XT 600 A/ACSERVICE MANUAL 1990 by Yamaha Motor Corporation, U.S.A.1st Edition, January 1990All rights reserved. Any reprinting orunauthorized use without the writtenpermission of Yamaha Motor Corporation,U.S.A. is expressly prohibited.Printed in U.S.A.PIN: L1T-11616-07-43NOTICEThis manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir qualified mechanics. It is not possible to put an entire mechanic's education into one manual,so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor-cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcyclerepair technology. Without such knowledge, attempted repairs or service to this model may renderit unfit to use and/or unsafe.This model has been designed and manufactured to perform within certain specifications in regardto performance and emissions. Proper service with the correct tools is necessary to ensure that themotorcycle will operate as designed. If there is any question about a service procedure, it is im-perative that you contact a Yamaha dealer for any service information changes that apply to thismodel. This policy is intended to provide the customer with the most satisfaction from his motor-cycle and to conform with federal environmental quality objectives.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 AuthorizedYamaha dealers and will, where applicable, appear in future editions of this manual.NOTE: _This Service Manual contains information regarding periodic maintenance to the emission controlsystem for the XT600EA/EAC. Please read this material carefully.TECHNICAL PUBLICATIONSSERVICE DIVISIONMOTORCYCLE GROUPYAMAHA MOTOR CO., LTD.PARTICULARLY IMPORTANT ANT INFORMATIONThis material is distinguished by the following notation.The Safety Alert Symbol means ATIENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!Failure to follow WARNING instructions could result in severe injury ordeath to the motorcycle operator, a bystander,or a person inspecting orrepairing the motorcycle.NOTE:A CAUTION indicates special precautions that must be taken to avoiddamage to the motorcycle.A NOTE provides key information to make procedures easier or clearer.HOW TO USE THIS MANUALCONSTRACTION OF THIS MANUALThis manual consists of chapters for the main categories of subjects. (See "Illustrated symbols")1st title CD :2nd title @ :3rd title :This is a chapter with its symbol on the upper right of each page.This title appears on the upper of each page on th'8 left of the chaptersymbol. (For the chapter "Periodic inspection and adjustment" the 3rdtitle appears.)This is a final title.MANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The infor-mation has been compiled to provide the mechanic with an easy to read, handy reference thatcontains comprehensive explanations of all disassembly, repair, assembly, and inspections.A set of particularly important procedure @ is placed between a line of asterisks" *" with eachprocedure preceded by " ".IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol . An encircled numeral indicates a part name, and an encircled alphabetical letter data or analignment mark (J) , the others being indicated by an alphabetical letter in a box . A condition of a faulty component will precede an arrow symbol and the course of action re-quired the symbol .EXPLODED DIAGRAMEach chapter provides exploded diagrams before each disassembly section for ease in identif-ying correct disassembly and assembly procedures.6978 ltn,pee.00"" sealG,ommetSe,alehesIOamage-t ealaee.5L"b"c.teO""eeha,n1 Inspectlnne"o'k'"be I O"le, 10'k I"be Se,alenu/8endllOamage -t Rel'l."eOll no. anemp' '1I "nighn a ben. innla'k ,,,be allhil may d;llng.,pully weak.n,1'1" '''be.4.1"...11O"veeha,nJo,n, Id"ve e".,nlelopld""ee".,n)________FR_ON_TF_OR_K ICHASletr01u.,ng.l,gu,.,"ghtnnd'''IIQ."e.n.NOTE: ----'---'----_Ro.... tile "."d .ev""lt,rn"" 10 .vo,d .,,"mO,"1nIl'ao much """rlillto'" on" I'C"2 R"mo" CnnlReplace.Bolt (seat):10Nm (1. Om-kg, 7 .2ft-lb)Bolt (carburetor joint):10 Nm (1.0 m - kg, 7.2 ft -Ib)Screw @ (clamp):2 Nm (0.2 m - kg, 1.4 ft - Ib)Bolt (seat):10Nm (1 .Om-kg, 7 .2ft-lb)3-28FUEL LINE INSPECTION / I I I______ EXHAUST SYSTEM INSPECTION, FUEL LINE INSPECTION1. Remove:-Seat- Side cover(left)- Air scoop(left)Refer to the "SEAT, FUEL TANK ANDCOVER"Section.2. Inspect:- Fuel hose CDCrack/Damage->Replace.3. Install:-Air scoop(left)- Side cover(left)-SeatBolt (seat):10Nm (1 .Om-kg, 7 .2ft-lh)

13-29CRANKCASE VENTILATION HOSEINSPECTION1. Inspect:-Crankcase ventilation hose CDCrack/Damage->Replace.EXHAUST SYSTEM INSPECTION1. Inspect:- Exhaust pipe CD-Muffler Crack/Damage->Replace.-Gasket @Exhaust gas leaks->Replace.Nut (exhaust pipe):10 Nm (1.0 m - kg, 7.2 ft - Ih)Bolt (muffler):40 Nm (4.0 m - kg, 29 ft - Ih)Bolt (clamp):20 Nm (2.0 m - kg, 14 ft - Ih)Screw (J) (protector):7 Nm (0.7 m - kg, 5.1 ft -Ih)Use LOCTITE.Screw (protector):7 Nm (0.7 m - kg, 5.1 ft -Ih)Use LOCTITE.__________ CANISTER INSPECTION, CANISTER INSPECTION(XT600EAC ONLY)1, Inspect:- Hose connectionPoor condition --4 Correct,- Hoses-CanisterCracks/Damage --4 Replace.Clogs --4 Clean.CD Roll over valve Carburetor Canister@ Hose (to atmosphere) Over flow hose Hose (to carburetor)Canister removal1. Remove:-Seat- Side covers-Air scoops- Cover (fuel tank)-Fuel tankRefer to the "SEAT, FUEL TANK ANDCOVER" section.2. Remove:- Filter case cover (right) CD- Breather hose (from crankcase) - Breather hose (filtercase) NOTE: _When removing the breather hose (filter case),take care so that the clamp @ dose not slidedown the hose.3. Disconnect:- Battery leadNOTE: _Disconnect the negative lead CD first, and thendisconnect the positive lead .3-30IAINOSJPlmlCANISTER INSPECTION ~---------------------4. Remove:-Battery _ Starter relay (from filter case projection)_ Starting circuit cut-off relay @ (from filtercase projection)- Flasher relay (from filter case projection)- Fuse box (J) (from filter case projection)- Filter case cover 5. Disconnect:-Ignitor unit CD6. Remove:- Bolts (air filter case) -Joint bands - Move airfilter case to the rear of shockabsorber as shown so that the canistercan be seen.CAUTION;Do not pinch ignitor leads when removing airfilter case.7. Disconnect:- Hose (to carburetor) CD8. Remove:-Canister Canister installationReverse the "Removal" procedure. Note thefollowing points.3-31FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT. CHASSISFRONT BRAKE ADJUSTMENT1. Check: Brake lever free play @Out of

Free play:2""'5 mm (0.08""'0.20 in)L....--__2. Adjust: Brake lever free play***********************Adjustment steps: Loosen the locknut CD. Turn the adjuster in or out until the speci-fied free play is obtained.Free play is decreased.Free play is increased . Tighten the locknut.***********************Proper lever free play is essential to avoidexcessive brake drag.REAR BRAKE ADJUSTMENT1. Check: Brake pedal height @Out of Brake pedal height:15 mm (0.59 in)Below top of footrest.2. Adjust: Brake pedal height***********************Adjustment steps: Loosen the locknut CD.Turn the adjuster in or out until the speci-fied pedal height is obtained.3-32BRAKE FLUID INSPECTION I~ J I I I ! i i I IPedal height is increased.Pedal height is decreased.~ - - - - - - - - - - -After adjusting the brake pedal height, visu-ally check the adjuster end through the holeCD of the joint holder. The adjuster end mustappear within this hole.eTighten the locknut.~ Locknut,26 Nm (2.6 m' kg, 19 ft Ib)***********************BRAKE FLUID INSPECTION1. Place the motorcycle on a level place.NOTE: _ Position the motorcycle straight up wheni.nspecting the brake fluid level . When inspecting the front brake fluid level,make sure the master cylinder top is horizon-tal by turning the handlebars.2. Inspect: Brake fluid levelFluid level is under "LOWER" level line CD~ F i l l up.Recommended brake fluid:Front: DOT No.4 or DOT No.3Rear: DOT No.4'N FrontJBl RearCAUTION:Brake fluid may erode painted surfaces or plas-tic parts. Always clean up spilled fluid immedi-ately.3-33__________ BRAKE PAD INSPECTION. Use only the designated quality brake fluid:otherwise, the rubber seals may deterio-rate, causing leakage and poor brake per-formance. Refill with the same type of brake fluid;mixing fluids may result in a harmful chem-ical reaction and lead to poor performance. Be careful that water does not enter themaster cylinder when refilling. Water willsignificantly lower the boiling point of thefluid and may result in vapor lock.

3-34BAKE PAD INSPECTION1. Activate the brake lever or brake pedal.2. Check: Pad thicknessOut of specification->Replace.Wear limit @:Front:1.0 mm (0.04 in)Rear:0.8 mm (0.03 in)Refer to the "BRAKE PAD REPLACE-MENT"section in the CHAPTER 6 forreplacement.IAI Front brake[BJ Rear brakeBRAKE LIGHT SWITCH ADJUSTMENT/ IINSPI IBRAKE HOSE INSPECTION/ AIR BLEEDING ADJRBRAKE LIGHT SWITCH ADJUSTMENTNOTE: _-The brake light switch is operated by move-ment of the brake pedal.- Proper adjustment is achieved when thebrake light comes on just before the brakebegins to take effect.1. Hold the switch body CD with your hand sothat it does not rotate and turn the adjustingnut.BRAKE HOSE INSPECTION1. Inspect:- Brake hose Replace.Refer to the "FRONT AND REAR BRAKE"section in the CHAPTER 6 for replace-ment.I8J Front[H] RearAIR BLEEDING Bleed the brake system if:- The system has been disassembled._ A brake hose has been loosened orremoved.-The brake fluid is very low.- The brake operation is faulty.A dangerous loss of braking performancemay occur if the brake system is not properlybled.3-35AIR BLEEDING/ 1 ~ 8 . r 1 ~ 1DRIVE CHAIN SLACK ADJUSTMENT . . ~1. Bleed: Brake system***********************Air bleeding steps:a. Add proper brake fluid to the reservoir.b. Install the diaphragm. Be careful not to spillany fluid or allow the reservoir to overflow.c. Connect the clear plastic tube CD tightly tothe caliper bleed screw.[8] Front[BJ Reard. Place the other end of the tube into a con-tainer.e. Slowly apply the brake lever or pedal severaltimes.f. Pull the lever in or push down on the pedal.Hold the lever or pedal in position.g. Loosen the bleed screw and allow the lever orpedal to travel towards its limit.h. Tighten the bleed screw when the lever orpedal limit has been reached; then release thelever or pedal.Bleed screw:6 Nm (0.6 m kg. 4.3 ft . Ib)i. Repeat steps (e) to (h) until all of the air bubbleshave been removed from the system.NOTE: _If the bleeding is difficult, it may be necessaryto let the brake fluid system stabilize for a fewhours. Repeat the bleeding procedure whenthe tiny bubbles in the system have disappear-ed.j. Add brake fluid to the level line on the reser-voir.***********************DRIVE CHAIN SLACK ADJUSTMENTNOTE: _Before checking and/or adjusting, rotate therear wheel through several revolutions andcheck slack at several points to find the tightestpoint. Check and/or adjust the chain slack withthe rear wheel in this "tightest"position.3-36DRIVE CHAIN SLACK ADJUSTMENT I~ 8 r l n l1. Check: Drive chain slack @Out of specification--->Adjust.Drive chain slack:30'"'-'40 mm (1.18'"'-'1.57 in)NOTE: _To check the chain slack, the motorcycle muststand vertically with its both wheels on theground and without a rider.2. Adjust: Drive chain slack***********************Adjustment steps:CAUTIQN:Too small chain slack will overload theengine and other vital parts; keep the slackwithin the specified limits. Remove the cotter pin CD and loosen the axlenut. Loosen the bolt @ (caliper bracket). Loosen the bolts @ (swingarm end) Turn the chain puller CD clockwise or coun-terclockwise until the specified slack isobtained.NOTE: _Turn each chain puller exactly the sameamount to maintain correct axle alignment.(There are marks on each side of swingarm andon each chain puller; use them to check forproper alignment) . Tighten the axle nut and bolt (caliperbracket) , bolts (swingarm end).Axle nut:90 Nm (9.0 m . kg, 65 ft Ib)Bolt (caliper bracket):45 Nm (4.5 m - kg, 32 ft - Ib\Bolt (swingarm end):3 Nm (0.3 m-kg, 2.2 ft-Ib)3-37________D_R_IV_E_C_H_A_I N_LU_B_R_I_C_A_TI_O_N_/_I AI NOSJPI~ IFRONT FORK INSPECTION . . . ~ .elnstall the cotter pinD343 003~ - - - - - - - - - - -Always use a new cotter pin on the axle nut.***********************DRIVE CHAIN LUBRICATIONThe chain consists of many parts which workagainst each other. If the chain is notmaintained properly, it will wear out rapidly,therefore, form the habit of periodically servic-ing the chain. This service is especially neces-sary when riding in dusty conditions.This motorcycle has a drive chain with smallrubber O-rings between the chain plates.Steam cleaning, high-pressure washes, andcertain solvents can damage these O-rings.Use only kerosene to clean the drive chain.Wipe it dry, and thoroughly lubricate it withSAE 30"'50W motor oil. Do not use any otherlubricants on the drive chain. They may containsolvents that could damage the O-rings.Recommended lubricant:SAE 30"'50 motor oilCD O-ringFRONT FORK INSPECTION~ - - - - - - -Securely support the motorcycle so there isno danger of it falling over.1. Place the motorcycle on a level place.3-382. Check:-Inner tube CDScratch/Damage--->Replace.-Oil seal Excessive oil leakage---> Replace.3. Hold the motorcycle in an upright positionand apply the front brake.STEERING HEAD ADJUSTMENT I 4. Check:.OperationPump the front fork up and down forseveral times.Unsmooth operation->Repair.STEERING HEAD ADJUSTMENT Securely support the motorcycle so there isno danger of it falling over.1. Place the motorcycle on a level place.2. Elevate the front wheel by placing a suitablestand under the engine.3. Check: Steering assembly bearingsGrasp the bottom of the forks and gentlyrock the fork assembly back and forth. steering head.4. Adjust: Steering head***********************Adjustment steps: Loosen the bolt CD (steering shaft) and bolt (handle crown). Remove the cover (fuel tank) Tighten the ring nut using the nng nutwrench.NOTE: _Set the torque wrench to the ring nut wrenchso that they form a right angle.Ring nut wrench:PIN. YU-33975PIN. 90890-014033-39REAR SHOCK ABSORBER ADJUSTMENT 1 ~ 8 . r l f i lRing nut (initial tightening):38 Nm (3.8 m'kg, 27 ft'lb).Loosen the ring nut one turn . Retighten the ring nut using the ring nutwrench.mmmmmJ _Avoid over-tightening.Ring nut (final tightening):6 Nm (0.6 m'kg, 4.3 ftlb).Tighten the bolts (steering shaft and handlecrown).Bolt (steering shaft):72 Nm (7.2 mkg. 52 ft'lb)Bolt (handle crown):23 Nm (2.3 mkg. 17 ft'lb).Install the cover (fuel tank)***********************REAR SHOCK ABSORBER ADJUSTMENTNOTE: _The spring preload of the rear shock absorbercan be adjusted to suit rider's preferance,weight, and the course conditions.mmmmmJ _Securely support the motorcycle so there isno danger of it falling over.1. Adjust: Spring preload***********************Adjustment steps:Spring preload.Loosen the locknut CD. Adjust the spring preload with the adjuster (spring preload).3-40IA I N D S J P I ~ ITIRE INSPECTION ~----------------------------Turn the adjuster Increase the springclockwise. preload.Turn the adjuster Decreased the springcounterclockwise. preload.~ Standard length:243.5 mm (9.6 in)Minimum length:237.5 mm (9.4 in)Maximum length:248.5 mm (9.8 in)NOTE: _ When adjusting, use the special wrenchwhich is included in the owner's tool kit . The length of the spring (installed) changes 1mm (0.04 in) per turn of the adjuster.Never attempt to turn the adjuster beyondthe maximum or minimum setting . Tighten the locknut.Locknut:42 Nm (4.2 mokg, 30 ftolb)Always tighten the locknut against the springadjuster and torque the locknut to specifica-tion.***********************TIRE INSPECTIONmEmIImI _ Tire inflation pressure should be checkedand adjusted when the temperature of thetire equals the ambient air temperature.Tire inflation pressure must be adjustedaccording to total weight of cargo, rider,passenger, and accessories (fairing,saddlebags, etc. if approved for this3-41 model), and vehicle speed.__________IA1NOSJPlmlTIRE INSPECTION " ~FRONT:Manufacture Size TypeBridgestone 90/90-21 54S TW41Dunlop 90/90-21 54S TRAIL MAXREAR:Manufacture Size TypeBridgestone 120/90-17 64S TW42BDunlop 120/90-17 64S TRAIL MAX3-42e After extensive tests, the tires mentionedhave been approved by Yamaha motor Co.,Ltd. for this model. No guarantee for han-dling characteristics can be given if tirecombinations other than what is approvedare used on this motorcycle.The front and rear tires should be of thesame manufacture and design.eThe use of tire valves and valve cores otherthan listed could cause tire deflation duringextreme high speed riding. Always usegenuine parts or their equivalent forrepl acement.e Be sure to install the valve caps securely,as these are important to prevent air pres-sure leakage during extreme high speedriding.1. Check:eTire pressureOut of specification->Adjust.Basic weight:With oil and full 168 kg (370 Ib)fuel tankMaximum load * 182 kg (401 Ib)Cold tire pressure Front RearUp to 90 kg (198 Ib) 150 kPa 150 kPa(1 ,5 kg/cm2, (1 ,5 kg/cm2,load * 21 psi) 21 psi)90kg (198 I b ) ~ 150 kPa 200 kPa(1 ,5 kg/cm2, (2,0 kg/cm2,Maximum load * 21 psi) 28 psi)150 kPa 150 kPaHigh speed riding (1 .5 kg/cm2, (1 .5 kg/cm2,21 psi) 21 psi)125 kPa 125 kPaOff-road riding (1,25 kg/cm2, (1.25 kg/cm2,18 psi) 18 psi)* Load is the total weight of cargo, rider, passenger,and accessories,I

TIRE INSPECTION ---------------------------2. Adjust:-Air pressure***********************Adjustment steps:eRemove the valve cap.Use an air pump or Increase the airpressurized air pressure.supply.Release the air by Decrease the airpushing the valve. pressure.@341-1J043-43el nstall the valve cap securely.***********************3. Inspect:-Tire surfacesWear/Damage->Replace.Minimum tire tread depth:(front and rear)0.8 mm (0.03 in)CD Tread depthCV Side wall Wear indicator

----------It is dangerous to ride with a worn out tire.When a tire tread begins to show lines,replace the tire immediately.- Patching a punctured tube is not recom-mended. If it is absolutely necessary to doso, use great care and replace the tube assoon as possible with a good qualityreplacement.4. Tighten:-Valve stem locknut 1.5 Nm (0.15 mkg. 1.1 ft-lb) Ride conservatively after installing a tire toallow it to seat itself properly on the rim.___________W_H_E_E_L_I_N_SP_E_C_T_IO_N_/_I CABLE INSPECTION AND LUBRICATION WHEEL INSPECTION1. Inspect:-WheelsDamage/Bends--->Replace.NOTE: _Always balance the wheel when a tire or wheelhas been changed or replaced. Never attempt even small repairs to thewheel.CABLE INSPECTION AND LUBRICATION Damaged cable sheath may cause corrosionand interfere with the cable movement.An unsafe condition may result so replacesuch cable as soon as possible.1. Inspect:- Cable sheathDamage--->Replace.2. Check:- Cable operationUnsmooth operation--->Lubricate.Recommended lubricant:SAE 10W30 motor oil.NOTE: _Hold cable end high and apply several drops oflubricant to cable.3-44_________L_EV_E_R_A_N_D_P_ED_A_L_LU_B_R_IC_A_T_I_O_N_/_I ~ N 8 J P 1&1SIDESTAND LUBRICATION/SWINGARM AND RELAY ARM LUBRICATIONLEVER AND PEDAL LUBRICATIONLubricate pivoting parts of each lever andpedal.Recommended lubricant:SAE 10W30 motor oilSIDESTAND LUBRICATIONLubricate the sidestand at pivot points.CD Grease nippleSWINGARM AND RELAY ARMLUBRICATIONLubricate the swingarm and relay arms at theirpivoting points.Recommended lubricant:SAE 10W30 motor oilLight weight lithium soap basegrease18] Swingarm[B] Relayarm3-45BATIERY INSPECTION 1 ~ 8 J l f i lELECTRICALBATTERY INSPECTIONNOTE: _Since the MF battery is of a sealed-type con-struction, it is impossible to measure the spe-cific gravity of the electrolyte in order to checkthe state of charge in the battery. Therefore, tocheck the state of charge in the battery, volt-age must be measured at the battery terminals.CAUTION:CHARGING METHOD- This battery is sealed type. Never removesealing caps even when charging. With thesealing cap removed, this balancing will notbe maintained, and battery performance willlower gradually.- Never add water. If distilled water is added,chemical reaction in the battery will not pro-ceed in the normal way, thus making it im-possible for the battery to operate regularly.-The charging time, charging current andcharging voltage for the MF battery is differ-ent than general type batteries.The MF battery should be charged as in-structed in the " Charging method."Shouldthe battery be overcharged, the electrolytelevel will lower extremely. Therefore, usespecial care when charging the battery.(Distilled water cannot be added)- Avoid using any electrolyte other than speci-fied. The specific gravity of the MF batteryelectrolyte is 1.32 at 20C (68F). (The spe-cific gravity of the general type battery elec-trolyte is 1.28.) If the electrolyte whose spe-cific gravity is less than 1.32, the sulfuricacid will decrease and thus low battery per-formance will result. Should any electrolyte,whose specific gravity is 1.32 or more, beused, the battery plates will corrode andbattery life will shorten.3-46BAITERY INSPECTION I~ r l f i l~----------367009Battery electrolyte is dangerous; it containssulfuric acid and therefore is poisonous andhighly caustic.Always follow these preventive measures; Avoid bodily contact with elecrolyte as itcan cause severe burns or permanent eyeinjury..Wear protective eye gear when handling orworking near batteries.Antidote (EXTERNAL):.SKIN-Flush with water. EYES-Flush with water for 15 minutes andget immediate medical attention.Antidote (INTERNAL): Drink large quantities of water or milk fol-low with milk of magnesia, beaten egg, orvegetable oil. Get immediate medicalattention.Batteries also generate el Battery (+) terminal.Tester (-) lead -> Battery (-) terminal.NOTE: _The state of a discharged MF battery can bechecked by measuring open circuit voltage (thevoltage measured with the positive terminalsbeing disconnected).Open-circuit voltage Charging time12.8 v or higher No charging isnecessary.12.7v-11.5v 5 - 10 hoursLess than 11.5 v 15 - 20 hoursBATTERY INSPECTIONRelationship between opencircuitvoltage and charging timeCharging timeVolt meterT --+- --+, _10 1520H. This varies depending on the temperature, the state of chargein battery plates and the electro lyle level..Battery condition chart as shown.***********************en!erature- 40'Cb:- Ambitemp~~ O'C~ .Condition of charge in battery(Ool 5. Charging method of MF battery-If it is impossible to set the standard chargingcurrent. be careful not to overcharge.- When charging the battery. be sure toremove it from the machine. (If charginghas to be done with the battery mounted onthe machine for some reason. be sure todisconnect the wire at the negative termi-nal. )- Never remove the sealing plug from the MFbattery.3-48I

BATTERY INSPECTION --------------------------- Use special care so that charging clips arein a full contact with the terminal and thatthey are not shorted. (A corroded clip of thecharger may cause the battery to generateheat at the contact area. A weak clip springmay cause sparks.) Before removing the clips from the batteryterminals, be sure to turn off the powerswitch of the charger. Change in the open-circuit voltage of theM F battery after being charged is shownbelow. As shown in the figure, the open-circuit voltage is stabilized 30 minutes aftercharging has been completed.Therefore, to check the condition of thebattery, measure the open-circuit voltage30 minutes after charging has been com-pleted.TlmelMlnul8S!Ambient temperature4- Check the Open-circuit voltageI-------- 25'C\"-J,,0'"Charging 14u ,c8.'o">Q) 11Cl 16"0> "3-49 BATTERY INSPECTION --------------------------------Charging method using a variable-current (voltage) type chargergei-v.Charger NOTE:AMP meter Measure the open-circuitVoltage should be measured 30 mEJ EJ EJ voltage prior to charging. nutes after the machine is stopped.+,0 00,"A "NOTE:Connect a charger and Set the changing voltage at 16-1 7\ AMP meter to the battery (If the setting is lower, charginand start charging. will be insufficient. If too high, thbattery will be over-charged.)Make sure the current isYES higher than the standard NOcharging current writtenon the battery.By turning the charging volt-..---age adjust dial, set the charg- I---ing voltage at 20 - 25 v.

Adjust the voltage so that Monitor the amperage for 3-5current is at standard charg- minutes to check if the stan-ing level. dard charging current is rea-ched.1A or more1A or less NOIf the current is more than 1amp, adjust the voltage to 16- 17 v and continue charging.Set the timer according to the After 5 minutes, If current doescharging time suitable for the adjust the voltage not exceed stan-open-circuit voltage. to 16 - 17 v, and dard chargingcontinue charging. current after 5minutes,replace the bat-tery.In case that charging requires more than 5 hours, it is advisable tocheck the charging current after a lapse of 5 hours. If there is anychange in the amperage, readjust the voltage to obtain the standardcharging current.+Measure the battery open-circuit voltage after having left thebattery unused for more than 30 minutes.12.8 v or more --- Charging is complete.12.7 v or less --- Recharging is required.Under 12.0 v --- Replace the battery.3-50__________ BATTERY INSPECTION, Charging method using a constant-voltage type chargerMeasure the open-circuitvoltage prior to charging.Connect a charger andAMP meter to the bat-tery. and start charging.NOTE: _Voltage should be measured 30 minutesafter the machine is stopped.NO YESMake sure the current ishigher than the standard1--------.charging current writtenon the battery.Charge the battery until the battery'scharging voltage is 16 volts or moreNOTE: _Set the charging time at 20 hours(maximum).This type of battery charger can-not charge the MF battery. A vari-able voltage charger or a constantcurrent charger is recommended.ChargerCheck the open-circuit voltageafter having left the battery for 30minutes after charging.12.8 v or more---Charging iscomplete.12.7 v or less---Recharging isnecessary.Under 12 v---Replace the battery.Volt meter3-51AMP meterL-_J EJABATTERY INSPECTION1 ~ 5 J I I A 1 I---------------------Charging method using a constant current type charger (Exclusive for MF Battery)YESMeasure the open-circuitvoltage prior to charging.Connect a charger andAMP meter to the bat-tery, and start charging.After one hour of charg-ing, make sure the ratedcharging current of thecharger is flowing bychecking AMP meter.NOTE: _Voltage should be measured 30 minutesafter the machine is stopped.NOSince the charging current is com:tant,the charging time varies depending onthe battery capacity.Set the charging time according to theinstructions specified for the charger.Measure the battery open-circuit volt-age after having left thebattery unused for more than 30 min-utes.12.8 v or more---Charging is complete.12.7 v or less---Recharging is required.Under 12.0 v---Replace the battery.3-52If rated current is not flowing, replacethe battery.Charger'L.-0 __o B_1 EJme,..AI AI N D S J P I ~ IFUSE INSPECTION rz-.---------------------------6. Inspect- Battery terminalDirty terminal ---> Clean with wire brush.Poor connection ---> Correct.NOTE: _After cleaning the terminals, apply grease light-ly to the terminals.7. Install- Battery8. Connect- Battery leadsNOTE: _Connect the positive lead first and then con-nect the negative lead.9. Install- Side cover (left)-SeatBolt (seat):10 Nm (1.0 m' Kg, 7.2 ft 'Ib)FUSE INSPECTION1. Remove:-Seat- Side cover (left)Refer to the "SEAT, FUEL TANK ANDCOVER" section.2. Remove:-Fuse CD3-53__________ HEADLIGHT BEAM ADJUSTMENT . 3. Inspect:eFuse***********************Inspection steps: Connect the Pocket Tester to the fuse andcheck it for continuity.NOTE: _Set the tester selector to "Q x 1" position.Pocket tester:PIN. YU-03112PIN. 90890-03112 If the tester is indicated at 00 The fuse ISblown, replace it.***********************4. Replace:eBlown fuse***********************Blown fuse replacement steps:.Turn off ignition and the circuit . Install a new fuse of proper amperage.Irra IFuse: 20 ampsx1pc..Turn on switches to verify operation of electri-cal device . If fuse blows immediately again, check circuitin question.***********************mmmIImI _Do not use fuses of higher amperage ratingthan recommended. Extensive electricalsystem damage and fire could result fromsubstitution of a fuse of improper amperage.5. Install:eSide cover (left)eSeatBolt (seat):10Nm (1 .Omkg,7 .2ftlbj3-54IA I N D S J P I ~ IHEADLIGHT BULB REPLACEMENT PZ:.-----------------------------HEADLIGHT BEAM ADJUSTMENT1. Adjust: Headlight beam (vertical)To raise the Turn both adjuster CDbeam clockwise at the sametime.To lower the Turn both adjuster CDbeam counterclockwise at thesame time.2. Adjust: Headlight beam (horizontal)Turn the adjuster CD c1ock-To right the wise whill turning adjusterbeam counterclockwise at thesame time.Turn the adjuster clock-To left the wise whill turning adjusterbeam CD counterclockwise at thesame time.HEADLIGHT BULB REPLACEMENT1. Remove: Cowling (headlight)NOTE: _When removing the cowling, remove the boltCD pull out the projections from thegromets to remove the cowling.2. Remove: Headlight lens unit3. Disconnect: Headlight leads CD Bulb cover 4. Remove: Bulb holder .Bulb3-55I

HEADLIGHT BULB REPLACEMENT ---------------------------NOTE: _Turn the bulb holder counterclockwise andremove the defective bulb.mw.mmImI _Keep flammable products or your handsaway from the bulb while it is on, it will behot. Do not touch the bulb until it coolsdown.5. Install: Bulb (new) CDSecure the new bulb with the bulb holder.Avoid touching glass part of bulb. Also keepit free from oil otherwise, transparency ofglass, bulb life and iIIuminous flux will beadversely affected. If oil gets on bulb, cleanit with a cloth moistened thoroughly withalcohol or lacquer thinner.6. Connect Bulb cover Headlight leads7. Install Headlight lens unit Cowling (headlight)Bolt (headlight upper):16 Nm (1.6 mokg, 12 ftolb)Bolt (headlight lower):7 Nm (0.7 Nmokg, 5.1 ft-lb)Bolt (cowling):7 Nm (0.7 mokg, 5.1 ftolb)3-56ENGINE REMOVAL ENGENGINE OVERHAULENGINE REMOVALNOTE: _It is not necessary to remove the engine in orderto remove the following components:- Cylinder head-Cylinder- Piston/ Piston ring-Camshaft/Rocker arm/Valve-Clutch- Primary drive gear-Oil pump-Shift shaft-A.C. magneto~ - - - - - - - - - -Securely support the motorcycle so there isno danger of it falling over.ENGINE OIL1. D ~ a i n :-Engine oilRefer to the "ENGINE OIL REPLACEMENT"section in the CHAPTER 3.SEAT AND FUEL TANK1. Remove:-Seat- Side covers-Air scoops- Cover (fuel tank)- Fuel tankRefer to the "SEAT, FUEL TANK ANDCOVER" section in the CHAPTER 3.BATTERY LEAD1. Disconnect:- Battery leadNOTE: _Disconnect the negative lead CD first, and thendisconnect the positive lead @.2. Remove:- Battery4-1ENGINE REMOVAL ENG ~..CARBURETOR1. Remove:-CarburetorRefer to the "CARBURETOR - REMOVAL"section in the CHAPTER 5.CLUTCH CABLE1. Remove: Clutch cable CD2. Disconnect: Clutch cable end CDNOTE: _Remove the cable end while pushing it towardholder @.EXHAUST PIPE1. Remove:- Exhaust pipe CD4-2ENGINE REMOVALSTARTER MOTOR1. Remove:- Oil delivery pipe CDENG '-2. Remove:- Bolt CD (oil hose clamp)3. Disconnect:- Starter motor lead CD-Ground lead 4. Remove:-Starter motor HOSE AND LEAD1. Remove:- Breather hose CD (oil tank)- Breather hose (crankcase)2. Remove:-Oil hose CD (inlet)-Oil hose (outlet)4-3ENGINE REMOVAL IENG I\-I3. Remove: Spark plug lead CD4. Disconnect: Magneto lead CD.Clamp NOTE: _Position the magneto lead so that it does notinterfere with engine removal.DRIVE CHAIN1. Remove: Change pedal CD Cover (drive sprocket)2. Remove: Drive sprocket CDNOTE: _ Before removing the nut (drive sprocket),straighten the lock washer tab . Loosen the nut (drive sprocket) while apply-ing the rear brake.ENGINE PROTECTOR1. Remove: Engine protector CD4-4____________E_N_G_I_N_E_R_E_M_O_V_A_L_I ENG I'-I2. Remove: Footrest CD (left)ENGINE REMOVALAWARNINGSecurely support the motorcycle so there isno danger of it falling over.1. Place a suitable stand under the engine.2. Remove: Engine stay CD (upper)3. Remove: Engine stay CD (front)4. Remove:-Bolt CD- Pivot shaft - Engine assemblyNOTE: _The engine and swingarm are installed using thesame pivot shaft. Therefore, take care so that thepivot shaft is pulled, not entirely out, but forenough to set the engine free.4-5ENGINE DISASSEMBLY IENG 1"-1ENGINE DISASSEMBLYCYLINDER HEAD, CYLINDER, CAMSHAFTAND PISTONNOTE: _With the engine mounted, the cylinder head,cylinder, camshaft and piston can be maintainedby removing the following parts.-Seat- Side covers-Air scoops- Cover (fuel tank)-Fuel tank- Carburetor- Exhaust pipe1. Remove:- Spark plug CD-Tappet cover (intake)-Tappet cover (exhaust)- Cylinder head cover @-Blind cap -Dowel pin 2. Loosen:- Bolt CD (chain tensioner)3. Remove:- Chain tensioner 4-6ENGINE DISASSEMBLY IENG I'\-Ir-------------------, 4. Remove: Cam sprocket CD Camshaft Plugs (crankcase cover left)2NOTE: _Fasten safety wire to the cam chain to pre-vent it from falling into the crankcase.5. Remove:-Chain guide CD6. Remove: Cylinder headNOTE: _Loosen each bolt 1/4 turn, and remove them af-ter all bolts are loosened.4-7ENGINE DISASSEMBLY IENG I ~ Ir--------------------. 7. Remove:eGasket CD (cylinder head)eDowel pin @eCylinder eGasket (cylinder)3I4-88. Remove: Dowel pin CD9. Remove: Piston pin clip CDNOTE: _Before removing piston pin circlip, cover crank-case with a clean rag to prevent circlip from fail-ing into crankcase cavity.10. Remove: Piston pin CDPiston @NOTE: _Before removing the piston pin, deburr the clipgrooved and pin hole area. If the piston pin grooveis deburred and piston pin is still difficult to re-move, use piston pin puller.ENGINE DISASSEMBLY IENG 1'\.1Piston pin puller:PIN. YU-01304PIN. 90890-01304Do not use a hammer to drive the piston pinout.STARTER IDLE GEAR AND CRANKCASECOVER (LEFT)NOTE: _With the engine mounted, the starter idle gearand crankcase cover(left) can be maintained byremoving the following parts.eStarter motore Drive sprocket cover1. Remove:eCover CD (starter idle gear)eDowel pineGasket2. Remove:e Starter idle gear 1 CDeBearing eShaft 3. Remove:e Neutral switch lead CD4-9ENGINE DISASSEMBLY IENG 1"-14. Remove:- Crankcase cover CD (left)-Dowel pin-a-ring-Gasket5. Remove:- Starter idle gear 2 CD-Searing Shaft 6. Remove:- Lead holder CD- Pickup coil - Stator coil CLUTCH, PRIMARY DRIVE GEAR ANDBALANCER GEARNOTE: _With the engine mounted, the clutch, primarydrive gear and balancer gear can be maintainedby removing the following parts.- Footrest (right)_ Union bolt (oil delivery pipe)1. Remove:- Oil filter cover CD-Oil filter-a-ring- Crankcase cover (right)4-10ENGINE DISASSEMBLY IENG 1"-12. Remove:-Clutch spring CD- Pressure plate -Ball@- Friction plate @-Clutch plate -Wave plate -Clutch boss (j)-Thrust washer - Clutch housing -Push rod NOTE: _ Before loosening the nut (jJ) (clutch boss),straighten the lock washer tab. Hold the clutch boss to loosen the nut (clutchboss) by the universal clutch holder @.Universal clutch holder:PIN. YM-91042PIN. 90890-04086! @ @ ~ ~ 7 jID[] I"'- '- "'- I~ . iLl c ~~ > . ~@ @ ~ / .CD4-113. Remove: Primary drive gear CDPlate Balancer drive gear @ Plate @.Key Plate washer Plate (j) Balancer gear .Key ENGINE DISASSEMBLY IENG NOTE: _Before loosening the nut (j]) (primary drivegear) and nut ([j) (balancer gear), straightenthe lock washer tab.NOTE: _Hold the rotor (A.C. magneto) to loosen thenut (j]) and ([j) by the rotor holder @.Rotor holder:PIN. YS-01880PIN. 90890-01701 Do not allow the rotor holder to touch theprojections @ on the rotor.4, Remove:- Push lever CD-Spring - Plain washer NOTE: _Loosen the screw to remove the push lever.OIL PUMP AND SHIFT LEVERNOTE: _With the engine mounted,the oil pump andshift lever can be maintained by removing thefollowing parts: Footrest (right) Union bolt (oil delivery pipe) Crankcase cover (right).Clutch4-12ENGINE DISASSEMBLY ENG ~ ..1. Remove:-Circlip Q)-Oil pump gear @-Oil pump -O-ring @2. Remove:-Circlip Q) (from drive axle)-Collar @-Circlip 3. Remove:-Circlip Q)-Shift lever @-Spring - Plain washer @4. Remove:- Stopper lever Q)-Collar @-Spring A.C. MAGNETO AND CAM CHAINNOTE: _With the engine mounted, the A.C. magnetocan be maintained by removing the followingparts.-Seat-Side cover (left)- Crankcase cover (left)4-13ENGINE DISASSEMBLY IENG 1"-1r - - ~ - - (6)6 - - ~ 1. Remove:~ - eNut CD( ~ \ eWasher ~ , .\. ~ ' eRotor@(withstarterwheelgear)eSearing e Plate washer @5 eKey@NOTE: _Hold the rotor to loosen the nut (rotor) by therotor holder (j).Rotor holder:PIN. YS-01880PIN. 90890-01701Do not allow the special tool to touch theprojections on the rotor.NOTE: _Remove the rotor by the rotor puller .Rotor puller:PIN. YU-33270PIN. 90890-013622. Remove:eChain guide CDeCam chain 4-14ENGINE DISASSEMBLY IENG I\-I------------------------CRANKCASE (RIGHT)1. Remove:-Crankcase (right)NOTE: _- Loosen the bolts starting with the highest num-bered one.- Loosen each bolt 1/4 turn, and remove them af-ter all bolts are loosened.***********************Removal steps:.Attach the crankcase separating tool CD.CAs pressure is applied, alternately tap on thefront engine mounting boss, transmissionshafts, and shift cam.Then, remove the crankcase.Crankcase separating tool:P/i\!. YU-01135-APIN. 90890-01135NOTE: _ If the crankcase will not come off, use thelever guides @ for removal. Turn the shift cam to the position shown inthe figure so that it does not contact thecrankcase.NOTE: _Fully tighten the tool holding bolts, but makesure the tool body is parallel with the case. Ifnecessary, one screw may be backed outslightly to level tool body.4-15 Be sure not to give damages to the matingsurface . Use soft hammer to tap on the case half.Tap only on reinforced portions of case.Do not tap on gasket mating surface.Work slowly and carefully. Make sure thecase halves separate evenly. If one end ..hangs". take pressure off the push screw.realign. and start over. If the cases do notseparate. check for a remaining case screwor fitting. Do not force.***********************SHIFTER AND TRANSMISSION1. Remove: Guide bar CD5 .Shift cam Shift fork # 3 @ Shift fork # 2 @.Shift fork # 1 2. Remove:-Transmission assembly CD I,4-16ENGINE DISASSEMBLY3. Remove:- Shift shaft # 1 CD-Shift shaft #2 ENG '-BALANCER AND CRANKSHAFT1. Remove:- Balancer CD2. Remove:-Crankshaft CDNOTE: _- Remove the crankshaft by the crankcase se-parating tool .--.::JiCrankcase separating tool:PIN. YU-01135-APIN. 90890-01135- Fully tighten the tool holding bolts, but makesure the tool body is parallel with the case. Ifnecessary, one screw may be backed out slightlyto level tool body.OIL STRAINERNOTE: _It is recommended that the oil strainer be replacedwhenever the engine is disassembled.1. Remove:- Oil strainer CD-Oil passage cover -Gasket4-17 ROCKER ARMNOTE:With the engine mounted, the rocker arm can bemaintained by removing the following parts.Seat Side covers.Air scoops Cover (fuel tank) Fuel tank Cylinder head cover1. Remove:-Plug CD2. Remove: Bolt CD (rocker arm shaft)3. Remove:- Rocker arm shaft-Rocker armNOTE: _Remove the rocker arm shaft by the slide ham-mer bolt CD and weight .Slide hammer set:PIN. YU-01083-ASlide hammer bolt:PIN. 90890-01083Weight:PIN. 90890-010844-18___________E_N_G_IN_E_D_IS_A_S_S_E_M_B_L_Y_I ENG I'-IVALVENOTE: _With the engine mounted, the valve can be main-tained by removing the following parts.-Seat- Side covers-Air scoops- Cover (fuel tank)-Fuel tank- Exhaust pipe-Carburetor- Cylinder head cover- Cylinder head1. Check:-Valve sealingLeakage at valve seat-+ Inspect the valveface, valve seat and valve seat width.Refer to the "INSPECTION AND REPAIR-VALVE SEAT" section.NOTE: _Before removing the internal parts (valve, valvespring, spring seat, etc.) ofthe cylinder head, thevalve sealing should be checked.***********************Checking steps:.Supply a clean solvent CD into the intake andexhaust ports . Check the valve sealing. There should be noleakage at the valve seats (V.***********************4-19____________EN_G_IN_E_D_I_s_A_s_s_E_M_B_l_y_1 ENG I~2. Remove:-Valve cotter CD-Valve retainer - Outer spring -Inner spring @- Spring retainer ~ V a l v e - Oil seal (j)NOTE: _Identify each part position very carefully so thatit can be reinstalled in its original place.6NOTE: _Compress the valve spring to remove the valvecotter by the valve spring compressor @.Valve spring compressor:PIN. YM-04019PIN. 90890-040194-20INSPECTION AND REPAIR IENG 1"-1INSPECTION AND REPAIRCYLINDER HEAD1. Eliminate:- Carbon deposit(from combustion chamber)Use rounded scraper CD .NOTE: _Do not use a sharp instrument and avoid damag-ing or scratching:- Spark plug threads-Valve seat2. Inspect:- Cylinder headScratches/ Damage--+ Replace.3. Measure:-WarpageOut of specification --+ Resurface.Cylinder head warpage:Less than 0.03 mm (0.0012 in)4. Resurface:- Cylinder head***********************Resurfacement steps:Place a 400........ 600 grit wet sandpaper on thesurface plate, and resurface the head using afigure-eight sanding pattern.NOTE: _Rotate the head several times to avoid remov-ing too much material from one side.***********************4-21INSPECTION AND REPAIR IENG 1"-1VALVE AND VALVE GUIDE1. Measure: Stem-to-guide clearanceStem-to-guide clearance =Valve guide inside diameter -Valve stem diameter @Out of specification-+ Replace valve guide.Stem-to-guide clearance:Intake 0.010-0.037 mm (0.0004-0.0014 in)Exhaust 0.030-0.057 mm (0.0012-0.0022 in)CD Bore gauge302-029302013***********************Valve guide remover7mm(0.28in):PIN. YM-01225-APIN. 90890-01225Valve guide installer:PIN. YM-04017PIN. 90890-04017Valve guide reamer 7mm (0. 28in):PIN. YM-01227PIN. 90890-01227***********************Replacement steps:NOTE: _Heat the cylinder head in an oven to 100C(212F) to ease guide removal and installationand to maintain correct interference fit . Remove the valve guide using the valve guideremover CD. Install the valve guide (new) using the valveguide installer @ and valve guide removerCD. After installing the valve guide, bore the valveguide using the valve guide reamer toobtain proper stem-to-guide clearance.4-22INSPECTION AND REPAIR ENG '--II-//3020044-232. Clean the valve face to remove carbondeposits.3. Inspect:-Valve facePitting/Wear-> Grind the face.4. Measure:- Margin thickness Out of specification-> Replace.Margin thickness limit:0.7 mm (0.028 in)5. Check:-Valve stem endMushroom shape or diameter larger than restof stem-> Replace.-RunoutOut of specification -> Replace.Stem runout limit:0.01 mm (0.0004 in)NOTE:- Always replace the guide if the valve is replaced.- Always replace the oil seal if the valve isremoved.VALVE SEAT1. Clean the valve face and valve seat to removecarbon deposits.2. Inspect:-Valve seatPitting/Wear-> Reface the valve seat.INSPECTION AND REPAIR ENG '-Valve seat width:3. Measure:-Valve seat width Out of specification -+ Reface valve seat.1.0....... 1.2 mm (0.04....... 0.05 in)1.0....... 1.2 mm (0.04....... 0.05 in)***********************Measurement steps: Apply the Mechanic's bluing dye (Oykem) CDto the valve face . Install the valve into the cylinder head. Press the valve through the valve guide andonto the valve seat to make a clear pattern. Measure the valve seat width. Wherever thevalve seat and valve face made contact,bluing will have been removed . If the valve seat width is too wide, too nar-row, or seat has not centered, the valve seatmust be refaced.***********************4. Reface:-Valve seatUse a 30, 45 and 60 valve seat cutterCD. _ PIN. YM-91043When twisting cutter, keep an even down-ward pressure (4-5 kg) to prevent chattermarks.4-2 Replace, then inspect lubrication system.3. Measure:- Arm-to-shaft clearanceArm-to-shaft clearance =Rocker arm inside diameter @Rocker arm shaft outside diameter @Out of specification -> Replace as a set.Arm-to-shaft clearance:0.009"-'0.042 mm(0.0003"-'0.0020 in)CAM CHAIN AND CAM SPROCKET1. Inspect:-Cam chainStiff/Cracks-> Replace cam chain and camsprocket as a set.3430072. Inspect:-Cam sprocketWear/Damage-> Replace cam sprocket andcam chain as a set.CD 1/4 tooth~ CorrectQ) Roller@ Sprocket343-0144-29INSPECTION AND REPAIR IENG 1'-1CAM CHAIN GUIDE1. Inspect:-Exhaust side chain guide CD-Intake side chain guide Wear / Replace.CYLINDER AND PISTON1. Inspect:-Cylinder and piston wallsVertical Rebore or replacecylinder and piston.2. Measure:- Piston-to-cylinder clearance***********************Measurement steps:IFirst steps I.Measure the cylinder bore "C" with a cylinderbore gauge.304-011 CD 50 mm (1.97 in) from the cylinder top1..---- ---1NOTE: _Measure the cylinder bore "C" in parallel to andat right angles to the crankshaft.Then, find the average of the measurements.Cylinderbore" C":Standard mm in)C=X+Y2Wesr limit95.1 mm(3.744 in) If out of the specification, rebore or replacethe cylinder, and the piston and piston ringsas a set.4-30INSPECTION AND REPAIR IENG I'\-I1 2nd steps I.Measure the piston skirt diameter "P" with amicrometer.CD 5.0 mm (0.20 in) from the piston bottomedgep307-001

Piston size P:Standard mm in)Oversize 2 95.5 mm(3.760 in)Oversize 4 96.0 mm(3.780 in)81f out of the specification, replace the pistonand piston rings as a set.I 3rd steps I Find the piston-to-cylinder clearance withfollowing formula.Piston-to-cylinder clearance =Cylinder bore "C" -Piston skirt diameter "P"Piston-to-cylinder clearance:0.045'"'-'0.065 mm(0.002'"'-'0.003 in)Limit:0.1 mm (0.004 in).If out of the specification, rebore or replacethe cylinder, and replace the piston and pis-ton rings as a set.***********************4-31IENG

INSPECTION AND REPAIR ..---------------------------l j ... " 307027PISTON RING1. Measure:-Ring side clearanceUse a feeler gauge.Out of specification -+ Replace piston.NOTE: _Clean carbon from piston ring grooves and ringsbefore measuring side clearance.

Piston ring side clearance:Top 0.04-0.08 mm (0.001-0.003 in)2nd 0.03-0.07 mm (0.001-0.003 in)Oil mm in)2. Position:- Piston ring(in cylinder)NOTE: _Insert a ring into cylinder, and push it approxi-mately 20 mm (0.8 in) into cylinder. Push ring withpiston crown so that ring will be at a right angleto cylinder bore. 20 mm (0.8 in)3. Measure:- Ring end gapOut of specification-+ Replace.NOTE: _You cannot measure end gap on expander spacerof oil control ring. If oil control ring rails show ex-cessive gap, replace all three rings.Piston ring end gap (installed):4-32 ,Top ring2nd ringOil ring mm in) mm in) 70 mm in)INSPECTION AND REPAIR ENG ~ ..IfPISTON PIN1. Inspect:- Piston pinBlue discoloration/Grooves ----> Replacethen inspect lubrication system.2. Measure:-Outside diameter @ (piston pin)Out of specification ----> Replace.Outside diameter (piston pin):21.991 '"'--'22.000 mm(0.8658'"'--'0.8661 in)307-0183. Measure:r. Piston pin-to-piston clearanceOut of specification ----> Replace piston.Piston pin-to-piston clearance =Bore size (piston pin) @ -Outside diameter (piston pin) @Piston pin-to-piston clearance:0 . 0 0 4 ~ 0 . 0 2 4 mm( 0 . 0 0 0 2 ~ 0 . 0 0 0 9 in)Limit: 0.07 mm (0.003 in)CLUTCH1. Inspect: Clutch housing dogsCracks/ Pitting (edges):Moderate----> Deburr.Severe ----> Replace clutch housing.NOTE: _Pitting on friction plate dogs of clutch housingwill cause erratic operation.4-33INSPECTION AND REPAIR IENG I'\.I2. Inspect: Clutch housing bearingDamage-+ Replace.3. Inspect: Clutch boss splinePitting:Moderate-+ Deburr.Severe-+ Replace.NOTE: _Pitting on clutch plate splines of clutch boss willcause erratic operation.4. Measure: Friction plate thicknessOut of specification-+ Replace as a set.311-000Type "A"(2 pes.)Type "B"(6 pes.)Thickness2.94"-'3.06 mm(O.116"-'O.120in)2.72"-'2.88 mm(O.107"-'O.113in)Wearlimit2.8mm(0.11 in)2.6mm(0.10 in)311-002311-0034-345. Measure: Clutch plate warpageOut of specification -+ Replace as a set.Clutch plate warpage limit:0.2 mm (0.008 in)6. Measure: Push rod runoutRoll the push rod on a V-block.Ouf of specification-+ Replace.Runout limit:0.2 mm (0.008 in)INSPECTION AND REPAIR ENG ~ ..7. Measure:- Clutch spring free length Out of specification-> Replace spring as aset.Clutch spring minimum freelength @:40.8 mm (1.606 in)302-005OIL PUMP1. Measure:-Tip clearance (between inner rotor CD and outer rotor (VI-Side clearance @(between outer rotor and pump housing@IOuf of specifications-> Replace oil pump.Tip clearanceOil pump clearance:0.12 mm (0.005 in)Side clearance 0.03-0.08 mm10.001 - 0.003 in)2. Inspect:- Oil pump drive gear CD-Oil pump driven gear Wear/Cracks/Damage -> Replace.PRIMARY DRIVE1. Inspect:- Primary drive gear teeth CD- Primary driven gear teeth Wear / Damage -> Replace both gears.Excessive noises during operation -> Replaceboth gears.4-35IENGI ~INSPECTION AND REPAIR---------------------------TRANSMISSION AND SHIFTER1. Inspect:- Shift fork cam follower CD- Shift fork pawl Scoring/ Bends/Wear--+ Replace.2. Inspect:-Shift cam groove CD- Shift cam segment Wear / Damage--+ Replace.3. Check:-Shift fork movementUnsmooth operation --+ Replace shift forkand/or guide bar.4. Inspect:-Guide barRoll the guide bar on a flat surface.Bends--+ Replace.~----------Do not attempt to straighten a bent guidebar.5. Measure:-Transmission shaft runoutUse centering device and dial gauge.Out of specification --+ Replace bent shaft.Maximum runout:0.08 mm (0.003 in)4-36o xllILITII II IIJ G:J--w3 56. Inspect:-Gear teethBlue discolorationI Pitting/Wear- Replace.-Mated dogsRounded edges/Cracks/Missing portions..... Replace.7. Check: Proper gear engagement (each gear)(to its counter part)-Gear movementRoughness ..... Replace.***********************Transmission gear reassembling points: Press the 2nd wheel gear in the drive axleCD as shown. 60.0 mm (2.36 in).Press the 2nd pinion gear and 5th piniongear @ in the main axle @.@ 90.5 mm (3.56 in)***********************8. Inspect: CirclipDamage/Looseness/Bends -0 Replace.SHIFT SHAFT AND STOPPER LEVER1. Inspect:-Shift shaftBends/Wear/Damage ---+ Replace.4-372. Inspect: Stopper lever CDRoller turns roughly ...... Replace.Bends/Damage --. Replace.3. Inspect: Return spring Damage/Cracks --> Replace.__________IN_S_P_E_C_T_IO_N_A_N_D_R_E_P_A_'R_I ENG ISTARTER DRIVE1. Inspect-Starter one-way CDCracks Damage -- Replace.,,***********************Starter clutch operation.lnstal1 the starter wheel gear to the starterclutch, and hold the starter clutch. When turning the starter wheel gear clock-wise ~ ,the starter clutch and the wheel gearshould be engaged.If not, the starter clutch is faulty. Replae,- It.When turning the starter wheel gear r JUnter-clockwise rEf , the starter wheel pr df shouldturn freely.If not, the starter clutch is fal''.Y. Replace It* * * * * * * . * * * * * ~ * * * * * * * * *2 Inspect: Starter idle gear 1 teeth CD Starter idle gear 2 teeth Starter wheel gear teeth Burrs/Chips/Roughness/Wear Replace.3. Inspect: Starter wheel gear(contacting surfaces)Pitting/Wear/Damage ...... Replace.4-38INSPECTION AND REPAIR ENG ~ .4-------.CRANKSHAFT1. Measure:-Crank width Out of specification ~ Replace crankshaft.Crank width:74.95 75.00 mm(2.950 2.953 in)-Runout @Out of specification ~ Replace crankshaftand!or bearing.~ Runnu' Ilml"0.03 mm (0.001 m)- Small end free play Out of specification~ Replace big end bear-ing, crank pin and!or connecting rod.Small end free play:0.8 mm (0.031 in)- Side clearance Out of specification ~ Replace connectingrod.Big end side clearance:0.35"-'0.65 mm (0.014"-'0.026 in)' ....Crankshaft reassembling point:The crankshaft CD and the crank pin oilpassages must be properly interconnected witha tolerance of less than 1 mm (0.04 in).BALANCER DRIVE GEAR AND BALANCERGEAR1. Inspect:- Balancer drive gear teeth CD Balancer gear teeth Wear! Damage-" Replace both gears.4-39INSPECTION AND REPAIR IENG I ~ I2. Check:- Match marks CDIf they are not aligned-+Align match marksas shown.CRANKCASE1. Inspect:-Crank halves- Bearing seatDamage-+ Replace.BEARING AND OIL SEAL1. Inspect:-BearingRoughness/ Pitting / Damage-+ Replace.-Oil seal lipDamage/Wear-+ Replace.4-40ENGINE ASSEMBLY AND ADJUSTMENT IENG 1'\.1ENGINE ASSEMBLY AND ADJUSTMENTRocker arm # 2Wave washerRocker arm shaft (intake)Rocker arm # 1Valve cotterValve retainerOil sealInner spring9 Outer spring10 Valve (intake)11 Valve retainer1 Rocker arm shaft (exhaust)13 Rocker arm # 414 Rocker arm # 315 Rocker arm shaft (exhaust)16 Valve (exhaust)VALVE SPRING TILT LIMIT:Inner spring:B 2.5'or1.7mm(0.067in)Outer spring:2.5' or 1.9 mm (0.075 in)14 Nm (1.4 m.kg. 10 ftlb)6STEM RUNOUT LIMIT:0.01 mm (0.0004 in)VALVE SEAT WIDTH:1.0- 1.2 mm 10.04-0.05 in)9VALVE CLEARANCE (COLD):A Intake: 0 . 0 5 ~ 0 . 1 0 mm ( 0 . 0 0 2 ~ 0 . 0 0 4 in)Exhaust: 0.12-0.17 mm (0.005-0.008 in)14 Nm (1.4 m.kg, 10 ftlb)",-__1m10 Nm (1.0 m.kg, 7.2 ft.lb)1 1e4-41ENGINE ASSEMBLY AND ADJUSTMENT ENG~ ID'- . ~ CD~ i .~~ ~~ ~ "-" ='ID'- 2~ ~VALVE1. Deburr:-Valve stem endUse an oil stone to smooth the stem end.302-0032. Lubricate:- High-Quality molybdenum disulfide motor oil(to the valve stem and oil seal)3. Install:-Oil seal CD-Valve -Valve retainer -Inner spring -Outer spring -Valve retainer NOTE: _Install the inner and outer springs with wider-gapped coils facing upwards as shown.WLarger pitch Smaller pitch4. Install:-Valve cotter CDNOTE: _Compress the valve spring to install the valvecotter by the valve spring compressor .Valve spring compressor:PIN. YM-04019PIN. 90890-040194-42ENGINE ASSEMBLY AND ADJUSTMENT ENG '-2. Install:-Rocker arm- Rocker arm shaftROCKER ARM1. Lubricate:eEngine oil(to the rocker arm shaft)Bolt CD (rocker arm shaft):10 Nm (1.0 mokg, 7.2 ftolb)NOTE: _Numeral is stamped on the rocker arm.CD #1~ #2 #3@ #43. Install:-Plug CD4-43IENGI ~ IENGINE ASSEMBLY AND ADJUSTMENT -_------------------------CRANKSHAFT, AND BALANCER;Crank pin2 Crank (left)3 Connecting rod4 Bearing Bearing Bearing(J) Balancer BearingCRANK WIDTH:A 74.95-75.00 mm (2.950-2.953 in)RUNOUT LIMIT:B 0.03 mm (0.0012 in)C SMALL END FREE PLAY:0.8 mm (0.031 in)BIG END SIDE CLEARANCE:D 0.35"-'0.65 mm (0.013"-'0.026 in)120 Nm (12.0 mokg. 85 ftolb)B6307SH2-C44-44IENGI ~ IENGINE ASSEMBLY AND ADJUSTMENT ...,------------------------CRANKSHAFT AND BALANCER1. Install: CrankshaftCrankshaft installer set CD:PIN. YU-90050Crankshaft installer pot @:PIN. 90890-01274Crankshaft installer bolt @:PIN. 90890-01275Adapter :j:j: 10 0:PIN. YM-90069PIN. 90890-04059Crank pot spacer @:PIN. YM-91044PIN. 90890-04081Spacer @:PIN. 90890-01016NOTE: _Hold the connecting rod at top dead centerwith one hand while turning the nut of theinstalling tool with the other. Operate the in-stalling tool until the crankshaft bottomsagainst the bearing.To protect the crankshaft against scratchesor to facilitate the operation of the instal-lation.Apply the grease to the oil seal lips, and ap-ply the engine oil to each bearing.2. Install: Balancer CD4-45IENGI ~ENGINE ASSEMBLY AND ADJUSTMENT 'Ii------------------------TRANSMISSIONCD Drive sprocketQ) Oil seal@ Bearing@ 2nd wheel gear@ Drive axle 5th wheel gear(j) 3rd wheel gear@ 4th wheel gear 1st wheel gear Bearing(jJ) Bearing@ 2nd pinion gear@ 5th pinion gear@ 3rd pinion gear 4th pinion gear Main axle@ Bearing@] USE NEW ONE IDRIVE AXLE RUNOUT LIMIT:0.08 mm (0.003 in)1116MAIN AXLE RUNOUT LIMIT:0.08 mm (0.003 in)B6305NRX1C34-46IENG1"--1ENGINE ASSEMBLY AND ADJUSTMENT ...------------------------SHIFTERQ) Stopper lever Guide bar Shift fork # 3@ Shift fork # 1mShift cam6 Guide bar7 Shift fork # 2 Shift shaft # 1Shift shaft # 2@Oil seal([j) Shift lever4-475012-22-6ENGINE ASSEMBLY AND ADJUSTMENT IENG I'\-ITRANSMISSION AND SHIFTER1. Install:-Transmission assembly CD2. Install:- Shift fork :If 1 CD- Shift fork :If 2 - Shift fork :If 3 -Shift cam @-Guide bar @NOTE: _Each shift fork is identified by a number cast onits side. All the numbers should face the left side.3. Install:-Shift shaft # 1 CD-Shift shaft #2 NOTE: _Align the punch mark on the change shaftwith the punch mark on the shift shaft.4. Check:-Transmission operationUnsmooth operation ---> Repair.4-48ENGINE ASSEMBLY AND ADJUSTMENT IENG I ~ IOIL STRAINER AND OIL PUMP~ Oil strainer2 Oil pump3 Oil pump gearOIL PUMP:TIP CLEARANCE:A 0.12 mm (0.005 in)SIDE CLEARANCE:0.03-0.08 mm (0.001-0.003 in)4-49ENGINE ASSEMBLY AND ADJUSTMENT ENG ~..CRANKCASECrankcase (right) Lock plateCrankcase (left)Crankcase ventilation hoseDowel pinDowel pinDowel pinStopper plateCollar~ I TIGHTENING SEQUENCE: I10Nm(1.0m-kg.7.2ft-lb)Ia7 Nm(0.7 mkg. 5.1 ftlb)~ < ~ " ~r ~r----------...., , I20 Nm (2.0 m.kg, 14 ft.lb) t - - - - - t - + - - " " " - < : : - - - - + - - ~SEALANT (QUICKB GASKET)B'YAMAHA BOND NO. 1215 B --4-50ENGINE ASSEMBLY AND ADJUSTMENT ENG ~..OIL STRAINER1. Install:-Gasket- Oil strainer CD-Oil passage cover Bolt (oil strainer):7 Nm (0.7 m'kg, 5.1 ft'lb)Bolt (oil passage cover):7 Nm (0.7 m'kg, 5.1 ftlb)~----------Always use a new gasket.CRANKCASE1. Apply:-Yamaha Bond No. 1215 CD(to the mating surfaces of both casehalves)Sealant (quick gasket)PIN. ACC-11 001-01Yamaha Bond No. 1215:PIN. 90890-855052. Install:-Dowel pin 3. Fit the left crankcase onto the right case. Taplightly on the case with a soft hammer.NOTE: _Turn the shift cam to the position shown in thefigure so that it dQes not contact the crankcasewhen installing the crankcase.Before installing and torquing the crankcaseholding screws, be sure to check whetherthe transmission is functioning properly bymanually rotating the shift cam either way.4-51Bolts (crankcase):10 Nm (1.0 m'kg, 7.2 ftlb)5. Apply:-4-stroke engine oil(to the crank pin, bearing and oil deliveryhole)6. Check:- Crankshaft and transmission operationUnsmooth operation -> Repair.NOTE: _Tighten the bolts starting with the lowest num-bered one.CD ENGINE ASSEMBLY AND ADJUSTMENT IENG I ~ I4. Tighten: Bolt(crankcase) CD",@SHIFT LEVER AND OIL PUMP1. Install:-Spring CD-Collar - Stopper lever Bolt @ (stopper lever):10 Nm (1.0 m'kg, 7.2 ftlb)~ INOTE: _Set the spring and stopper lever at proper po-sition.2. Install:- Plain washer CD-Spring - Shift lever -Circlip @4-52ENGINE ASSEMBLY AND ADJUSTMENT IENG I'\.INOTE: _When installing the shift lever, align the punchedmark on the shift lever with the punched markon the shift shaft.3. Install:- Circlip CD (to drive axle)-Collar -Circlip 4. Apply:-4 stroke engine oil(to the oil passages in the crankcase)Apply a liberal amount of 4-stroke engine oilto the oil pump passages in the crankcase,or the engine may be damaged.5. Apply:-4 stroke engine oil(to the oil passages in the oil pump)6. Install:-O-ring CD-Oil pump -Oil pump gear -Circlip @Bolt (oil pump):10 Nm (1.0 m'kg, 7.2 ft'lb)4-53ENGINE ASSEMBLY AND ADJUSTMENTENG ~..CAM CHAIN1. Install:-Cam chain CD-Chain guide CV4-54ENGINE ASSEMBLY AND ADJUSTMENTPISTON AND PISTON RINGENG ..Piston ring (top)Piston ring (2nd)Piston ring (oil)PistonPiston pinPiston pin clipPISTON SIZE:A mm(3. 737 739 in)PISTON RING END GAP:Top: B 2nd: Oil PISTON RING SIDE CLEARANCE:C Top: mm 2nd: mm Oil: mm CDD USE NEW ONE4-5556ENGINE ASSEMBLY AND ADJUSTMENT IENG I'\-ICYLINDERCD Gasket Cylinder@ O-ring@ Gasket@ Dowel pin@ Dowel pin129 Nm (2.9 m.kg, 21 ftlb) IBORE SIZE: 741 in)B : Replace as a set.***********************Bearing race replacement steps: Remove the bearing races using a long rod CDand hammer as shown . Remove the bearing race on the steering stemusing the floor chisel and the hammer asshown . Install the new dust seal and races.NOTE: _Always replace bearings, races and dust seal asa set.***********************6-52STEERING HEAD AND HANDLEBAR ICHASI ~ I3. Inspect: Handlebar crown CD Lower bracket Cl>Cracks/Damage -> Replace . Steering shaft Bends/Damage -> Replace lower bracketassembly.4. Inspect: HandlebarsBends/Cracks/Damage -> Replace.~ - - - - - - - - - -Do not attempt to straighten a bent handlebaras this may dangerously weaken the handle-bar.***********************Handlebar replacement steps: Remove the handlebar grip and lever holder . Install the lever holder to a new handlebar . Apply a light coat of an adhesive for rubber onthe left handlebar end . Install the handlebar grip.NOTE: _Wipe off excess adhesive with a clean rag.~ - - - - - - - - - - -Leave the handlebar intact until the adhesivebecomes dry enough to make the grip andhandlebar stuck securely.***********************INSTALLATIONReverse the "REMOVAL" procedure.Note the following points.1. Lubricate:.Bearings (upper and l o w e ~ Bearing races~ Wheel bearing grease6-53STEERING HEAD AND HANDLEBAR ICHASI AI2. Install: Bearing (lower)(onto steering shaft) Lower bracket Bearing (upper) Bearing cover~-----------Hold the under bracket until it is secured.3. Tighten:.Ring nut CD***********************Ring nut tightening steps:-Tighten the ring nut using the ring nut wrench.Ring nut wrench:PIN. YU-33975PIN. 90890-01403NOTE: _Set the torque wrench to the ring nut wrenchso that they form a right angle.Ring nut (initial tightening):38 Nm (3.8 m kg. 27 ft Ib)- Loosen the ring nut one turn.- Retighten the ring nut using the ring nutwrench.~-----------Avoid over-tightening.Ring nut (final tightening):6 Nm (0.6 m . kg, 4.3 ft . Ib)**********.*************4. Install: Handlebar crownNOTE: _Temporary tighten the steering shaft bolt CD.6-54STEERING HEAD AND HANDLEBAR I C H A S I ~ I5 Install:eThrottle holder assemblyNOTE: _Before installing the throttle holder assemblyonto the handlebar, apply a light coat of lithiumsoap base grease onto the handlebar end andinstall the throttle holder assembly to thehandlebar.6. Install: HandlebarNOTE: _The upper handlebar holder should be installedwith the punched mark CD forward.Bolt (handlebar):20 Nm (2.0 m . kg, 14 ft Ib)354-014[AJ ForwardiicIPIlgN;/i-----------First tighten the bolts on the front side of thehandlebar holder, and then tighten the boltson the rear side.7. Install:e Handleber sVliitch (right) CDNOTE: _When installing the handlebar switch (right)make sure its projection fits into the hole asshown.8. Install:e Handlebar switch CD (left)eClutch switch @eBands eClutch cable NOTE: _Apply a light coat of lithium soap base greaseonto the clutch cable end.6-55STEERING HEAD AND HANDLEBAR ICHASI ~ I9. Install: Brake master cylinder CD Brake switch.Bands Br ake lever Protecter (right) Mirror (right)NOTE: _ Install the master cylinder bracket with the"UP" mark facing upward. Tighten first the upper bolt, then the lowerbolt.Bolts (master cylinder bracket):7 Nm (0.7 m' kg. 5.1 ft 'Ib)10. Install: Meter assembly CD Headlight stay Bolt (meter assembly) :7 Nm (0.7 m' kg. 5.1 ft 'Ib)Bolt (headlight stay)7 Nm (0.7 mkg. 5.1 ft'lb)11. Install: Speed meter cable 12. Install: Front forkRefer to the "FRONT FORK - INSTALLA-TION" section.Nut (lower bracket):23 Nm (2.3 m' kg. 17 ft Ib)Pinch bolt (handlebar crown):23 Nm (2.3 m kg. 17 ft Ib)13. Tighten: Steering shaft boltSteering shaft bolt:72 Nm (7.2 m'kg, 52 ft'lb)6-56STEERING HEAD AND HANDLEBAR ICHASI AI14. Connect Flasher light lead (right) Pilot box coupler Brake switch coupler Handlebar switch coupler (right) Main switch coupler.Clutch switch coupler Handlebar switch coupler (left) Meter leads.Flasher light lead (left)Refer to the "CABLE ROUTING" sectionin the CHAPTER 2.15. Install: Headlight lens unit.CowlingBolt (headlight upper) :16 Nm (1.6 mokg, 12ftlb)Bolt (headlight lower):7 Nm (0.7 mokg, 5.1 ftlb)Bolt (cowling):7 Nm (0.7 mokg, 5.1 ftlb)16. Install: Front wheelRefer to the "FRONT WHEEL - INSTAL-LATION" section.Wheel axle:58 Nm (5.8 mokg, 42 ftolb)Nut (axle holder):9 Nm (0.9 mokg, 6.5 ftolb)17. Adjust: Clutch cable free playRefer to the "CLUTCH ADJUSTMENT"section in CHAPTER 3.Free play:2 '" 3 mm (0.08 '" 0.12 in)at lever pivot.18. Install: Protecters (left)6-57REAR SHOCK ABSORBER AND SWfNGARM ICHASI ~ IREAR SHOCK ABSORBER AND SWINGARMCD Rear shock absorber assembly SpringSPRING PRELOAD:STANDARDFITTING LENGTH:243.5 mm (9.6 in)A MINIMUM LENGTH: .-/.-4"'1'-"'--237.5 mm (9.4 in) .-- Replace.Washer thickness:1.90.-....- 2.00 mm(0.075 .-....- 0.079 in)6-665. Calculate: Swingarm side clearanceOut of specification -> Adjust side clear-ance using shim.By using formula given below.Side clearance:(@ + x 2) - ( + @ x 2)Side clearance (at swingarm pivot):0.4.-....- 0.7 mm(0.016.-....- 0.028 in)Limit: O.3mm(O.012in)REAR SHOCK ABSORBER AND SWINGARM ICHASI ~ I***********************Example:a.If the engine mounting boss width @, bushlength @, are below.@ : 63.6 mm (2.50 in)@ : 74.9 mm (2.949 in)b.lf the pivot width @ and washer thickness@ are below.@ : 208.8 mm (8.22 in)@ : 1.9 mm (0.075 in)Side clearance= (63.6 + 74.9 x 2) - (208.8 + 1.9 x2)= 0.8 mm (0.03 in)Then, install the one shim.~ Shim thickness:[6] 0.3 mm (0.012 in)***********************INSTALLATIONReverse the "REMOVAL" procedure.Note the following points.1. Lubricate:- Bearing-Bushing-Thrust cover (inside)-Collar- Pivot shah- Bolt (relay arm - swingarm)- Bolt (connecting rod - relay arm)- Bolt (connecting rod - frame)- Shaft (shock absorber)~ Lith;um soap base grease6-67REAR SHOCK ABSORBER AND SWINGARM ICHASI et:Ye12. Tighten: Nut CD (relay arm-swingarm) Nut (relay arm-connecting rod) Bolt @ (chain protector)Nut (relay arm-swingarm):59 Nm (5.9 m kg, 43 ft Ib)Nut (relay arm-connecting rod):32 Nm (3.2 m kg, 23 ft Ib)Bolt (chain protector):7 Nm (0.7 m kg, 5.1 ft Ib)3. Tighten: Nut CD (pivot shaft)4. Tighten: Bolt CD (chain guide)5. Tighten: Nut CD (connecting rod-frame)Nut CD (pivot shaft):85 Nm (8.5 m kg, 61 ft Ib)Bolt CD (chain guide)7 Nm (0.7 m kg, 5.1 ft Ib)Nut CD (connecting rod-frame):32 Nm (3.2 m kg, 23 ft Ib)6-68REAR SHOCK ABSORBER AND SWINGARM ICHASI ~ I6. Tighten: Bolt Q) (rear shock absorber)Bolt Q)(rear shock absorber):59 Nm (5.9 m kg, 43 ft Ib)7. Install: Shaft Q)Washer @ Cotter pin Rubber cover @NOTE: _Bend the ends of the cotter pin.~---------Always use a new cotter pin.8. Tighten: Screw Q) (chain case)Screw Q) (chain case):4 Nm (0.4 m: kg, 2.9 ft Ib)9. Install: Rear wheelRefer to the "REAR WHEEL - INSTALLA-TION" section.10. Adjust: Drive chain slackDrive chain slack:30'" 40 mm (1.18'" 1.57 in)Refer to the "DRIVE CHAIN SLACKADJUSTMENT" section in the CHAPTER36-69REAR SHOCK ABSORBER AND SWINGARM ICHASI ~ I11. Tighten:-Axle nut- Bolt (swingarm end)- Bolt (caliper bracket)- Bolt (brake caliper)Axle nut:90 Nm (9.0 m kg, 65 ft . Ib}Bolt (swingarm end):3 Nm (0.3 m kg, 2.2 ft Ib)Bolt (caliper bracket) :45 Nm (4.5 m kg, 32 ft . Ib)Bolt (brake caliper):35 Nm (3.5 m kg, 25 ft Ib)Refer to the "REAR WHEEL - INSTALLA-TION" section in the CHAPTER 6.12. Install:-Cotter pinNOTE: _Bend the ends of the cotter pin as illustration.AWARNINGAlways use a new cotter pin.349 00013. Install:- Fuel tank- Cover (fuel tank)-Air scoops- Side covers-SeatBolt (seat):10 Nm (1.0 m' kg, 7.2 ft 'Ib)6-70DRIVE CHAIN AND SPROCKET ICHASI DRIVE CHAIN AND SPROCKET

Clutch hub2 Collar3 Driven sprocket4 Bearing

Oil seal6 Collar7 Drive chain8 Drive sprocket45 Nm (4.5 moll,. 32 ftolb)8DR1VE CHAIN SLACK:A 86203RS

110 Nm (11.0 mokg. 80 ftlb)6-71DRIVE CHAIN AND SPROCKET ICHASI ~ IREMOVAL1. Place the motorcycle on a level place.NOTE: _Before removing the drive chain and sprockets,drive chain slack and 10-link length of drivechain should be measured.2. Remove: Change pedal CD Cover (drive sprocket)3. Remove: Drive sprocket CDNOTE: _ Before removing the nut (drive sprocket),straighten the lock washer tab. Loosen the nut (drive sprocket) while apply-ing the rear brake.4. Elevate the rear wheel by placing a suitablestand under the engine.~ - - - - - - - - - - -Securely support the motorcycle so there isno danger of it falling over.5. Remove:.Rear wheel Driven sprocket assembly Damper rubberRefer to the "REAR WHEEL - REMOVAL"section.6-72DRIVE CHAIN AND SPROCKET ICHASI 6. Remove:.Swingarm Drive chainRefer to the "REAR SHOCK ABSORBERAND SWINGARM - REMOVAL" section.INSPECTION1. Measure:.1 a-link length (drive chain)Out of specification ---> Replace drivechain.10-link length Iimit@:150.2 mm (5.91 in) II:

@343-0080006-73NOTE: _ For measurement make the chain tense byfinger..1 a-link length is a measurement between theinsides of the Q) and (jJ) rollers as shown . Two or three different 1a-link lengths shouldbe measured.2. Clean: Drive chainPlace it in kerosene, and brush off asmuch dirt as possible. Then remove thechain from the kerosene and dry thechain.This motorcycle has a drive chain with smallrubber O-rings Q) between the chain plates.Steam cleaning, high-pressure washes, andcertain solvent can damage these O-rings.Use only kerosene to clean the drive chain.DRIVE CHAIN AND SPROCKET ICHASI ~ Ir-----------:::-----------, 3. Inspect:eO-rings CD (drive chain)Damage -> Replace drive chain.eRollers eSide plates @Damage/Wear -> Replace drive chain.4. Lubricate:e Drive chainDrive chain lubricant:SAE 30 "-' 50 motor oil343-0145. Inspect:e Drive chainStiff -> Clean and lublicate or replace.6. Inspect:e Drive sprockete Driven sprocketMore than 1/4 teeth CD wear -> Replacesprocket.Bent teeth -> Replace sprocket.~ Correct3 Roller4 Sprocket6-74***********************Driven sprocket replacement steps: Straighten the lock washer tabs and removethe driven sprocket . Install a new driven sprocket and lockwashers.~----------Always use new lock washers.DRIVE CHAIN AND SPROCKET ICHASI ~ INut (driven sprocket):62 Nm (6.2 mokg, 45 ftlb) Bend the lock washer tabs along the nut flats.***********************7. Inspect:-Bearing CDBearing turns roughly ~ Replace.-Oil seal Wear/Damage ~ Replace.***********************Oil seal and wheel bearing replacementsteps: Clean the outside of the sprocket hub. Remove the oil seals CD using a flat-headscrew driver.NOTE: _Place a rag on the outer edge to preventdamage. Remove the bearing using a general bear-ing puller . Install the new bearing and oil seal by revers-ing the previous steps.NOTE: _Use a socket @ that matches the outsidediameter of the race of the bearing and oil seal.i;';DlbBal:!)'!!----------Do not strike the center race or balls ofthe bearing. Contact should be made onlywith the outer race (J).***********************6-75DRIVE CHAIN AND SPROCKET ICHASI AI8. Inspect: Sprocket wheel hub CDCracks/Damage ~ Replace. Dumper rubber Wear/Damage ~ Replace.INSTALLATIONReverse the "REMOVAL" procedure.Note the following points.1. Install: Drive chain.SwingarmNut (pivot shaft):85 Nm (8.5 m' kg. 61 ft 'Ib)Nut (frame - connecting rod):32 Nm (3.2 m . kg. 23 ft Ib)2. Install:.Rear wheelRefer to the "REAR WHEEL INSTALLA-TION" section.3. Install: Drive sprocketNut (drive sprocket):110 Nm (11 .0 m . kg. 80 ft Ib)mEmIImI----------Always use a new lock washer.NOTE: _ Tighten the nut (drive sprocket) while apply-ing the rear brake. After tightening the nut, bend the lockwasher tab along the nut flats.6-76DRIVE CHAIN AND SPROCKET ICHASI c#Ye14. Adjust:- Drive chain slackRefer to the "DRIVE CHAIN SLACKADJUSTMENT" section in the CHAPTER3.Drive chain slack:30 '"'-' 40 mm (1 .18 '"'-' 1.57 in)5. Tighten:-Axle nut- Bolt (swingarm end)- Bolt (caliper bracket)- Bolt (brake caliper)Axle nut:90 Nm (9.0 mokg. 65 ftolb)Bolt (swingarm end):3 Nm (0.3 mokg. 2.2 ftolb)Bolt (caliper bracket):45 Nm (4.5 mokg. 32 ftolb)Bolt (brake caliper):35 Nm (3.5 mokg. 25 ftolb)Refer to the "REAR WHEEL INSTALLATION"section.6. Install:-Cotter pinNOTE: _Bend the ends of the cotter pin as illastration.AWARNINGAlways use a new cotter pin.349 ()()()7. Install:-Cover (drive sprocket)- Change pedalBolt (cover):10 Nm (1.0 m kg. 7.2 ft Ib)Bolt (change pedal):10 Nm (1.0 m kg. 7.2 ft lb)6-77XT600EA!EAC CIRCUIT DIAGRAM IElEc11iii IELECTRICALXT600EA/EAC CIRCUIT DIAGRAMQ)Gy BrfWBr pONGIYLBrh @'----L-----......-----------.JROWO@t:LlYw wB -=-Br,...-------+---R/W- s-=-(j)@ @IR Br LONOFFLOCKP

Bt@ rRfW RfWOFFRUN 0- f-O .-----. L Sb R R-=- -=-ID Br@HILOYB B

J,. @ @7-1XT600EA/EAC WIRING DIAGRAM IELECIIliii I@ "HORN" switch@ Front brake switch@ Rear brake switch Tail/brake light "LIGHTS" (dimmer) switch@ Meter light@ Headlight@ "HIGH BEAM" indicator light@ "START" switch Starter relay@ Starter motor@ Battery@Fuse@ "ENGINE STOP" switch@ Starting circuit cut-off relayMain switchRectifier/regulatorA.C. magnetoPickup coilIgnitorIgnition coilSpark plugClutch switchDiode"NEUTRAL" indicator lightNeutral switchSidestand switch"REV." indicator lightFlasher relay"TURN" switch16 "TURN" indicator light1 Front flasher/position light (right)@ Rear flasher light (right)@ Rear flasher light (left)Front flasher/position light (left)@ HornCOLOR CODEB Black Gy GrayBr Brown Y YellowCh Chocolate B/W Black/WhiteDg Dark green B/Y BlackIYellowG Green Br/W Brown/WhiteL Blue G/W Green/White0 Orange G/Y GreenIYellowP Pink L/Y Blue/YellowR Red L/W Blue/WhiteSb Sky blue R/W Red/WhiteW White RIY RedIYeliow7-2ELECTRICAL COMPONENTS IElECI iii IELECTRICAL COMPONENTSWire harnessMain switchIgnition coilRectifier/RegulatorBatteryIgnitor unitIGNITION COIL:PRIMARY COIL RESISTANCE:3.4'" 4.6 Q at 20'C (6S'F)SECONDARY COIL RESISTANCE:10.4'" 15.6kQ at 20'C (6S'F)BATTERY:CAPACITY:12V SAHSPECIFIC GRAVITY:1.3207-3ELECTRICAL COMPONENTS IELEcl1ii I~ Rear brake switch2 Horn3 Neutral switch4 Sidestand switch5 Flasher relay20 Nm (2.0 mokg, 14 ftlb)17 Nm (0.7 m.kg, 5.1 ftlb) I4@27-4CHECKING OF SWITCHES IELECIIiilICHECKING OF SWITCHESNOTE: _This section is written based on a generalmodel.Check the switches for the continuity betweenthe terminals to determine correct connection.Read the following for switch inspection.SWITCH CONNECTION AS SHOWN INMANUALThe manual contains a connection chart asshown left showing the terminal connections ofthe switches (e.g., main switch, handlebarswitch, brake switch, lighting switch, etc.)The extreme left column indicates the switchpositions and the top line indicates the colors ofleads connected with the terminals in theswitch component.ONOFFLOCKpB B/W R Br L/W LlR7-5"0--0" indicates the terminals betweenwhich there is a continuity of electricity; i.e., aclosed circuit at the respective switch posi-tions.In this chart:"R and Br" and "L/W and L/R" are continuouswith the "ON" switch position."B and B/W" is continuous with the "OFF"switch position."B and B/W" is continuous with the "LOCK"switch position."B and B/W" and "R and L/R" are continuouswith the "P" switch position.CHECKING SWITCH FOR TERMINALCONNECTIONBefore checking the switch, refer to the con-nection chart as shown above and check forthe correct terminal connection (closed circuit)by the color combination.To explain how to check the switch, the mainswitch is taken for example in the following.CHECKING OF SWITCHES IREel iii I1. Disconnect the main switch coupler fromthe wire harness.Never disconnect the main switch coupler bypulling the leads. Otherwise, leads may bepulled off the terminals inside the coupler.2. Inspect whether any lead is off the terminalinside the coupler. If it is, repair it.NOTE: _If the coupler is clogged with mud or dust,blow it off by compressed air.3. Use the connection chart to check the colorcombination for continuity (a closed cir-cuit). In this example, the continuity is asfollows."R and Br" and L/W and L/R" are continu-ous with the "ON" switch position.~ B B/W R Br LlW LlRON 0 -0 0--0OFF 0 --0LOCK 0 --0p0 -0 0 0L!il Br LlRC> Replace startermotor.Commutator wear limit @:27 mm (1.06 in)7-31ELECTRICAL STARTING SYSTEM IELECI iii I1 MS1 or more 0S1S1" 1 0@X1S1- x 1kS1 +3. Measure:e Mica undercut @Out of specification ---> Scrape the mica toproper value use a hacksaw blade can beground to fit.~ __M_ic_a_u_n_d_e_rc_u_t_@_: _[6] 0.7 mm (0.027 in)NOTE: _The mica insulation of the commutator must beundercut to ensure