Tightening torque Nm mSkg 2.0 3.0 11.0 1.8 2.0 2.3 1.0 3.0 0.9 1.0 0.7 0.8 0.7 4.0 3.0 4.0 4.0 4.0 7.4 1.3 0.7 3.0 6.2 6.2 10.0 0.7 10.0 7.0 0.7 2.3 0.7 0.7 2.6 2.6 0.6 2.3 0.7 0.7 0.7 0.7

See NOTE

Part to be tightened g Passenger footrest and frame Sidestand bracket and frame Sidestand and sidestand bracket Sidestand switch Brake pedal/footrest and frame Front wheel axle Front wheel axle pinch bolt Brake caliper Brake disc and front wheel Caliper bleed screw Rear wheel axle nut Tension bar and swingarm Tension bar and brake shoe plate Brake cam shaft lever Clutch hub and damper Final gear case (housing cover) Bearing housing (final gear case) Bearing housing (final gear case) Bearing retainer (final drive pinion gear) Oil filter bolt (final gear) Oil drain bolt (final gear) Housing cover
Thread size M8 M10 M10 M5 M6 M16 M8 M10 M8 M7 M14 M8 M8 M6 M10 M10 M8 M10 M65 M14 M14 M10
Tightening torque Nm mSkg 2.6 6.4 5.6 0.4 6.4 5.9 2.0 4.0 2.3 0.6 9.7 2.0 2.0 1.0 6.2 1.8 2.3 2.3 11.5 2.3 2.3 4.2

LH thread

NOTE: 1. First, tighten the ring nut approximately 52 Nm (5.2 mSkg) by using the torque wrench, then loosen the ring nut completely. 2. Retighten the ring nut to specification.
ELECTRICAL Item Voltage: Ignition system: Ignition timing (B.T.D.C.) Advancer type T.C.I.: Pickup coil resistance/color T.C.I. unit model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Spark plug cap: Type Resistance Charging system: Type Model/manufacturer Nominal output Stator coil resistance/color Voltage regulator: Type Model/manufacturer No load regulated voltage Rectifier: Model/manufacturer Capacity Withstand voltage Battery: Specific gravity Electric starter system: Type Starter motor: Model/manufacturer I.D.number Output Brush overall length Commutator diameter Mica undercut Starter relay: Model/manufacturer Amperage rating 12 V 12S at 1,200 r/min TPS and electrical type at 20SC/Gray Black J4T079/MITSUBISHI F6T541 /MITSUBISHI 6 mm 3.8 4.6 at 20SC 10.1 15.1 k at 20SC Resin type 10 k Standard

Frame bracket Wire harness Fuse box Battery positive (+) lead Spark plug lead Starter cable Right handlebar switch lead Brake hose Throttle cables 10 Thermo switch lead 11 Flasher light relay 9
Starter relay Carburetor heater relay Neutral switch lead Pickup coil lead A.C. magneto lead Battery negative () lead Starter motor lead Starting circuit cut-off relay Fuel tank breather hose Speedometer cable Ignitor unit
A Pass the tail/brake light lead between the frame bracket and battery box. B Fasten the tail/brake light lead with a battery band. Do not pinch the harness and tail/ brake light lead. C To the ignition coil. D The end of the plastic locking tie should face towards the under the handlebar.
E Fasten the right handlebar switch lead with a plastic locking tie. F Pass the right handlebar switch lead behind the upper bracket. G Fasten the brake hose with a brake hose holder. H Pass the left handlebar switch lead under the main switch. I Fasten the spark plug lead with a metal clamp. J Pass the ignition coil lead inside of the starter cable.
K Fasten the fuse box lead with a plastic locking tie. L Fasten the battery positive (+) lead with a battery box clamp. M The carburetor heater relay should not touch the wire harness. N Fasten the wire harness with a plastic locking tie. O From the engine. P Pass the starter motor lead over the battery negative () lead.
Q Fasten the pickup coil lead, A.C. magneto lead, neutral switch lead and starter motor lead with a plastic locking tie. R Fasten the battery negative () lead, starter motor lead and wire harness with a plastic locking tie. S Fasten the wire harness with a battery band. T Pass the wire harness between the frame and battery box. U Place the end of the plastic locking tie as shown.
V Fasten the starter cable with a plastic locking tie. W Inside the motorcycle. X Pass the fuel tank breather hose through the holder. Y Fasten the fuel tank breather hose with a metal clamp. Z Pass the speedometer cable through the front side guide. a Fasten the wire harness and leads with a plastic locking tie.
b Fasten the wire harness and leads with a metal clamp. c To the carburetor heater relay. d Fasten the wire harness and leads with a plastic locking tie. e Pass the plastic band through the frame hole. Fasten the wire harness with a plastic band at the point where the tape is located. f The wire harness and leads should not touch the rear shock absorber. g To the starter relay.

h To the flasher light relay. i To the rear fender. j To the battery negative () lead. k Pass the ignitor unit leads through the battery box hole.
Front flasher light (right) Throttle cables Brake hose Right handlebar switch lead Clutch cable Left handlebar switch lead Front flasher light (left) Ignition coil Spark plug lead 10 Silencer 11 Starter cable 9
Speedometer cable Neutral switch lead Pickup coil lead A.C. magneto lead Thermo switch lead Fuel tank breather hose Frame Wire harness Air filter case
A Pass the throttle cables through the cable guide. B Pass the brake hose in front of the upper bracket. C Pass the left handlebar switch lead over the right handlebar switch lead. D Pass the clutch cable through the cable guide. E Fasten the handlebar switch leads with a plastic band. F Fasten the wire harness with a plastic locking tie.
G To the ignition coil. H Pass the starter cable between the ignition coil and spark plug lead. I To the throttle position sensor (TPS). J To the carburetor. K To the fuel tank. L Pass the neutral switch lead, pickup coil lead and A.C. magneto lead under the ignition coil lead, thermo switch lead and throttle position sensor (TPS) lead. M From the engine.
N 20 mm O Pass the thermo switch lead inside of the silencer breather hose. P Place the end of the plastic locking tie as shown. Q Inside the motorcycle. R Fasten the wire harness with a plastic locking tie. S Pass the wire harness between the air filter case groove and frame.
CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION. 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS. 3-1 FUEL TANK AND SEATS. 3-3 ENGINE. VALVE CLEARANCE ADJUSTMENT. CARBURETOR SYNCHRONIZATION. IDLING SPEED ADJUSTMENT. THROTTLE CABLE ADJUSTMENT. SPARK PLUG INSPECTION. IGNITION TIMING CHECK. COMPRESSION PRESSURE MEASUREMENT. ENGINE OIL LEVEL INSPECTION. ENGINE OIL REPLACEMENT. CLUTCH ADJUSTMENT. AIR FILTER CLEANING. CARBURETOR JOINT INSPECTION. FUEL LINE INSPECTION. BREATHER HOSE INSPECTION. EXHAUST SYSTEM INSPECTION. CHASSIS. FRONT BRAKE ADJUSTMENT. REAR BRAKE ADJUSTMENT. BRAKE FLUID LEVEL INSPECTION. BRAKE PAD INSPECTION. BRAKE SHOE INSPECTION. BRAKE LIGHT SWITCH ADJUSTMENT. BRAKE HOSE INSPECTION. AIR BLEEDING (HYDRAULIC BRAKE SYSTEM). SHIFT PEDAL ADJUSTMENT. FINAL GEAR OIL LEVEL INSPECTION. FINAL GEAR OIL REPLACEMENT. STEERING HEAD INSPECTION. FRONT FORK INSPECTION. REAR SHOCK ABSORBER ADJUSTMENT. TIRE INSPECTION. WHEEL INSPECTION. SPOKE INSPECTION AND TIGHTENING. CABLE INSPECTION AND LUBRICATION. LEVER AND PEDAL LUBRICATION. SIDESTAND LUBRICATION. 3-4 3-4 3-7 3-9 3-10 3-11 3-12 3-14 3-16 3-17 3-19 3-19 3-20 3-20 3-21 3-21 3-22 3-22 3-23 3-24 3-25 3-25 3-25 3-26 3-26 3-27 3-28 3-29 3-29 3-31 3-32 3-32 3-35 3-35 3-35 3-36 3-36

***************************************************** Measurement steps: D Crank the engine with the throttle wide open until the reading on the compression gauge stabilizes.
To prevent sparking, ground all spark plug leads before cranking the engine. D Repeat the previous steps for the other cylinders. NOTE: The difference in compression pressure between the highest and lowest cylinder compression readings should not exceed 100 kPa (1 kg/cm2, 1 bar). ***************************************************** 7. Install: S Spark plugs S Spark plug caps

18 Nm (1.8 mSkg)

ENGINE OIL LEVEL INSPECTION
ENGINE OIL LEVEL INSPECTION 1. Stand the motorcycle on a level surface. NOTE: D Make sure the motorcycle is upright when inspecting the oil level. D Place the motorcycle on a suitable stand.
2. Inspect: S Oil level Oil level should be between the maximum a and minimum b marks. Oil level is below the minimum mark ! Add oil up to the proper level. Recommended engine oil: Refer to the chart for selection of oils suited to the atmosperic temperature. API Standard: API SE or higher grade
D Do not put in any chemical additives or use oils with a grade of CD a or higher. D Be sure not to use oils labeled ENERGY CONSERVING ll b or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage. D Be sure no foreign material enters the crankcase. 3. Start the engine and let it warm up for several minutes. 4. Stop the engine and inspect the oil level once again. NOTE: Wait until the oil settles before inspecting the oil level.

ENGINE OIL REPLACEMENT

EB303080
ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Turn off the engine and place a container under the drain bolt. 3. Remove: S Oil filler plug 1 S O-ring 2 S Drain bolt 3 S Gasket Drain the crankcase of its oil.
4. If the oil filter is to be replaced during this procedure, remove the following parts and reinstall them afterwards. ***************************************************** Replacement steps: D Remove the oil filter element cover 1 and oil filter element 2. D Check the O-ring 3. If cracked or damaged, replace them with new one. D Install the oil filter element and oil filter element cover. Oil filter cover: 10 Nm (1.0 mSkg) *****************************************************
5. Install: S Gasket S Drain bolt

43 Nm (4.3 mSkg)

4. Inspect: S Rocker arms S Rocker arm shafts Damage/wear ! Replace. ***************************************************** Inspection steps: D Inspect the two contact areas on the rocker arms for signs of abnormal wear. 1) Rocker arm shaft hole. 2) Camshaft lobe contact surface. Excessive wear ! Replace. D Inspect the surface of the rocker arm shafts. Blue discoloration/pitting/scratches ! Replace/check lubrication. D Measure the inside diameter a of the rocker arm holes. Out of specification ! Replace. Rocker arm inside diameter: 14.000 14.018 mm D Measure the outside diameter b of the rocker arm shafts. Out of specification ! Replace. Rocker arm outside diameter: 13.980 13.991 mm D Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Clearance greater than 0.08 mm ! Replace the defective part(s). Rocker arm to shaft standard clearance: 0.009 0.038 mm *****************************************************
ROCKER ARM AND CAMSHAFT INSTALLATION 1. Apply: S Molybdenum disulfide oil (onto the camshaft journals) 2. Install: S Camshaft 1 S Camshaft bushing 2 S Stopper plate 3 S Lock washer 4 S Bolts (stopper plate) 5
NOTE: D The dowel pin a on the end of the camshaft must align with the timing mark b on the cylinder head. D Make sure that the No.1 camshaft 6 is installed in the rear cylinder head and the No.2 camshaft 7 is installed in the front cylinder head. 3. Apply: S Engine oil (onto the rocker arm shafts) 4. Install: S Rocker arms 1 S Rocker arm shafts (intake and exhaust) 2 NOTE: D The thread hole a of the rocker arm shafts must face to the outside. D After installation, make sure that the thread hole a of the rocker arm shaft is positioned correctly, as shown in the illustration.

VALVES AND VALVE SPRINGS

Job name/Part name Valve and valve spring removal Cylinder heads Rocker arms and camshafts
Remarks Remove the parts in the order below. Refer to CYLINDER HEADS. Refer to ROCKER ARMS AND CAMSHAFT. Refer to VALVE AND VALVE SPRING REMOVAL/INSTALLATION.
Valve cotters Valve spring retainers Valve springs Valve (intake) Valve (exhaust) Valve stem seals Valve spring seats
Refer to VALVE AND VALVE SPRING INSTALLATION.
VALVE AND VALVE SPRING REMOVAL 1. Check: S Valve sealing Leakage at the valve seat ! Inspect the valve face, valve seat and valve seat width. Refer to INSPECTION. ***************************************************** Checking steps: D Pour a clean solvent 1 into the intake and exhaust ports. D Check that the valve seals properly. There should be no leakage at the valve seat 2. *****************************************************

5. Inspect: S Crank pin surfaces S Bearing surfaces Wear/scratches ! Replace. 6. Inspect: S Timing chain sprockets 1 Damage/wear ! Replace the crankshaft.
7. Measure: S Oil clearance (crank pin) Out of specification ! Replace the bearing. Oil clearance (crank pin): 0.026 0.050 mm ***************************************************** Measurement steps:
Do not interchange the bearings and connecting rods. To obtain the correct oil clearance and to prevent engine damage they must be installed in their original positions. _ Clean the bearings, crank pins and bearing portions of the connecting rods. _ Install the upper half of the bearing into the connecting rod and the lower half of the bearing into the connecting rod cap. NOTE: Align the projection a of the bearing with the notch b of the connecting rod and its cap. _ Put a piece of Plastigauge 1 on the crank pin. _ Assemble the connecting rod halves. NOTE: _ Do not move the connecting rod or crankshaft until the oil clearance measurement has been completed. _ Apply molybdenum disulfide grease to the bolts, threads and nut seats.
_ The stamped Y mark 2 on the connecting rods should face towards the left side of the crankcase. _ Be sure that the characters 3 on the side of the cap and connecting rod are aligned. _ Tighten the nuts. Nuts (connecting rod caps): 36 Nm (3.6 mSkg)
_ When tightening the nuts be sure to use an F-type torque wrench. _ Without pausing tighten to full torque specifications. Apply continuous torque between 3.0 and 3.6 mSkg. Once you reach 3.0 mSkg DO NOT STOP TIGHTENING until final torque is reached. If the tightening is interrupted between 3.0 and 3.6 mSkg, loosen the nut to less than 3.0 mSkg and start again. _ Remove the connecting rods and bearings. _ On each crank pin measure the width of the compressed Plastigauge 1. If the oil clearance is out of specification, select a replacement bearing. ***************************************************** 8. Select: S Crank pin bearing (P1) NOTE: _ The numbers 1 indicate crankshaft journal sizes are stamped on the crankweb, as shown in the illustration. _ The numbers 2 are stamped in ink on the connecting rod and connecting rod cap, as shown in the illustration. ***************************************************** Selection of crank pin bearings: _ If P1 on the connecting rod is 4 and P1 on the crankweb is 2, then the bearing size for P1 is: Bearing size of P1: Connecting rod P1 Crankweb P1 = = 2 (black)

Sheave holder: 90890-01701
MIDDLE DRIVEN PINION GEAR INSTALLATION 1. Install: S Spring retainers NOTE: Attach the damper spring compressor 1 on the spring seat 2 and compress the damper spring, then install the spring retainers. Damper spring compressor: 90890-04090 2. Install: S Bearing ***************************************************** Installation steps: _ Install the new bearing by reversing the removal steps. NOTE: Use a socket 1 that matches the diameter of the outer bearing race and the oil seal.
Do not contact the bearing center race 2 or balls 3. Contact should be made only with the outer race 4. ***************************************************** 3. Install: S Bearing retainer 1 ***************************************************** Install steps: _ Attach the folded rag 2. _ Secure the bearing housing edge in the vise. _ Attach the bearing retainer wrench 3. Bearing retainer wrench: 90890-04057 _ Tighten the bearing retainer.
The middle driven shaft bearing retainer has left-handed threads. To tighten the retainer turn it counterclockwise. Bearing retainer: 110 Nm (11.0 mSkg) *****************************************************
4. Install: S Middle driven shaft assembly ***************************************************** Install steps: _ Clean the outside of the middle driven shaft and the inside of the bearing. _ Fit the middle driven shaft assembly onto the bearing housing. _ Place the middle driven shaft assembly onto a hydraulic press.
_ Never directly press the shaft end with a hydraulic press, this will result in damage to the shaft thread. _ Install the hand-made tool 1 to protect the bearing and bearing housing from damage. _ Install the wood piece 2 on the shaft end to protect the thread from damage. _ Press the wood piece and secure the middle driven shaft assembly. *****************************************************
5. Tighten: S Nut (middle driven pinion gear) 1

90 Nm (9.0 mSkg)

NOTE: Use the universal joint holder 2 to hold the yoke 3. Universal joint holder: 90890-04062 6. Install: S Yoke (cross joint) 1 (into the hole on yoke)
7. Install: S Bearings 1 (onto the cross joint)
The needles can easily fall out of their races, so check each bearing. Slide the universal joint yoke back and forth on the bearings. If a needle is out of place the yoke will not go all the way onto the bearing. 8. Using a suitable socket press each bearing into the hole on yoke. NOTE: The bearings must be inserted far enough into the cross joint so that the circlips can be installed.
9. Install: S Circlips 3 (into the groove of each bearing)

EB707031

FINAL GEAR BACKLASH ADJUSTMENT 1. Remove: S Bolts (bearing housing) NOTE: Working in a crisscross pattern, loosen each nut 1 /4 of a turn. After all the nuts are loosened, remove them.
2. Remove: S Bearing housing 1 S Ring gear 2 S Thrust washer 3 S Shim(s) 4 3. Adjust: S Final gear backlash ***************************************************** Adjustment steps: D Use the following chart to select the suitable shims and thrust washer. Reducing the shim thickness: Increasing the shim thickness: gear backlash is increased. gear backlash is decreased.
D If it is necessary to increase the final gear backlash by more than 0.1 mm: Reduce the thrust washer thickness by 0.1 mm for every 0.1 mm increase of ring gear shim thickness. D If it is necessary to reduce the final gear backlash by more than 0.1 mm: Increase the thrust washer thickness by 0.1 mm for every 0.1 mm decrease of ring gear shim thickness. Ring gear shim Thickness (mm) 0.25, 0.30, 0.40
Thrust washer Thickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0

DRIVE SHAFT

115 Nm (11.5 m _ kg)

42 Nm (4.2 m _ kg)

Job name/Part name Drive shaft removal
Securely support the motorcycle so there is no danger of it falling over. Rear wheel assembly Collar Drive shaft assembly Final drive pinion gear assembly Final gear assembly Refer to REAR WHEEL. For installation, reverse the removal procedure.
Refer to FINAL DRIVE GEAR DISASSEMBLY.

FINAL GEAR

Job name/Part name Final gear disassembly
Remarks Disassemble the parts in the order below. NOTE: Working in a crisscross pattern, loosen each bolt 1/4 of a turn. After all the bolts are loosened, remove them.
Bolts (bearing housing) Bolt (bearing housing)
Bearing housing/O-ring Ring gear Thrust washer Shim(s)
1/For assembly, reverse the disassembly procedure.
FINAL DRIVE GEAR DISASSEMBLY 1. Remove: _ Bearing retainer (final drive shaft) Use a bearing retainer wrench 1. Bearing retainer wrench: 90890-04050
The final drive shaft bearing retainer has left-handed threads. To loosen the retainer turn it clockwise. 2. Remove: _ Final drive shaft assembly With a soft hammer lightly tap on the final drive shaft end.

Since final drive gear shims can only be selected in 0.10 mm increments, round off the hundredths digit and select the appropriate shim(s). Hundredths 0, 1, 2, 3, 4 5, 6, 7, 8, 9 Rounded value 0 10
In the example above, the calculated final drive gear shim thickness is 0.51 mm. The chart instructs you to round off the 1 to 0. Thus you should use a 0.50 mm final drive gear shim. D To find the ring gear shim thickness B, use the following formula. Ring gear shim thickness: B= c + d ( e + f ) Where: c = a numeral on the final gear case (i.e.45.55) d = a numeral on the bearing housing (i.e.1.35) e = a numeral (usually a decimalnumber) on the inside of the ring gear either added to or subtracted from 35.40. f = the ring gear bearing thickness (considered constant). Ring gear bearing thickness f : 11 mm Example: If the final gear case is marked 55. c is 45.55 d is 1.35 If the ring gear is marked 05. e is 35.35 f is 11.00 B = 45.55 + 1.35 (35.35 + 11.00) = 46.9 (46.35) = 0.55
Therefore, the ring gear shim thickness is 0.55 mm. Shim sizes are supplied in the following thickness. Ring gear shim Thickness (mm) 0.25, 0.30, 0.40
Since ring gear shims can only be selected in 0.10 mm increments, round off the hundredths digit and select the appropriate shim(s). Hundredths 0, 1, 2, 3, 4 5, 6, 7, 8, 9 Rounded value 0 10
2. Install: _ Shims (proper size as calculated) _ Final drive shaft assembly _ Bearing retainer (final drive shaft)

115 Nm (11.5 m_kg)

Use a bearing retainer wrench.
The final drive shaft bearing retainer has left-hand threads. Turn the retainer counterclockwise to tighten it. Bearing retainer wrench: 90890-04050 3. Adjust: _ Gear backlash Refer to FINAL GEAR BACKLASH MEASUREMENT and FINAL GEAR BACKLASH ADJUSTMENT. 4. Measure/select: _ Ring gear thrust washer clearance
***************************************************** Ring gear thrust washer clearance measurement steps: D Remove the ring gear assembly. D Place four pieces of Plastigauge between the originally installed ring gear thrust washer and the ring gear. D Install the ring gear assembly and tighten the bolts to specification. Bolt (bearing housing): 23 Nm (2.3 mSkg) NOTE: When using Plastigauge to measure the ring gear thrust washer clearance do not turn the shaft drive and ring gear. D Remove the ring gear assembly. D Measure the ring gear thrust washer clearance and the width of the flattened Plastigauge 1. Ring gear thrust washer clearance: 0.1 0.2 mm D If the clearance is correct, install the ring gear assembly. D If out of specification, select the correct thrust washer. Ring gear thrust washer selection steps: D Using the following chart select the suitable thrust washer. Thrust washer Thickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0

D Repeat the measurement steps until the ring gear thrust washer clearance is within the specified limits. Ring gear thrust washer clearance: 0.1 0.2 mm *****************************************************

EB707040

DEIVE SHAFT INSPECTION 1. Inspect: _ Drive shaft splines Wear/damage ! Replace.
FINAL GEAR CASE INSTALLATION 1. Apply: _ Sealant (onto the mating surface of both final gear case halves) Yamaha Bond No. 1215: 90890-85505

CHAPTER 7. ELECTRICAL

ELECTRICAL COMPONENTS. 7-1 SWITCH INSPECTION. SWITCH INSPECTION. INSPECTING A SWITCH SHOWN IN THE MANUAL. SWITCH CONTINUITY INSPECTION. 7-2 7-2 7-2 7-3
IGNITION SYSTEM. 7-5 CIRCUIT DIAGRAM. 7-5 TROUBLESHOOTING. 7-6 ELECTRIC STARTING SYSTEM. CIRCUIT DIAGRAM. STARTING CIRCUIT OPERATION. TROUBLESHOOTING. STARTER MOTOR. STARTER MOTOR INSPECTION. STARTER MOTOR ASSEMBLY. 7-11 7-11 7-12 7-13 7-17 7-18 7-19
CHARGING SYSTEM. 7-21 CIRCUIT DIAGRAM. 7-21 TROUBLESHOOTING. 7-22 LIGHTING SYSTEM. CIRCUIT DIAGRAM. TROUBLESHOOTING. LIGHTING SYSTEM CHECK. SIGNAL SYSTEM. CIRCUIT DIAGRAM. TROUBLESHOOTING. SIGNAL SYSTEM CHECK. FUEL PUMP SYSTEM. CIRCUIT DIAGRAM. FUEL PUMP CIRCUIT OPERATION. TROUBLESHOOTING. FUEL PUMP TEST. 7-24 7-24 7-25 7-27 7-30 7-30 7-32 7-34 7-38 7-38 7-39 7-40 7-43
CARBURETOR HEATER SYSTEM. 7-44 CIRCUIT DIAGRAM. 7-44 TROUBLESHOOTING. 7-45
SELF-DIAGNOSIS. 7-49 TROUBLESHOOTING. 7-50

ELECTRICAL COMPONENTS

EB800000
Thermo switch Main switch Ignition coil Fuse Carburetor heater relay Relay unit Battery Headlight relay
9 Starter relay Igniter unit Flasher relay Neutral switch Rear brake switch Side stand switch Rectifier/regulator Horn
IGNITION COIL: PRIMARY WINDING RESISTANCE: 3.8 4.6 at 20_C SECONDARY WINDING RESISTANCE: 10.1 15.1 k at 20_C

SWITCH INSPECTION

SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty as any point, replace the switch. Pocket tester: 90890-03112 NOTE: D Set the pocket tester to 0 before starting the test. D The pocket tester should be set to the 1 range when testing the switch for continuity. D Turn the switch on and off a few times when checking it.
INSPECTING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches (main switch, handlebar switch, engine stop switch, light switch, etc.) are shown in a chart similar to the one on the left. This chart shows the switch positions in the column and the switch lead colors in the top row. indicates the For each switch position, terminals with continuity. The example chart shows that: 1 There is continuity between the Black and Black/White leads when the switch is set to OFF. 2 There is continuity between the Red and Brown leads when the switch is set to ON.

EB802014

INCORRECT
Repair or replace the spark plugs.
4. Ignition spark gap S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker 1 as shown. 2 Spark plug cap S Turn the main switch to ON.
S Check the ignition spark gap a. S Crank the engine by pushing the starter switch, and increase the spark gap until a misfire occurs. Minimum spark gap: 6.0 mm OUT OF SPECIFICATION OR NO SPARK

EB802015

MEETS SPECIFICATION
The ignition system is not faulty.
5. Spark plug cap resistance S Remove the spark plug cap. S Connect the pocket tester ( spark plug cap. 1k) to the
S Check if the spark plug cap has the specified resistance. Spark plug cap resistance: 10 k at 20_C MEETS SPECIFICATION

EB802016

OUT OF SPECIFICATION
Replace the spark plug cap.
6. Ignition coil resistance S Disconnect the ignition coil connector from the wire harness. S Connect the pocket tester ( 1) to the ignition coil.
Tester (+) lead ! Red/Black terminal Tester () lead ! Orange (Gray) terminal
S Check if the primary coil has the specified resistance. Primary coil resistance: 3.8 X 4.6 at 20_C S Connect the pocket tester ( ignition coil. 1 k) to the
Tester (+) lead ! spark plug lead 1 Tester () lead ! Red/Black terminal 2
S Check if the secondary coil has the specified resistance. Secondary coil resistance: 10.1 X 15.1 k at 20_C
Replace the ignition coil. BOTH MEET SPECIFICATION :

EB80201C

7. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester ( 100) to the pickup coil terminal. Tester (+) lead ! Gray terminal 1 Tester () lead ! Black terminal 2 S Check if the pickup coil has the specified resistance. Pickup coil resistance: 182 X 222 at 20_C (Gray Black) MEETS SPECIFICATION 8. Main switch Refer to SWITCH INSPECTION. CORRECT 9. Engine stop switch Refer to SWITCH INSPECTION. CORRECT 10. Neutral switch Refer to SWITCH INSPECTION. CORRECT 11. Sidestand switch Refer to SWITCH INSPECTION. CORRECT : Replace sidestand switch. Replace neutral switch. INCORRECT Replace handlebar switch (right). INCORRECT Replace main switch. INCORRECT INCORRECT OUT OF SPECIFICATION

Replace the pickup coil.

12. Relay unit (diode) S Remove the relay unit from the wire harness. S Check for continuity as follows: Sky blue Blue/Yellow 2 Tester (+) lead ! Sky blue 1 Conti2 nuity Tester () lead ! Blue/Yellow Tester (+) lead ! Blue/Yellow 2 No Continuity Tester () lead ! Sky blue 1 NOTE: When you switch the and + leads of the digital pocket tester the readings in the above chart will be reversed. INCORRECT

Replace the relay unit.

CORRECT

EB80201D

13. Wiring connection S Check the connections of the entire ignition system. Refer to CIRCUIT DIAGRAM. CORRECT

EB803021

: D A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn. D This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity. DOES NOT MOVE
3. Starter motor S Connect the battery positive terminal 1 and starter motor cable 2 using a jumper lead 3 :. S Check the operation of the starter motor.
Repair or replace the starter motor. MOVES

EB803023

4. Relay unit (starting circuit cut-off relay) S Remove the relay unit from the wire harness. S Connect the pocket tester ( 1) and battery (12 V) to the relay unit terminals. Battery (+) terminal ! Red/Black terminal 1 Battery () terminal ! Black/Yellow terminal 2 Tester (+) lead ! Blue terminal 3 Tester () lead ! Blue/White terminal 4 S Check the starting circuit cut-off relay for continuity. CONTINUITY : NO CONTINUITY
5. Relay unit (diode) S Remove the relay unit from the wire harness. S Check for continuity as follows: Sky blue 1 Black/Yellow 2 Sky blue 1 Blue/Yellow 3 ContiTester (+) lead ! Sky blue 1 Tester () lead ! Black/Yellow 2 nuity Tester (+) lead ! Black/Yellow 2 No ConTester () lead ! Sky blue 1 tinuity ContiTester (+) lead ! Sky blue 1 Tester () lead ! Blue/Yellow 3 nuity Tester (+) lead ! Blue/Yellow 3 No ConTester () lead ! Sky blue 1 tinuity NOTE: When you switch the and + leads of the digital pocket tester the readings in the above chart will be reversed. INCORRECT
Replace the relay unit. CORRECT

EB803024

6. Starter relay S Remove the starter relay from the wire harness. S Connect the pocket tester ( 1) and battery (12 V) to the starter relay terminals.
Battery (+) terminal ! Red/White terminal 1 Battery () terminal ! Blue terminal 2 Tester (+) lead ! Red terminal 3 Tester () lead ! Black terminal 4 S Check the starter relay for continuity. CONTINUITY :
Replace the starter relay.
: INCORRECT 7. Main switch Refer to SWITCH INSPECTION. Replace main switch. CORRECT INCORRECT 8. Engine stop switch Refer to SWITCH INSPECTION.
Replace handlebar switch (right). CORRECT INCORRECT 9. Neutral switch Refer to SWITCH INSPECTION. Replace neutral switch. CORRECT INCORRECT 10. Sidestand switch Refer to SWITCH INSPECTION. Replace sidestand switch. CORRECT INCORRECT 11. Clutch switch Refer to SWITCH INSPECTION. Replace clutch switch. CORRECT INCORRECT 12. Start switch Refer to SWITCH INSPECTION. Replace handlebar switch (right). CORRECT