Professional Documents
Culture Documents
2KA-AE2
SUPPLEMENTARY
SERVICEMANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
TW200N. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
TW200T 87 SERVICE MANUAL: 2KA-ME1
TW200J 97 SUPPLEMENTARY SERVICE MANUAL: 2KA-AE1
TW200N
SUPPLEMENTARY
SERVICE MANUAL
2000 by Yamaha Motor Co., Ltd.
First Edition, November 2000
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00003
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
Designs and specifications are subject to change without notice.
@
@@
EAS00004
WARNING
CAUTION:
NOTE:
EAS00007
EAS00008
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 8 indicate the subject of each
chapter.
SPEC
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Engine
5 Carburetion
6 Chassis
7 Electrical system
8 Troubleshooting
ENG
CHAS
CARB
7
ELEC
TRBL
SHTG
T.
R.
E
J
K
B
L
M
LS
LT
G Engine oil
H Gear oil
I Molybdenum disulfide oil
J Wheel bearing grease
K Lithium soap base grease
L Molybdenum disulfide grease
New
CONTENTS
GENERAL INFORMATION ...............................................................................1
MOTORCYCLE IDENTIFICATION ...........................................................1
VEHICLE IDENTIFICATION NUMBER .................................................1
MODEL CODE ......................................................................................1
SPECIFICATIONS .............................................................................................2
GENERAL SPECIFICATIONS ..................................................................2
MAINTENANCE SPECIFICATIONS .........................................................4
ENGINE ................................................................................................4
TIGHTENING TORQUES .....................................................................6
CHASSIS ..............................................................................................7
TIGHTENING TORQUES .....................................................................8
ELECTRICAL ........................................................................................9
CABLE ROUTING ...................................................................................10
PERIODIC CHECKS AND ADJUSTMENTS ...................................................17
INTRODUCTION .....................................................................................17
PERIODIC MAINTENANCE CHART FOR EMISSION
CONTROL SYSTEM ...............................................................................17
GENERAL MAINTENANCE AND LUBRICATION CHART .....................18
ENGINE ...................................................................................................20
ADJUSTING THE THROTTLE CABLE FREE PLAY ..........................20
CHASSIS .................................................................................................22
ADJUSTING THE FRONT BRAKE .....................................................22
CHECKING THE BRAKE FLUID LEVEL ............................................23
CHECKING THE BRAKE PADS .........................................................24
CHECKING THE BRAKE HOSE .........................................................24
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...............................25
ENGINE ...........................................................................................................27
CYLINDER HEAD ...................................................................................27
CHECKING THE TIMING CHAIN TENSIONER .................................28
INSTALLING THE TIMING CHAIN TENSIONER ...............................28
AC MAGNETO ........................................................................................29
STATOR COIL ASSEMBLY AND PICKUP COIL ...............................29
AC MAGNETO ....................................................................................30
CARBURETION...............................................................................................31
CARBURETOR .......................................................................................31
CHECKING THE CARBURETOR .......................................................34
ASSEMBLING THE CARBURETOR ..................................................36
INSTALLING THE CARBURETOR .....................................................37
MEASURING AND ADJUSTING THE FUEL LEVEL ..........................38
CHASSIS .........................................................................................................39
FRONT WHEEL AND BRAKE DISC .......................................................39
REMOVING THE FRONT WHEEL .....................................................41
CHECKING THE BRAKE DISC ..........................................................41
INSTALLING THE FRONT WHEEL ....................................................43
FRONT BRAKE .......................................................................................45
FRONT BRAKE PADS ........................................................................45
REPLACING THE FRONT BRAKE PADS ..........................................46
FRONT BRAKE MASTER CYLINDER ...............................................49
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER .........51
CHECKING THE FRONT BRAKE MASTER CYLINDER ...................51
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER ..........................................................................52
FRONT BRAKE CALIPER ..................................................................54
DISASSEMBLING THE FRONT BRAKE CALIPER ............................56
CHECKING THE FRONT AND REAR BRAKE CALIPERS ................57
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS ..........................................................................................58
FRONT FORK .........................................................................................61
STEERING HEAD ...................................................................................62
INSTALLING THE BEARINGS
(RETAINER TYPE) .............................................................................64
ELECTRICAL ..................................................................................................65
ELECTRICAL COMPONENTS ...............................................................65
SWITCHES .............................................................................................66
CHECKING SWITCH CONTINUITY ...................................................66
CHECKING THE SWITCHES .................................................................67
IGNITION SYSTEM .................................................................................69
CIRCUIT DIAGRAM ............................................................................69
TROUBLESHOOTING ........................................................................70
ELECTRIC STARTING SYSTEM ............................................................74
CIRCUIT DIAGRAM ............................................................................74
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ....................75
TROUBLESHOOTING ........................................................................76
SIGNALING SYSTEM .............................................................................80
CIRCUIT DIAGRAM ............................................................................80
TROUBLESHOOTING ........................................................................81
CHECKING THE SIGNALING SYSTEM .............................................82
TW200N WIRING DIAGRAM
MOTORCYCLE IDENTIFICATION
GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
EAS00018
MODEL CODE
The model code label 1 is affixed to the
frame. This information will be needed to order
spare parts.
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model code number:
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Engine:
Engine type
Cylinder arrangement
Displacement
Bore stroke
Compression ratio
Compression pressure (standard)
Starting system
Carburetor:
Type/manufacturer
Spark plug:
Type/manufacturer
Gap
Chassis:
Frame type
Caster angle
Trail
Tire:
Type
Size (F)
Size (R)
Wear limit
TW200N
5FYA
2,090 mm (82.3 in)
820 mm (32.3 in)
1,120 mm (44.1 in)
790 mm (31.1 in)
1,325 mm (52.2 in)
265 mm (10.4 in)
Air cooled 4-stroke, SOHC
Forward inclined single cylinder
196 cm3 (11.96 cu.in)
67.0 55.7 mm (2.638 2.193 in)
9.5 : 1
900 kPa (9 kg/cm2, 128 psi)
Electric starter
MV28/TEIKEI
DR8EA (NGK), X24ESR-U (N.D.)
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Diamond
25.8
95 mm (3.74 in)
With tube
130/80-18 66P TW31
180/80-14M/C 78P TW34
<1.0 mm (0.04 in)>
GENERAL SPECIFICATIONS
Model
Basic weight:
With oil and full fuel tank
Maximum load*
Cold tire pressure:
Up to 80 kg (176 lb) load*
80 kg (176 lb) ~ Maximum load*
Off-road riding
High speed riding
Brake:
Front brake type
Operation
Rear brake type
Operation
Shock absorber:
Front shock absorber
Rear shock absorber
Bulb wattage/quantity:
Headlight
Tail/brake light
Front turn signal/position light
Rear turn signal light
Meter light
SPEC
TW200N
126 kg (278 lb)
157 kg (346 lb)
Front
125 kPa
(1.25 kg/cm2, 18 psi)
150 kPa
(1.5 kg/cm2, 22 psi)
125 kPa
(1.25 kg/cm2, 18 psi)
150 kPa
(1.5 kg/cm2, 22 psi)
Rear
125 kPa
(1.25 kg/cm2, 18 psi)
175 kPa
(1.75 kg/cm2, 25 psi)
125 kPa
(1.25 kg/cm2, 18 psi)
175 kPa
(1.75 kg/cm2, 25 psi)
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Model
TW200N
Camshaft:
Drive method
Cam cap inside diameter
Camshaft outside diameter
Shaft-to-cap clearance
Cam dimensions:
Intake:
A
B
C
C
A
Exhaust:
A
B
B
C
Camshaft runout limit
2nd ring
B
T
Oil ring
B
T
Side clearance
Top ring
2nd ring
Oil ring
Top ring
2nd ring
Barrel
B = 1.2 mm (0.047 in)
T = 2.7 mm (0.106 in)
Taper
B = 1.2 mm (0.047 in)
T = 2.7 mm (0.106 in)
Expander
B = 2.5 mm (0.098 in)
T = 2.8 mm (0.110 in)
0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
0.15 ~ 0.35 mm (0.006 ~ 0.014 in)
0.3 ~ 0.9 mm (0.012 ~ 0.035 in)
0.03 ~ 0.07 mm (0.001 ~ 0.003 in)
0.02 ~ 0.06 mm (0.001 ~ 0.002 in)
MAINTENANCE SPECIFICATIONS
Model
Carburetor:
ID mark
Main jet
Main air jet
Jet needle-clip/position
Main nozzle
Pilot jet
Pilot air jet
Pilot screw
Pilot outlet
Bypass
Valve seat
Starter jet
SPEC
TW200N
(M.J.)
(M.A.J.)
(J.N)
(M.N.)
(P.J.)
(P.A.J.)
(V.S.)
(G.S1.)
(G.S2.)
Fuel level
(above the line on the float chamber
mating surface)
(F.L.)
Float height
Engine idling speed
Vacuum pressure at idling speed
5FY10
#126
1.2
5B21-1/1
2.600
#31
0.95
1-1/2 turns out
0.8
0.7
1.6
0.6
0.8
0.5 ~ 1.5 mm (0.02 ~ 0.06 in)
SPEC
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUES
Parts to be tightened
Cam sprocket cover
Tappet cover
Timing chain tensioner
Oil filter cover
Muffler protector
Crankcase
Crankcase cover (left)
Crankcase cover (right)
Pickup coil lead holder
Pickup coil
Stator coil assembly
Thread
Part name
Qty
size
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
2
5
2
2
4
12
9
12
1
2
3
Tightening
torque
Remarks
Nm mkg ftlb
10
10
10
10
7
10
10
10
10
10
10
1.0
1.0
1.0
1.0
0.7
1.0
1.0
1.0
1.0
1.0
1.0
7.2
7.2
7.2
7.2
5.1
7.2
7.2
7.2
7.2 Apply LOCTITE
7.2 Apply LOCTITE
7.2 Apply LOCTITE
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Model
Steering system:
Steering bearing type
Drive chain:
Type/manufacturer
Number of links
Chain free play
Front brake:
Brake type
Disc outside diameter thickness
Max. deflection
Brake pad lining thickness
<Limit>
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
Rear brake:
Brake type
Drum inside diameter
<Limit>
Lining thickness
Front
<Limit>
Shoe spring free length
Brake lever and brake pedal:
Brake lever free play (at lever end)
Brake pedal free play (at pedal end)
Brake pedal position
Clutch lever free play (at lever end):
TW200N
Angular ball bearing
428HG (I)/DAIDO
121 links + joint
35 ~ 60 mm (1.38 ~ 2.36 in)
Single-disc brake
220 3.5 mm (8.66 0.14 in)
0.15 mm (0.006 in)
5.3 mm (0.21 in)
<0.8 mm (0.03 in)>
11 mm (0.43 in)
26.9 mm (1.06 in) + 22.2 mm (0.87 in)
DOT4
Drum brake (leading and trailing)
110 mm (4.33 in)
<111 mm (4.37 in)>
4 mm (0.16 in)
<2 mm (0.08 in)>
50.5 mm (1.99 in)
2 ~ 5 mm (0.08 ~ 0.20 in)
20 ~ 30 mm (0.8 ~ 1.2 in)
15 mm (0.6 in)
(Vertical height below footrest top.)
10 ~ 15 mm (0.39 ~ 0.59 in)
MAINTENANCE SPECIFICATIONS
SPEC
TIGHTENING TORQUES
Parts to be tightened
Throttle cable and carburetor
Pivot shaft and frame
Rear shock absorber and frame
Drive chain case and swingarm
Handlebar holder upper and upper bracket
Steering shaft and ring nut
Front brake master cylinder and handlebar
Front wheel hub and brake disc
Front brake caliper bracket and outer tube
Front brake caliper and caliper bracket
Brake hose union bolt
Air bleeder screw
Passenger footrest and frame
Rear fender and cover
Thread size
M6 1.0
M12 1.25
M10 1.25
M5 0.8
M8 1.25
M25 1.0
M6 1.0
M6 1.0
M10 1.25
M10 1.25
M10 1.25
M7 1.0
M8 1.25
M6 1.0
Tightening torque
Nm
mkg
ftlb
5
83
56
5
20
18
7
13
30
27
30
6
15
5
0.5
8.3
5.6
0.5
2.0
1.8
0.7
1.3
3.0
2.7
3.0
0.6
1.5
0.5
3.6
60
41
3.6
14
13
5.1
9.4
22
19
22
4.3
11
3.6
Remarks
See NOTE.
NOTE:
1. First, tighten the ring nut to approximately 38 Nm (3.8 m kg, 27 ft lb) with a torque wrench,
then loosen the ring nut completely.
2. Retighten the ring nut to specification.
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Model
C.D.I.:
Magneto model/manufacturer
Pickup coil resistance (color)
Source coil resistance (color)
C.D.I. unit-model/manufacturer
Ignition coil:
Model/manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
Charging system:
Type
Model/manufacturer
Charge coil resistance (color)
Rectifier/regulator:
Type
Model/manufacturer
No load regulated voltage
Capacity
Withstand voltage
Starter motor:
Model/manufacturer
Output
Armature coil resistance
Brush overall length
<Limit>
Brush spring pressure
<Limit>
Commutator diameter
<Limit>
Mica undercut
Flasher relay:
Type
Model/manufacturer
Self-cancelling device
Flasher frequency
Wattage
Circuit breaker:
Type
Amperage for individual circuit
Main
TW200N
F5BT/YAMAHA
656 ~ 984 at 20 C (68 F) (RW)
624 ~ 936 at 20 C (68 F) (BrG)
5LB/YAMAHA
2JN/YAMAHA
6 mm (0.24 IN) or more at 500 r/min
0.18 ~ 0.28 at 20 C (68 F)
6.3 ~ 9.5 k at 20 C (68 F)
A.C. magneto generator
5FBT/YAMAHA
0.5 ~ 0.7 at 20 C (68 F) (WW)
Semi conductor type
SH629A-12/SHINDENGEN
14.1 ~ 14.9 V
10 A
200 V
5FY/YAMAHA
0.4 kW
0.017 ~ 0.021
10 mm (0.39 in)
<3.5 mm (0.14 in)>
560 ~ 840 g (19.8 ~ 29.6 oz)
<450 g (0.98 oz)>
22 mm (0.87 in)
<21 mm (0.83 in)>
1.5 mm (0.06 in)
Full transistor
FE246BH/DENSO
No.
75 ~ 95 cycle/min
27 W 2 + 3.4 W
Fuse
20 A
CABLE ROUTING
SPEC
CABLE ROUTING
1 Throttle cable
2 Front brake light switch lead
3 Right handlebar switch lead
4 Clutch cable
5 Left handlebar switch lead
6 Clutch switch lead
7 Front turn signal/position
light lead (left)
8 Main switch lead
10
CABLE ROUTING
1 Clutch cable
2 Left handlebar switch lead
3 Clutch switch lead
4 Resonator hose
5 Main switch lead
6 Rectifier/regulator lead
7 Fuel hose
8 Brake hose
9 Speedometer cable
0 Horn lead
SPEC
Fasten the resonator hose with a plastic band between the resonator
hose protectors so that the fastener does not squeeze the hose.
Fasten the resonator hose with a plastic band in front of the resonator
hose protector.
Fasten the rectifier/regulator lead and resonator hose with a plastic
band between the resonator hose protectors so that the fastener does
not squeeze the hose.
Fasten the brake hose with a plastic locking tie to the brake hose
grommet.
11
CABLE ROUTING
1 Sidestand switch lead
2 Crankcase breather hose
3 Battery negative terminal
4 Carburetor air vent hose
5 Carburetor overflow hose
6 AC magneto lead
7 Starter motor lead
8 Neutral switch lead
SPEC
Fasten the AC magneto leads with a plastic locking tie to the frame at
the section where the frame starts to curve.
Fasten the carburetor air vent hose, carburetor overflow hose, and
neutral switch lead with a plastic clip.
12
CABLE ROUTING
1 Ignition coil
2 Throttle cable
3 Horn lead
4 Spark plug
5 Starter motor lead
SPEC
Fasten the wire harness, right handlebar switch lead, front brake light
switch lead, clutch switch lead, main switch lead, and throttle cable
with a plastic band.
Fasten the wire harness, right handlebar switch lead, front brake light
switch lead, clutch switch lead, main switch lead, and resonator hose
with a plastic band.
Fasten the throttle cable with a plastic locking tie through the hole in
the frame bracket.
Fasten the wire harness, right handlebar switch lead, front brake light
switch lead, clutch switch lead, main switch lead, resonator hose, ignition coil lead, ground lead, and horn lead with a plastic band.
13
CABLE ROUTING
1 Diode
2 Battery positive lead
3 Starter relay
4 Starter motor lead
5 CDI unit
6 Wire harness
7 Turn signal relay
SPEC
Fasten the wire harness with a plastic locking tie at the section just before the
leads split.
Pass the battery breather hose underneath the battery positive lead.
Pass the rear brake light switch lead in front of the frame so that it is not
squeezed by the side cover and frame.
Fasten the rear brake light switch lead and turn signal relay lead with a plastic
locking tie.
Face the rear brake light switch lead to the rear of the frame.
Pass the battery breather hose through the hose guide.
Pass the battery breather hose through the hole in the electrical components box.
Fasten the wire harness and diode with a plastic locking tie.
14
CABLE ROUTING
1 Clutch switch lead
2 Clutch cable
3 Brake hose
4 Throttle cable
5 Front brake light switch lead
6 Right handlebar switch lead
7 Starter motor lead
8 AC magneto lead
9 Rectifier/regulator
0 Battery negative lead
A Neutral switch lead
SPEC
15
CABLE ROUTING
1 Battery positive lead
2 Rear turn signal light lead (right)
3 Tail/brake light lead
4 Rear turn signal light lead (left)
5 Sidestand switch lead
6 Battery negative lead
7 AC magneto lead
8 Neutral switch lead
9 Starter motor lead
SPEC
Fasten the wire harness and rear turn signal light lead (right)
with a plastic locking tie at the section behind the hook.
Fasten the rear turn signal light lead (left) with a plastic locking
tie.
16
CHK
ADJ
ITEM
ROUTINE
1 * Valve clearance
INITIAL
ODOMETER READINGS
1,000 km or
1 month
(600 mi)
Check condition.
Adjust gap and clean.
Replace at 11,000 km (or 12 months) and
thereafter every 10,000 km (or 12 months).
Replace
Replace
3 * Fuel line
4 * Exhaust system
5 * Idle speed
Spark plug
*: Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
From 26,000 km (16,000 mi) or 30 months, repeat the maintenance intervals starting from 6,000 km
(4,000 mi) or 6 months.
17
CHK
ADJ
ITEM
Engine oil
ROUTINE
Warm-up engine
before draining.
TYPE
INITIAL
ODOMETER READINGS
1,000 km or
1 month
(600 mi)
1) Yamalube 4
(20 W 40) or
SAE 20 W 40 type
SE/SF motor oil.
2) Yamalube 4
(10 W 30) or
SAE 10 W 30 type
SE/SF motor oil.
2 * Oil filter/strainer
3 * Air filter
Wet type filter must Yamaha foam air filter oil or other quality
be washed and
air filter oil
damped with oil.
4 * Brake system
5 * Clutch
Drive chain
8 *
10
Lithium-soap-based
grease (all-purpose
grease)
Lithium-soap-based
grease (all-purpose
grease)
Lubricate.
Apply chain lube
lightly
Lithium-soap-based
grease (all-purpose
grease)
11 * Sidestand pivots
Check operation
and lubricate.
Apply chain lube
lightly.
Lithium-soap-based
grease (all-purpose
grease)
12 * Front fork
Check operation
and leakage.
13 * Steering bearings
Check bearings
assembly for
Medium weight
looseness.
wheel bearing
Moderately repack
grease.
every 16,000 km
(10,000 mi)
Repack
14 * Wheel bearings
18
15
ITEM
Battery
16 * Sidestand switch
ROUTINE
TYPE
Check specific
gravity.
Check that the
breather pipe is
working properly.
Correct if necessary.
CHK
ADJ
INITIAL
ODOMETER READINGS
1,000 km or
1 month
(600 mi)
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
1. The air filter element needs more frequent service if you are riding in unusually wet or dusty
areas.
2. Hydraulic brake system
Replace the brake fluid after disassembling the master cylinder or caliper cylinder.
Check the brake fluid level and add fluid as required.
Replace the master cylinder and caliper cylinder oil seals every two years.
Replace the brake hoses every four years or if cracked or damaged.
19
CHK
ADJ
ENGINE
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play,
the engine idling speed should be adjusted
properly.
1. Measure:
throttle cable free play a
Out of specification Adjust.
Throttle cable free play
(at the flange of the throttle grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
throttle cable free play
Carburetor side
a. Loosen the locknut 1.
b. Turn the adjusting nut 2 in direction a or
b until the specified throttle cable free play
is obtained.
Direction a
Direction b
20
CHK
ADJ
Handlebar side
a. Slide back the rubber cover 3.
b. Loosen the locknut 4.
c. Turn the adjusting nut 5 in direction c or
d until the specified throttle cable free play
is obtained.
Direction c
Direction d
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
21
CHK
ADJ
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
brake lever free play a
Out of specification Adjust.
Brake lever free play
(at the end of the brake lever)
2 ~ 5 mm (0.08 ~ 0.20 in)
2. Adjust:
brake lever free play
Direction b
WARNING
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.
CAUTION:
After adjusting the brake lever free play,
make sure there is no brake drag.
22
CHK
ADJ
2. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Recommended brake fluid
DOT 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 brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
23
CHK
ADJ
24
CHK
ADJ
WARNING
Bleed the hydraulic brake system whenever:
the brake system was disassembled,
a brake hose was loosened, disconnected
or replaced,
the brake fluid level is very low,
brake operation is faulty.
NOTE:
Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
When bleeding the hydraulic brake system,
make sure that there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably lengthening the bleeding procedure.
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 hose have disappeared.
1. Bleed:
hydraulic brake system
25
CHK
ADJ
T.
Bleed screw
6 Nm (0.6 m kg, 4.3 ft lb)
R.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
26
CYLINDER HEAD
ENG
ENGINE
CYLINDER HEAD
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the cylinder head
Carburetor
Fuel tank
Exhaust pipe
Resonator hose
Carburetor joint
Timing chain tensioner cap bolt
Timing chain tensioner
Gasket
Camshaft sprocket cover/O-ring
Camshaft sprocket
Cylinder head
Dowel pin
Gasket
Qty
Remarks
Remove the parts in the order listed.
Refer to CARBURETOR.
1
1
1
1
1
1/1
1
1
3
1
Disconnect.
27
CYLINDER HEAD
ENG
WARNING
Always use a new gasket.
New
4
T.
R.
New
3
2
28
AC MAGNETO
ENG
AC MAGNETO
STATOR COIL ASSEMBLY AND PICKUP COIL
T.
R.
1
LT
LT
2
LT
LT
T.
R.
Order
1
2
3
4
Job/Part
Removing the stator coil assembly
and pickup coil
Engine oil
Crankcase cover (left)
Lead holder
Pickup coil bracket
Pickup coil
Stator coil assembly
Qty
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
1
For installation, reverse the removal
procedure.
29
AC MAGNETO
ENG
AC MAGNETO
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the AC magneto
AC magneto
Starter idle gear shaft/collar
Starter idle gear
Woodruff key
Starter wheel gear
Washer
Roller
Spring cap
Spring
Starter clutch
Qty
Remarks
Remove the parts in the order listed.
1
1/1
1
1
1
1
3
3
3
1
For installation, reverse the removal
procedure.
30
CARBURETOR
CARB
CARBURETION
CARBURETOR
2
3
4
Order
1
2
3
4
Job/Part
Removing the carburetor
Seat
Side cover
Fuel tank
Throttle cable
Clamp (carburetor joint)
Clamp (air filter joint)
Carburetor assembly
Qty
Remarks
Remove the parts in the order listed.
2
1
1
1
For installation, reverse the removal
procedure.
31
CARBURETOR
CARB
New
9
C
B
0
7
1
8
H
(4)
6
G
E
Order
1
2
3
4
5
6
7
8
9
Job/Part
Disassembling the carburetor
Starter plunger
Vacuum chamber cover/spring
Jet needle holder
Piston valve
Jet needle kit
Coasting enricher cover/spring
Coasting enricher
Air vent hose/joint
Throttle stop screw assembly
Qty
1
1/1
1
1
1
1/1
1
1/1
1
32
New
Remarks
Remove the parts in the order listed.
CARBURETOR
CARB
New
9
C
B
0
7
1
8
H
(4)
6
G
E
Order
0
A
B
C
D
E
F
G
H
Job/Part
Float chamber/gasket
Float pin
Float
Needle valve
Valve seat set
Main jet
Pilot jet
Main jet nozzle
Pilot screw
Qty
1/1
1
1
1
1
1
1
1
1
New
Remarks
Refer to ASSEMBLING THE CARBURETOR.
33
CARBURETOR
CARB
2. Check:
fuel passages
Obstruction Clean.
3. Check:
float chamber body
Dirt Clean.
4. Check:
float chamber rubber gasket 1
Cracks/damage/wear Replace.
5. Check:
float
Damage Replace.
34
CARBURETOR
CARB
6. Check:
needle valve 1
needle valve seat 2
Damage/obstruction/wear Replace the
needle valve, needle valve seat and O-ring
as a set.
7. Check:
O-ring 3
Damage/wear Replace the needle valve,
needle valve seat and O-ring as a set.
8. Check:
piston valve 1
Damage/scratches/wear Replace.
piston valve diaphragm 2
Cracks/tears Replace.
9.
Check:
vacuum chamber cover 1
piston valve spring 2
jet needle holder 3
jet needle spring 4
Cracks/damage Replace.
10.Check:
jet needle kit 1
main jet 2
main jet holder 3
pilot jet 4
pilot screw 5
starter plunger 6
Bends/damage/wear Replace.
Obstruction Clean.
Blow out the jets with compressed air.
11.Check:
piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness Replace the piston valve.
35
CARBURETOR
CARB
12.Check:
caosting enricher 1
Cracks/tears Replace.
caosting enricher cover 2
caosting enricher spring 3
Cracks/damage Replace.
13.Check:
fuel hoses
Cracks/damage/wear Replace.
Obstruction Clean.
Blow out the hoses with compressed air.
14.Check:
hose joint
Cracks/damage/wear Replace.
Obstruction Clean.
Blow out to the joint with compressed air.
CAUTION:
Before assembling the carburetor, wash
all of the parts in a petroleum-based solvent.
Always use a new gasket.
1. Install:
pilot screw 1
Pilot screw setting
1-1/2 turns out
2.
Install:
needle valve 1
float 2
float pin 3
NOTE:
Install the float pin from the side opposite the
arrow a.
36
CARBURETOR
CARB
3. Measure:
float height a
Out of specification Adjust.
Float height (F.H.):
10 ~ 11 mm (0.39 ~ 0.43 in)
THE
ENGINE
2. Adjust:
throttle cable free play
Throttle cable free play
(at the flange of the throttle grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
Refer to ADJUSTING THE THROTTLE
CABLE FREE PLAY in chapter 3.
37
CARBURETOR
CARB
2. Adjust:
fuel level
38
CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC
1
7
8
T.
R.
T.
R.
(6)
LS
LT
LT
Order
Job/Part
Qty
Remarks
Removing the front wheel and brake
Remove the parts in the order listed.
disc
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
1
2
3
4
5
6
7
8
Speedometer cable
Axle nut
Washer
Front wheel axle
Front wheel
Speedometer gear unit
Collar/dust seal
Brake disc
1
1
1
1
1
1
1/1
1
39
Order
1
2
3
Job/Part
Disassembling the front wheel
Oil seal
Wheel bearing (left and right)
Spacer
Qty
CHAS
Remarks
Remove the parts in the order listed.
1
2
1
For assembly, reverse the disassembly
procedure.
40
CHAS
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
2.
3.
Loosen:
axle nut
Elevate:
front wheel
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
4.
Remove:
axle nut
washer
front wheel axle
front wheel
NOTE:
Do not squeeze the brake lever when removing the front wheel.
41
CHAS
2. Measure:
brake disc deflection
Out of specification Correct the brake
disc deflection or replace the brake disc.
Max. brake disc deflection
0.15 mm (0.006 in)
3. Measure:
brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
Min. brake disc thickness
Standard: 3.5mm (0.14 in)
Limit: 3.0 mm (0.12 in)
4. Adjust:
brake disc deflection
T.
R.
42
CHAS
T.
R.
2. Install:
brake disc
NOTE:
Apply locking agent (LOCTITE) to the
threads of the brake disc bolts.
Tighten the brake disc bolts in stages and in
a crisscross pattern.
3. Install:
speedometer gear unit
NOTE:
Make sure the projections a in the wheel hub
are meshed with the slots b in the speedometer gear unit.
4. Install:
front wheel
NOTE:
Make sure the projection a (torque stopper) in
the front fork is placed b in the speedometer
gear unit as shown.
43
CHAS
5. Tighten:
wheel axle nut 1
T.
R.
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds
smoothly.
44
FRONT BRAKE
CHAS
FRONT BRAKE
FRONT BRAKE PADS
LS
1
T.
R.
Order
1
2
3
4
Job/Part
Removing the front brake pads
Retaining bolt (lower)
Brake caliper
Brake pad
Brake pad spring
Qty
Remarks
Remove the parts in the order listed.
1
1
2
2
For installation, reverse the removal
procedure.
45
FRONT BRAKE
CHAS
CAUTION:
Disc brake components rarely require disassembly.
Therefore, always follow these preventive
measures:
Never disassemble brake components
unless absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
Never use solvents on internal brake
components.
Use only clean or new brake fluid for
cleaning brake components.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
First aid for brake fluid entering the eyes:
Flush with water for 15 minutes and get
immediate medical attention.
1. Remove:
retaining bolt (lower) 1
NOTE:
Move the brake caliper 2 upward.
46
FRONT BRAKE
CHAS
2. Remove:
brake pads 1
brake pad springs
3. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.8 mm (0.03 in)
4. Install:
brake pad springs
brake pads
NOTE:
Always install new brake pads and a brake pad
springs as a set.
1
2
T.
Bleed screw
6 Nm (0.6 m kg, 4.3 ft lb)
R.
47
FRONT BRAKE
CHAS
5. Install:
retaining bolt (lower)
T.
R.
6. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL.
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM.
48
FRONT BRAKE
CHAS
T.
R.
7
LS
1
9
New 5
2
3
6
LS
T.
R.
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the front brake master
cylinder
Brake fluid
Rear view mirror (right)
Brake lever/spring
Front brake light switch
Union bolt
Copper washer
Brake hose
Brake master cylinder holder
Brake master cylinder reservoir cap
Brake master cylinder assembly
Qty
Remarks
Remove the parts in the order listed.
Drain.
1
1/1
1
1
2
1
1
1
1
For installation, reverse the removal
procedure.
49
CHAS
FRONT BRAKE
2
New 3
1
Order
1
2
3
4
5
Job/Part
Disassembling the front brake master cylinder
Brake master cylinder reservoir diaphragm
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder
Qty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
50
FRONT BRAKE
CHAS
2
3
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
2. Check:
brake master cylinder kit
Damage/scratches/wear Replace.
3. Check:
brake master cylinder reservoir 1
Cracks/damage Replace.
brake master cylinder reservoir diaphragm
2
Damage/wear Replace.
51
FRONT BRAKE
CHAS
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake
components.
R.
NOTE:
Install the brake master cylinder holder with
the UP mark facing up.
Align the end of the brake master cylinder
holder with the punch mark a in the right
handlebar.
First, tighten the upper bolt, then the lower
bolt.
Install:
copper washers New
brake hose
30 Nm (3.0 m kg, 22 ft lb)
union bolt
T.
R.
2.
WARNING
4510
52
FRONT BRAKE
CHAS
3. Fill:
brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 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 brake fluid reservoir. Water
will significantly 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
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM.
5. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL.
6. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM.
53
FRONT BRAKE
CHAS
2 New
3
1
T.
R.
LS
4
T.
R.
4
T.
R.
Order
1
2
3
4
5
Job/Part
Removing the front brake calipers
Brake fluid
Union bolt
Copper washer
Brake hose
Retaining bolt
Brake caliper
Qty
1
2
1
2
1
Remarks
Remove the parts in the order listed.
Drain.
Loosen.
For installation, reverse the removal
procedure.
54
FRONT BRAKE
Order
1
2
3
4
5
6
7
CHAS
Job/Part
Qty
Remarks
Disassembling the front brake caliRemove the parts in the order listed.
pers
Retaining bolt
2
Brake caliper bracket
1
Brake pad
2
Brake pad spring
2
Brake caliper piston
2
Brake caliper piston seal
4
Bleed screw
1
For assembly, reverse the disassembly
procedure.
55
FRONT BRAKE
CHAS
3
1
1.
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
WARNING
Cover the brake caliper pistons with a
rag. Be careful not to get injured when the
pistons are expelled from the brake caliper.
Never try to pry out the brake caliper pistons.
b. Remove the brake caliper piston seals.
56
FRONT BRAKE
CHAS
Brake pads
If necessary
Piston seals
Brake hoses
Brake fluid
1. Check:
brake caliper pistons 1
Rust/scratches/wear Replace the brake
caliper.
brake caliper cylinders 2
Scratches/wear Replace the brake caliper.
brake calipers
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.
2. Check:
brake caliper bracket 1
Cracks/damage Replace.
57
FRONT BRAKE
CHAS
WARNING
Before installation, all internal brake components 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 disassembled, replace the brake caliper piston
seals.
1. Install:
brake caliper bracket 1
T.
R.
brake caliper 2
NOTE:
Temporarily tighten the retaining bolts.
1
Install:
copper washers New
brake hose 1
30 Nm (3.0 m kg, 22 ft lb)
union bolt 2
T.
R.
2.
WARNING
CAUTION:
When installing the brake hose onto the
brake caliper, make sure that the brake
pipe a touches the projection b on the
brake caliper.
58
FRONT BRAKE
Remove:
retaining bolt (lower)
Install:
brake pad springs
brake pads
27 Nm (2.7 m kg, 19 ft lb)
brake caliper
T.
R.
3.
4.
CHAS
5. Fill:
Brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT4
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 brake fluid reservoir. Water
will significantly 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. Bleed:
brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM.
59
FRONT BRAKE
CHAS
7. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL.
8. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM.
60
FRONT FORK
CHAS
FRONT FORK
T.
R.
T.
R.
T.
(4)
R.
T.
R.
Order
Job/Part
Removing the front fork legs
Qty
Front wheel
1
2
3
4
5
6
7
1
1
1
1
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to FRONT WHEEL AND BRAKE
DISC.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal
procedure.
61
STEERING HEAD
CHAS
STEERING HEAD
T.
R.
3
T.
R.
1
4
LS
6
7
8
LS
9
12
10
11
LS
13
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Qty
Remarks
Removing the lower bracket
Remove the parts in the order listed.
Front fork legs
Headlight stay assembly/meter assembly
Main switch coupler
1
Disconnect.
Steering stem bolt
1
Upper bracket
1
Ring nut
1
Lower bracket
1
Bearing cover
1
Bearing inner race
1
Upper bearing ball assembly
1
Lower bearing ball assembly
1
Bearing inner race
1
Rubber washer
1
62
STEERING HEAD
CHAS
T.
R.
3
T.
R.
1
4
LS
6
7
8
LS
9
12
10
11
LS
13
Order
12
13
Job/Part
Bearing outer race
Bearing outer race
Qty
1
1
Remarks
63
STEERING HEAD
CHAS
64
ELECTRICAL COMPONENTS
ELECTRICAL
ELECTRICAL COMPONENTS
1 Wire harness
2 Main switch
3 Front brake light switch
4 Main fuse
5 Starter relay
6 Neutral relay
7 Diode
8 CDI unit
9 Clutch switch
0 Battery
A Rectifier/regulator
B Turn signal relay
C Sidestand switch
D Neutral switch
E Pickup coil
F Stator coil assembly
G Rear brake light switch
H Horn
I Ignition coil
65
ELEC
SWITCHES
ELEC
SWITCHES
CAUTION:
Never insert the tester probes into the coupler terminal slots 1. Always insert the
probes from the opposite end of the coupler, taking care not to loosen or damage
the leads.
Pocket tester
YU-03112
R Br/L
L/Y L/B
NOTE:
Before checking for continuity, set the pocket
tester to 0 and to the 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:
66
ELEC
2
P
Br/W Ch
P B
Dg L/B
3
Dg Br/W Ch
FREE
PUSH
NL
Br
LO
HI
OFF
NR
(BLACK)
7
L/W B
OFF
ON
RUN
OFF
ON
R/W R/W
L/W B
(RED)
B
B
B
B
(BLACK)
0
B
Sb
A
B
B
B
(BLUE)
67
R/W R/W
OFF
68
ELEC
Sb
Sb
R
R
6
8
69
9
ON
OFF
R/W
Br/W Ch
P B
Dg L/B
(BLACK)
Ch Br/W
B P
Br Dg
L/W
R/W
R/W
L/W
Dg
Dg
Dg
NR
OFF
Br/W
Br
(BLACK)
B/W
NL
FREE
Br
RUN
OFF
PUSH
R/W R/W
L/W B
(BLACK)
B/W B
L/W R/W
R/W
Br
Br R/W
(BLACK)
Br
Br
L/Y
R Br/L
L/Y L/B
Ch
Ch
RQ
Ch
L/B
LO
HI
(RED)
Br R
L/B L/Y
Br
L/B
L/B
B/W
L/W
L/B
L/W
L/B
L/W
G
B
(BLUE)
(BLUE)
L/B
Br
G/Y
L/W
L/W
Br
B
B
Sb
B/W
(BLACK) (BLACK)
L/B
B/W
B
B
B
B
(RED)
Sb B/W
Y L
G/Y
Br
Br
G/Y
Br L/W
Br Sb
B
Br/W Br
Br/W
Br
Br
Sb
Sb Br
B
Dg Ch
O B W/R W/L
B/R L/Y G/W
O
B
ELEC
Br/W
Br/W
OFF
ON
L/Y
B/R
W/L
G/W
B/R
G/W
Sb
W/R
(GRAY)
W/L
(GRAY)
W/R
W/L W/R
G/W B/R
Br
1 AC magneto
0 Engine stop switch
A Main switch
D Sidestand switch
F CDI unit
G Ignition coil
H Spark plug
W W W
W W W
W W
W W
IGNITION SYSTEM
+
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
TROUBLESHOOTING
ELEC
1. Spark plug
Check:
1. spark plug
2. ignition spark gap
3. spark plug cap resistance
4. ignition coil resistance
5. pickup coil resistance
6. source coil resistance
7. main switch
8. engine stop switch
9. sidestand switch
10.wiring (of the entire ignition system)
NOTE:
Before troubleshooting, remove the following
part(s):
1) rider seat
2) fuel tank
3) side cover (left and right)
Troubleshoot with the following special
tool(s).
Dynamic spark tester
YM-34487
Pocket tester
YU-03112
70
NO
Re-gap or replace
the spark plug.
IGNITION SYSTEM
ELEC
YES
Min. ignition spark gap
6 mm (0.24 in)
Is there a spark and is the spark gap within
specification?
NO
YES
The ignition system
is OK.
71
Replace the
plug cap.
spark
ELEC
IGNITION SYSTEM
NO
Replace the pickup
coil.
YES
NO
Replace the ignition
coil.
72
IGNITION SYSTEM
ELEC
NO
Replace the right
handlebar switch.
EB802414
9. Sidestand switch
Check the sidestand switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the sidestand switch OK?
YES
NO
side-
EB802416
10.Wiring
YES
YES
EB802411
7. Main switch
Properly connect or
repair the ignition
systems wiring.
YES
Replace
switch.
the
main
73
Sb
Sb
R
R
6
8
74
9
ON
OFF
R/W
Br/W Ch
P B
Dg L/B
(BLACK)
Ch Br/W
B P
Br Dg
L/W
R/W
R/W
L/W
Dg
Dg
Dg
NR
OFF
Br/W
Br
(BLACK)
B/W
NL
FREE
Br
RUN
OFF
PUSH
R/W R/W
L/W B
(BLACK)
B/W B
L/W R/W
R/W
Br
Br R/W
(BLACK)
Br
Br
L/Y
R Br/L
L/Y L/B
Ch
Ch
RQ
Ch
L/B
LO
HI
(RED)
Br R
L/B L/Y
Br
L/B
L/B
B/W
L/W
L/B
L/W
L/B
L/W
G
B
(BLUE)
(BLUE)
L/B
Br
G/Y
L/W
L/W
Br
B
B
Sb
B/W
(BLACK) (BLACK)
L/B
B/W
B
B
B
B
(RED)
Sb B/W
Y L
G/Y
Br
Br
G/Y
Br L/W
Br Sb
B
Br/W Br
Br/W
Br
Br
Sb
Sb Br
B
Dg Ch
O B W/R W/L
B/R L/Y G/W
O
B
ELEC
Br/W
Br/W
OFF
ON
L/Y
B/R
W/L
G/W
B/R
G/W
Sb
W/R
(GRAY)
W/L
(GRAY)
W/R
W/L W/R
G/W B/R
Br
2 Neutral switch
4 Battery
5 Main fuse
6 Starter relay
7 Starter motor
9 Start switch
0 Engine stop switch
A Main switch
B Diode
C Clutch switch
D Sidestand switch
E Neutral relay
W W W
W W W
W W
W W
CIRCUIT DIAGRAM
ELEC
75
ELEC
2. Battery
Check the battery fluid level, battery terminals and specific gravity.
Check:
1. main fuse
2. battery
3. starter motor
4. neutral relay
5. diode
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10.sidestand switch
11.clutch switch
12.start switch
13.wiring (of the entire starting system)
Specific gravity
1.280 at 20 C (68 F)
Is the battery OK?
NO
YES
NOTE:
Before troubleshooting, remove the following
part(s):
1) rider seat
2) fuel tank
3) side cover (left and right)
Troubleshoot with the following special
tool(s).
3. Starter motor
Connect the battery positive terminal 1 and
starter motor lead 2 with a jumper lead 3.
Pocket tester
YU-03112
EB802400
WARNING
1. Main fuse
Check the main fuse for continuity.
Is the main fuse OK?
YES
NO
Replace the fuse.
NO
Repair or replace the
starter motor.
76
ELEC
4. Neutral relay
5. Diode
NO
YES
NO
Replace the diode.
77
ELEC
6. Starter relay
NO
Replace the right
handlebar switch.
EB802413
9. Neutral switch
Check the neutral switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
EB802414
YES
10.Sidestand switch
Check the sidestand switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the sidestand switch OK?
YES
NO
Replace the
stand switch.
EB802411
7. Main switch
Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the main switch OK?
EB803405
11.Clutch switch
Check the clutch switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the clutch switch OK?
NO
YES
Replace
switch.
the
side-
main
YES
NO
Replace the clutch
switch.
78
NO
Replace the right
handlebar switch.
EB803408
13.Wiring
Check the entire starting systems wiring.
Refer to CIRCUIT DIAGRAM.
Is the starting systems wiring properly connected and without defects?
NO
Properly connect or
repair the starting
systems wiring.
YES
The starting system
circuit is OK.
79
ELEC
Sb
Sb
R
R
6
8
80
9
ON
OFF
R/W
Br/W Ch
P B
Dg L/B
(BLACK)
Ch Br/W
B P
Br Dg
L/W
R/W
R/W
L/W
Dg
Dg
Dg
NR
OFF
Br/W
Br
(BLACK)
B/W
NL
FREE
Br
RUN
OFF
PUSH
R/W R/W
L/W B
(BLACK)
B/W B
L/W R/W
R/W
Br
Br R/W
(BLACK)
Br
Br
L/Y
R Br/L
L/Y L/B
Ch
Ch
RQ
Ch
L/B
LO
HI
(RED)
Br R
L/B L/Y
Br
L/B
L/B
B/W
L/W
L/B
L/W
L/B
L/W
G
B
(BLUE)
(BLUE)
L/B
Br
G/Y
L/W
L/W
Br
B
B
Sb
B/W
(BLACK) (BLACK)
L/B
B/W
B
B
B
B
(RED)
Sb B/W
Y L
G/Y
Br
Br
G/Y
Br L/W
Br Sb
B
Br/W Br
Br/W
Br
Br
Sb
Sb Br
B
Dg Ch
O B W/R W/L
B/R L/Y G/W
O
B
ELEC
Br/W
Br/W
OFF
ON
L/Y
B/R
W/L
G/W
B/R
G/W
Sb
W/R
(GRAY)
W/L
(GRAY)
W/R
W/L W/R
G/W B/R
Br
2 Neutral switch
4 Battery
5 Main fuse
A Main switch
J Neutral indicator light
K Turn signal indicator light
M Rear brake light switch
N Front brake light switch
O Tail/brake light
Q Rear turn signal light
R Front turn signal/position light
T Horn switch
U Turn signal switch
W Horn
X Turn signal relay
W W W
W W W
W W
W W
SIGNALING SYSTEM
+
SIGNALING SYSTEM
CIRCUIT DIAGRAM
SIGNALING SYSTEM
TROUBLESHOOTING
ELEC
2. Battery
Check the battery fluid level, battery terminals and specific gravity.
Specific gravity
1.280 at 20 C (68 F)
Check:
1. main fuse
2. battery
3. main switch
4. wiring (of the entire signaling system)
YES
NOTE:
Before troubleshooting, remove the following
part(s):
1) seats
2) fuel tank
3) side cover (left and right)
4) headlight cover
5) rear fender
Troubleshoot with the following special tool
(s).
3. Main switch
Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the main switch OK?
NO
YES
Pocket tester
YU-03112
Replace
switch.
EB802400
1. Main fuse
the
main
EB806400
4. Wiring
NO
81
NO
Properly connect or
repair the signaling
systems wiring.
SIGNALING SYSTEM
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
3. Horn
Disconnect the pink connector at the horn
terminal.
Connect a jumper lead 1 to the horn terminal and ground the jumper lead.
Set the main switch to ON.
Push the horn switch.
Does the horn sound?
1. Horn switch
Check the horn switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the horn switch OK?
NO
YES
ELEC
NO
YES
The horn is OK.
4. Voltage
Connect the pocket tester (DC 20 V) to the
horn connector at the pink terminal as
shown.
NO
The wiring circuit
from the main switch
to the horn connectors is faulty and
must be repaired.
82
NO
Replace the horn.
SIGNALING SYSTEM
ELEC
3. Voltage
NO
NO
Replace the brake
light switch.
YES
This circuit is OK.
NO
Replace the turn signal light bulb, socket
or both.
83
SIGNALING SYSTEM
ELEC
4. Voltage
YES
NO
NO
Replace the left handlebar switch.
NO
The wiring circuit
from the main switch
to the turn signal
relay coupler (turn
signal relay side) is
faulty and must be
repaired.
84
ELEC
SIGNALING SYSTEM
5. Voltage
6. Voltage
NO
The turn signal relay
is faulty and must be
replaced.
85
NO
The wiring circuit
from the turn signal
switch to the turn signal light connectors
is faulty and must be
repaired.
SIGNALING SYSTEM
ELEC
3. Voltage
NO
Replace the meter
assembly.
2. Neutral switch
Check the neutral switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the neutral switch OK?
YES
NO
YES
NO
86
W W
W W
W/L W/R
Br
G/W B/R
(GRAY)
O B W/R W/L
B/R L/Y G/W
(GRAY)
W/R
W/R
W/L
W/L
B/R
B/R
G/W
Sb
G/W
Sb
5
R
Br
OFF
ON
R/W
4
B
Br R
L/B L/Y
(RED)
(RED)
R/W
R Br/L
L/Y L/B
B/W B
L/W R/W
L/W
L/W
OFF
OFF
ON
RUN
Br
L/W
B/W
L/W
L/W
R/W
R/W
B
L/B
B
L/B
R/W R/W
L/W B
L/B
B
B
L/W
L/B
L/B
Br
L/B
L/W
B
B
L/B
B/W
(BLUE)
(BLUE)
Sb B/W
Br L/W
Sb
B/W
B/W
I
L
J
Sb
Br
Br
Br/W
Br
Br Sb
B
Br/W Br
Br/W
Br
Br
Sb Br
B
Dg Ch
(BLACK)
B
Br/W
B
P
(BLACK)
Br
LO
HI
NL
PUSH
Br
V
L
FREE
Ch Br/W
B P
Br Dg
Br
Br/W
OFF
Br/W Ch
P B
Dg L/B
Br
G/Y
NR
R
(BLACK)
B
B
(BLACK) (BLACK)
G/Y
Dg
G/Y
Ch
G
Dg
Dg
Ch
Ch
Y L
G
Y
RQ
G
Y
COLOR CODE
B ............black
Br ...........brown
Ch ..........chocolate
Dg ..........dark green
G ............green
L.............blue
O ........... orange
P............ pink
R............ red
Sb.......... sky blue
W........... white
Y............ yellow
B/R.........black/red
B/W........brake/white
Br/W.......brown/white
G/W .......green/white
G/Y ........green/yellow
L/B .........blue/black
G
H
L/Y
O
B
R
Br R/W
(BLACK)
W W W
L/Y
Sb
W W W
1 AC magneto
2 Neutral switch
3 Rectifier/regulator
4 Battery
5 Main fuse
6 Starter relay
7 Starter motor
8 Right handlebar switch
9 Start switch
0 Engine stop switch
A Main switch
B Diode
C Clutch switch
D Sidestand switch
E Neutral relay
F CDI unit
G Ignition coil
H Spark plug
I Meter light
J Neutral indicator light
K Turn signal indicator light
L High beam indicator light
M Rear brake light switch
N Front brake light switch
O Tail/brake light
P Headlight
Q Rear turn signal light
R Front turn signal/position light
S Left handlebar switch
T Horn switch
U Turn signal switch
V Dimmer switch
W Horn
X Turn signal relay