y.........Green/Yellow
O............Orange B/W........Black/White L/W ........Blue/White
P ............Pink B/Y.........Black/Yellow L/Y .........Blue/Yellow
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN

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What is the purpose of the service manual?

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What safety precautions are mentioned regarding working on the motorcycle?

What safety precautions are mentioned regarding working on the motorcycle?

SX-4

TECHNICAL PUBLICATION GROUP 1

PARTICULARLY IMPORTANT INFORMATION

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

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

3rd title 3: This is a final title.

alignment mark 7, the others being indicated by an alphabetical letter in a box 8.

G H I Illustrated symbols G to N in the exploded

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

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

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

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

4. When disassembling the machine, always

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

3. Connect and disconnect the connector two

7. Check for continuity with a tester.

This tool is used for removing the rotor.

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

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

GENERAL TORQUE SPECIFICATIONS ................................................... 2-17

DEFINITION OF UNITS .............................................................................. 2-17

LUBRICATION POINTS AND LUBRICANT TYPE .................................... 2-18

CABLE ROUTING ...................................................................................... 2-20

* Lines indicate straight edge measurement.

Wear limit <0.01 mm>

“A” head dia. IN. 33.9 ~ 34.1 mm

DRIVE AXLE MAIN AXLE OIL PUMP

Chain tensioner Bolt M6 2 10 1.0

Neutral switch lead clamp Screw M6 1 7 0.7

Shift arm Bolt M6 1 10 1.0

A: Distance across flats

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

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

SEAT ............................................................................................................. 3-3

SIDE COVER ................................................................................................ 3-3

FUEL TANK .................................................................................................. 3-3

ENGINE ........................................................................................................ 3-4

CHASSIS .................................................................................................... 3-17

● Hydraulic brake systems

● Fuel sender coupler

● Tappet cover (intake side) 1

● Tappet cover (exhaust side) 2

● Camshaft end cover (with O-ring) 2

Valve clearance (cold):

Tappet adjusting tool:

● Hold the adjuster to prevent it from moving

● Measure the vale clearance.

● Tappet cover (intake side)

IDLING SPEED ADJUSTMENT

Out of specification → Adjust.

Engine idling speed:

● Turn the throttle stop screw 2 in or out until