Instrument Purchase Scheme
Price list as of January 2011
THIS PRICE LIST SUPERSEDES ANY AND ALL PREVIOUS PRICE LISTS
Education Leeds ArtForms The West Park Centre Spen Lane, Leeds, West Yorkshire LS16 5BE Tel 4074 Fax 4073 Email educ.artforms@educationleeds.co.uk Web www.artformsleeds.co.uk
This scheme enables schools to purchase instruments VAT free, either for school use or for pupils who meet one of the following criteria:
They receive instrumental tuition from an ArtForms Musician Teacher in their school They play in a school ensemble They are studying on a GCSE, AS or A2 music course
This price list contains details of instruments for which we frequently receive enquiries or orders and as such only represents a small sample of the range of instruments available through the scheme. If you would like a price for any other instrument do not hesitate to contact Mark Tunnicliffe at the ArtForms office, using the details above or via mark.tunnicliffe@educationleeds.co.uk Occasionally prices or specifications may change, in which case we will do our best to inform you before going ahead with your order. In addition to the VAT relief, most of the prices listed include an additional education discount and as such represent a substantial reduction from the manufacturer's recommended retail price. The price also includes a small charge to cover administrative costs. For non beginners looking to upgrade an existing instrument a good music shop should offer the chance to try a range of models, allowing the player to make an informed choice as to which model best suits them. If specific accessories are tested with an instrument (such as third party mouthpieces, ligatures etc) it is important to note all make & model information for these if they are to be included in the quoted price. ArtForms seeks quotes (for non list models) from a number of suppliers & as such the price quoted by one retailer may not be the best price available to us. Please be aware that time spent testing instruments at a particular shop does not oblige you to purchase the instrument from that supplier! Parents: You are welcome to discuss you requirements either with your child's school, instrument teacher or with Mark at ArtForms, however your order must be placed via the school and as such any payment arrangements must also be made with the school. Please make sure you include an IPS order form and an official order (SIMS, FAB, etc.) when ordering goods, otherwise we can not process your request. Once the goods have arrived at ArtForms you will be informed by phone & charged by internal recharge.

Schools:

Education Leeds, ArtForms The West Park Centre, Spen Lane, Leeds, West Yorkshire LS16 5BE Tel 4074 Fax 4073 Email educ.artforms@educationleeds.co.uk Web www.artformsleeds.co.uk
Note to parents: This form has to be processed through school & they may require payment before they place the order.
ARTFORMS (MUSIC) INSTRUMENT PURCHASE SCHEME SCHOOL ORDER FORM
Note to schools: Please keep this form as a master & send your order on a photocopy, along with your SIMS or FAB order.
This form must be received by ArtForms together with a SIMS (or FAB) order form (via post or fax, for the attention of Mark Tunnicliffe) before any instruments can be ordered. Please do not send cash or cheques. ArtForms (Music) will contact the school when the instrument(s) are available for collection. SCHOOL ADDRESS POST CODE INSTRUMENT TEL NO IPS No SIZE QUANTITY PRICE
PURCHASE The following section must be completed if instruments are being bought for pupils through the school: The instruments ordered above are for use for the following children who are either (a) receiving peripatetic instrumental lessons in school from an ArtForms Teacher or (b) involved weekly in an organised school ensemble or (c) Studying on a GCSE, AS or A2 music course NAME 3 NAME 6

I confirm that the information given above is correct. Signed Head Teacher Date
SIMS or FAB order form number (order must be enclosed)
ARTFORMS MUSIC - INSTRUMENT PURCHASE SCHEME (Price List from Jan 2011) PLEASE NOTE - ALL PRICES ARE SUBJECT TO CHANGE WITHOUT NOTICE
If the item you require is not listed, please contact us and we will be happy to obtain a price for you.
Cat. No. Instrument Type WOODWIND
IPS 101 IPS 102 IPS 103 IPS 104 IPS 105 IPS 106 IPS 107 IPS 108 IPS 109 IPS 110 IPS 111 IPS 112 IPS 113 IPS 114 IPS 115 IPS 116 IPS 117 IPS 118 IPS 119 IPS 120 IPS 121 IPS 122 IPS 123 IPS 124 IPS 125 IPS 126 IPS 127 IPS 128 IPS 129 IPS 130 IPS 131 IPS 132 IPS 133 IPS 134 IPS 135 IPS 136 IPS 137 IPS 138 Recorder Recorder Recorder Recorder Recorder Recorder Recorder Fife Fife Package Flute Flute Flute Flute Flute Flute Flute Flute Piccolo Piccolo Oboe Clarinet Clarinet Clarinet Clarinet Clarinet Clarinet Clarinet case Alto Saxophone Alto Saxophone Alto Saxophone Alto Saxophone Alto Saxophone Alto Saxophone Alto Saxophone Case Tenor Saxophone Tenor Saxophone Tenor Saxophone Tenor Saxophone Yamaha Descant 24BUK11 - ideal beginners instrument Aulos Descant 303 (blue bag) - ideal beginners instrument Aulos Descant 205 (yellow bag) - wamer tone than the 303 Aulos Treble 209 - ideal beginners instrument Yamaha Treble 28BUK11 - ideal beginners instrument Aulos Tenor 211 - ideal beginners instrument Yamaha Tenor 304B - ideal beginners instrument Yamaha YRF21 - useful for recorder to flute transition Yamaha Fife & Tutor Book JP 111 - starter model Yamaha E1 - student model Trevor James 10XE (Split E) - student model Trevor James 10XE + curved head - as above, for smaller players Yamaha YFL 211SII (Split E) - student model JP Celebration Silver Head - intermediate model Trevor James Cantabile Silver Head - intermediate model Yamaha YFL 311 Silver Head - intermediate model JP 114 - starter model Yamaha YPC32 - student model Buffet 4121 - student model JP 121 - starter model Yamaha E1 - student model Jupiter JCL631II - student model Yamaha YCL 250 SUK - higher spec student model Buffet B12 - higher spec student model Yamaha YCL 650 (Wood) - intermediate model Gator Lightweight (black,blue,red,pink or teal) JP041 Blues - starter model Yamaha E1 - student model Trevor James Artemis - student model Jupiter 565GL - student model Trevor James Revolution - higher spec student model Yamaha YAS 275 - higher spec student model Gator Lightweight (black or red) JP042 Blues - student model Jupiter JTS-587GL-F - student model Trevor James Revolution - higher spec student model Yamaha YTS 275 - higher spec student model 5.23 5.04 9.35 15.12 10.29 38.01 43.37 5.46 12.97 72.45 299.25 231.00 229.95 354.00 313.95 494.00 534.00 99.75 344.00 1,013.00 115.50 229.95 187.95 271.95 229.95 604.00 25.73 177.45 473.00 208.95 303.45 495.00 564.00 41.79 208.95 564.00 610.00 734.00 8.00 7.99 14.95 23.95 23.95 59.95 97.00 8.49 16.45 141.00 N/A 495.00 549.00 594.00 499.00 899.00 940.00 175.00 593.00 1,593.00 204.00 N/A 359.99 471.00 560.00 1,477.00 36.50 389.00 N/A 499.00 584.99 985.00 989.00 62.99 499.00 999.99 1,125.00 1,285.00

Make & Model

ArtForms Cost RRP inc VAT

STRINGS

IPS 201 IPS 202 IPS 203 IPS 204 IPS 205 IPS 206 IPS 207 IPS 208 IPS 209 IPS 210 IPS 211 IPS 212 IPS 213 IPS 214 IPS 215 IPS 216 IPS 217 IPS 218 IPS 219 IPS 220 IPS 221 IPS 222 Violin Outfit Violin Outfit Violin Outfit Coloured Violin Outfit Violin Outfit Chin Rest Chin Rest Shoulder Rest Shoulder Rest Student Violin Bow Violin Case Viola Outfit Viola Outfit Viola Bow Cello Outfit Cello Outfit Cello Outfit Cello Outfit Cello Bow Cello Cover Cello Cover Cello Case Stentor I - student model Primavera - student model Stentor II - higher spec student model Harlequin (please specify colour on order)* - student model Andreas Zeller - intermediate model Wittner Hypo Allergenic Basic Strad pattern Wolfe Forte Primo/Secundo Jegro As supplied with Stentor I outfit or equivalent Stentor 1372 or equivalent Stentor I - student model Stentor II - higher spec student model As supplied with Stentor II outfit or equivalent Stentor II 1/4 size - higher spec student model Stentor II 1/2 size - higher spec student model Stentor II 3/4 size - higher spec student model Stentor II 4/4 size - higher spec student model As supplied with Stentor II outfit or equivalent Soft Cover (all sizes) Fully padded (all sizes) Rigid - full size only (Hiscox) 65.10 66.15 93.45 75.81 134.40 13.00 4.70 18.27 7.14 11.34 27.41 93.45 123.90 19.43 298.20 313.95 350.00 419.00 23.10 24.26 47.57 134.40 99.95 95.00 145.00 115.00 215.00 18.34 6.95 27.10 12.95 16.35 40.40 145.00 190.00 29.50 445.00 470.00 525.00 540.00 35.00 36.30 71.55 199.00
An 'outfit' includes a case or cover & a bow of appropriate quality. String instruments, bows & cases come in several sizes please ask your teacher for advice & state the size on your order. *Harlequin colours - lilac, red, deep purple, marine blue, rasberry pink, black. Check before ordering as not all size/colour options are available

VIOLIN STRINGS

IPS 801 IPS 802 IPS 803 IPS 804 IPS 805 IPS 806 IPS 807 IPS 808 IPS 809 IPS 810 IPS 811 Astrea Astrea Astrea Astrea Astrea Dogal Dogal Dogal Dogal Dogal Thomastik Dominant Set (budget strings - steel throughout) E A D G Set (Beginner strings - bronze wound on a steel core) E A D G Set (Intermediate - Platinum/Silver winding on a Perlon core) 5.57 0.77 1.44 1.68 1.68 10.15 1.07 2.65 3.15 3.32 30.66 8.30 1.15 2.14 2.51 2.51 15.15 1.60 3.95 4.70 4.95 45.74

Cat. No. Instrument Type VIOLA STRINGS
IPS 812 IPS 813 IPS 814 IPS 815 IPS 816 IPS 817 IPS 818 IPS 819 IPS 820 IPS 821 IPS 822 Astrea Astrea Astrea Astrea Astrea Dogal Dogal Dogal Dogal Dogal Thomastik Dominant Set (budget strings - steel throughout) A D G C Set (Beginner strings - bronze wound on a steel core) A D G C Set (Intermediate - Platinum/Silver wound on a Perlon core) 7.35 1.50 1.72 1.89 3.72 15.41 2.88 4.13 4.13 4.45 50.52 10.96 2.24 2.57 2.82 5.54 23.00 4.30 6.15 6.15 6.65 75.37

CELLO STRINGS

IPS 823 IPS 824 IPS 825 IPS 826 IPS 827 IPS 828 IPS 829 IPS 830 IPS 831 IPS 832 Astrea Astrea Astrea Astrea Astrea Dogal Dogal Dogal Dogal Dogal Set (budget strings - steel throughout) A D G C Set (Beginner strings - bronze wound on a steel core) A D G C 13.80 2.29 3.43 3.72 4.36 23.49 4.45 5.32 5.83 7.88 20.58 3.42 5.13 5.54 6.50 35.05 6.65 7.95 8.70 11.95

DOUBLE BASS STRINGS

IPS 833 IPS 834 IPS 835 IPS 836 IPS 837 IPS 838 IPS 839 IPS 840 IPS 841 IPS 842 Astrea Astrea Astrea Astrea Astrea Dogal Dogal Dogal Dogal Dogal Set (budget strings - steel throughout) G D A E Set (Beginner strings - bronze wound on a steel core) G D A E 36.03 7.02 8.66 9.65 10.52 66.79 14.04 16.45 17.49 18.84 53.75 10.48 12.93 14.39 15.70 99.65 20.95 24.55 26.10 28.10
Minimum order for strings is 10.
IPS 301 IPS 302 IPS 303 IPS 304 IPS 305 IPS 306 IPS 307 IPS 308 IPS 309 IPS 310 IPS 311 IPS 312 IPS 313 IPS 314 IPS 315 IPS 316 IPS 317 IPS 318 IPS 319 IPS 320 IPS 321 IPS 322 IPS 323 IPS 324 IPS 325 IPS 326 IPS 327 IPS 328 IPS 329 IPS 330 IPS 331 IPS 332 IPS 333 Trumpet Trumpet Trumpet Trumpet Trumpet Stand Trumpet Mute Trumpet Mute Trumpet Case Trumpet Mouthpiece Trumpet Mouthpiece Cornet (silver plate) Cornet Cornet Mouthpiece Cornet Mouthpiece Cornet Case Trombone Trombone Trombone Trombone Mute Trombone Mouthpiece Trombone Mouthpiece Trombone Case Tenor Horn Tenor Horn Baritone Horn Euphonium Euphonium F Horn F Horn Mouthpiece F Horn Mouthpiece Tuba Tuba Mouthpiece Tuba Mouthpiece Packer JP051 - starter model Yamaha E1 - student model Yamaha 1335E - student model Yamaha 4335 G - intermediate model K and M Straight Practice Gator Lightweight (black, teal & red) Dennis Wick (standard range) Vincent Bach (standard range) Packer JP 171 MKII - student model Yamaha 2330 II - student model Dennis Wick (standard range) Vincent Bach (standard range) Gator Lightweight Packer JP 136 Alto Packer JP 031 Tenor - student model Yamaha YSL-354 - higher spec student model Practice Dennis Wick (standard range) Vincent Bach (standard range) Gator Lightweight Packers JP172L MKII - Student model Yamaha YAH-203L - higher spec student model Packers JP273L 3 valve compensating - Student model Packers JP374L 4 valve (compensating) - Student model Packers JPvalve - Student model Yamaha 567 - intermediate model Dennis Wick (standard range) Vincent Bach (standard range) Packers JP177 - Student model Denis Wick (standard range) Vincent Bach (standard range) 78.75 222.60 240.45 344.00 14.70 17.33 17.64 33.39 26.15 34.65 78.75 238.35 23.42 34.65 30.77 99.75 92.40 403.00 23.94 30.35 44.42 60.69 145.95 694.00 344.00 444.00 208.95 1,784.00 26.46 37.70 414.00 38.64 56.96 111.37 N/A 382.00 594.00 21.50 25.50 27.50 49.95 39.00 51.50 116.48 585.00 34.60 51.50 40.95 129.76 129.76 1,161.00 35.50 45.20 65.94 86.95 174.65 1,220.00 468.98 999.00 280.98 2,926.26 39.00 52.70 587.00 60.30 85.15

Cat. No. Instrument Type GUITARS and AMPLIFIERS
IPS 401 IPS 402 IPS 403 IPS 404 IPS 405 IPS 406 IPS 407 IPS 408 IPS 409 IPS 410 IPS 411 IPS 412 IPS 413 IPS 414 IPS 415 IPS 416 IPS 417 IPS 418 IPS 419 IPS 420 IPS 421 Bass Guitar Lead Guitar Lead Guitar Lead Guitar Guitar Outfit* Guitar Outfit* Guitar Case Guitar Case Guitar Case Guitar Case Guitar Guitar Guitar Guitar Guitar Guitar Guitar Guitar Amplifier Amplifier Amplifier Encore E20 SB - starter model Stagg 300 - starter model Fender Squier - affinity solid colour - student model Fender Squier - affinity sunburst - student model Fender Squier - solid colour - student model Yamaha Pacifica 012 - red, black or blue - student model Dust Cover/Soft Case Basic padded soft case Higher grade padded soft case Rigid (Lead/Bass) Student nylon strung 'classical' Guitar with case - 1/2 size Student nylon strung 'classical' Guitar with case - 3/4 size Student nylon strung 'classical' Guitar with case - full size Classico - starter model with 4/4 neck on 3/4 body Almeria - student model Espana - student model Malaga solid top - higher spec student model Solista solid top - intermediate model Yamaha GA10 (10W Practice Amp) Laney LX 35 (30W Lead) Laney RB2 (30W Bass Amp) 90.30 81.90 132.30 132.30 177.45 187.95 8.82 12.08 20.16 39.90 33.18 35.18 36.75 95.55 120.75 124.64 145.95 219.45 42.00 82.95 95.55 129.00 115.00 186.00 186.00 269.99 282.00 12.95 17.95 29.95 60.00 49.50 53.00 55.00 150.00 185.00 197.00 230.00 344.00 69.00 119.95 135.95
*A 'Guitar Outfit' is an Electric Guitar + practice amplifier with other accessories such as a strap, cover, spare strings etc. (dependent on supplier). All other Guitars are supplied without a case unless specified.

PERCUSSION

IPS 501 IPS 502 IPS 503 IPS 504 IPS 505 IPS 506 IPS 507 Drum Kit Drum Kit Drum Kit Drum Kit Electronic Drum Kit Cymbal Set Cymbal Set Pearl Forum (inc. stands, cymbals & stool) Pearl Vision (inc. stands & stool) Yamaha Stage Custom (inc. stands & stool) Mapex Fusion (inc. stands & stool) Yamaha DTXPLORER Zildjian ZXTs Zildjian ZBTs oc = number of octaves, vox = number of voices YPT 210 - 5 oc, 134 vox - beginners model PSRE 223 - 5 oc, 375 vox - beginners model EZ 200 - 5 oc, 375 vox, key lighting system - beginners model PSRE 323 - 5 oc, 482 vox - student model PSR 423 - 5 oc, 509 vox - higher spec student model CTK 240 - 4 oc, 100 vox - beginners model CTK 2100 - 5 oc, 325 vox - beginners model CTK 3000 - 5 oc, 325 vox - student model CTK 4000 - 5 oc, 570 vox - student model WK7500 - 6 oc, 300 vox - student model Yamaha KPA 3 (for YPT 210, EZ200 & PSR's E 223, E313, E413) Yamaha KPA 6 (for higher spec models) Casio AD5EL (for CTK models) Casio AD12EL (for higher spec models) 4 Octave Size 5 Octave Size Universal adjustment - to fit all keyboards Mini Large 68.25 94.50 142.80 127.05 192.15 57.75 98.70 126.00 141.54 351.00 5.99 16.38 6.72 12.60 17.85 17.85 19.32 3.99 8.82 94.00 135.00 201.00 180.00 270.00 79.99 139.99 179.99 199.99 499.99 9.00 22.00 9.99 18.99 29.95 29.95 24.95 5.95 12.95 425.00 524.00 615.00 475.00 397.00 220.50 170.10 705.00 850.00 995.00 679.00 649.00 386.00 303.00

KEYBOARDS

IPS 601 IPS 602 IPS 603 IPS 604 IPS 605 IPS 606 IPS 607 IPS 608 IPS 609 IPS 610 IPS 611 IPS 612 IPS 613 IPS 614 IPS 615 IPS 616 IPS 617 IPS 618 IPS 619 Yamaha Keyboard* Yamaha Keyboard* Yamaha Keyboard* Yamaha Keyboard* Yamaha Keyboard* Casio Keyboard* Casio Keyboard* Casio Keyboard* Casio Keyboard* Casio Keyboard* Power Adaptor Power Adaptor Power Supply Power Supply Carry Case Carry Case Keyboard Stand Headphones Headphones
*These Yamaha/Casio 'portable' keyboard models are not supplied with power adaptors: please remember to include these on your order, if required ('portable' models can also run on batteries). Adaptors to power several keyboards at once are also available, removing the need for separate power supplies & plug sockets for each keyboard

ACCESSORIES

IPS 701 IPS 702 IPS 703 IPS 704 IPS 705 IPS 706 IPS 707 Music Stand Music Stand Music Stand Music Stand Instrument Tuner Instrument Tuner Metronome Folding - Bronze Folding - Nickel Plated Folding - Coloured Conductors style (solid tray) Seiko SAT100BK for Guitar/Bass Seiko SAT500SL Chromatic (all instruments) Seiko SQ50 Digital 9.98 9.45 9.45 19.95 12.23 15.86 23.52 14.95 15.95 15.95 29.95 16.99 22.99 33.99

This gauge is needed for carburetor synchronization. Engine tachometer

YU-08036-A 90890-03113

This tool is needed for observing engine rpm. Timing light

YU-33277-A 90890-03141

This tool is necessary for checking ignition timing. Compression gauge/Set

YU-33223 90890-03081

These tools are needed to measure engine compression. Oil filter wrench

YU-38411 90890-01426

This tool is needed to remove and install the oil filter. Pressure gauge/adapter
Gauge 90890-03153 Adapter 90890-03124
These tools are needed to measure engine oil pressure.
Tool No. YU-01268 90890-01268 YU-33975 90890-01403 Tool name/Usage Ring nut wrench

Illustration

This tool is needed to loosen and tighten the steering stem ring nut. Pocket tester
YU-03112 90890-03112 Compressor YM-04019 90890-04019 Adapter YM-01253-1 90890-04114 YM-4064-A 90890-04064
This instrument is needed for checking the electrical system. Valve spring compressor/adapter
These tools are needed to remove and install the valve assemblies. Valve guide remover (6.0 mm)
This tool is needed to remove and install the valve guide. Vale guide installer (6.0 mm)

YM-04065-A 90890-04065

This tool is needed to install the valve guide. Valve guide reamer (6.0 mm)

YM-04066 90890-04066

This tool is needed to rebore the new valve guide. Universal clutch holder

YM-91042 90890-04085

This tool is needed to hold the clutch when removing or installing the clutch boss nut. Sheave holder
YS-01880 90890-01701 Puller YU-33270 90890-01362 Adapter YM-33282 90890-04089
This tool is needed to hold the rotor when removing or installing the rotor bolt. Flywheel puller/adapter
These tools are needed to remove the rotor.
Tool No. ACC-1100-15-01 90890-85505 Tool name/Usage Quick gasket Yamaha Bond No.1215 This sealant (bond) is used on crankcase mating surfaces, etc. Piston pin puller YU-01304 90890-01304
This tool is used to remove the piston pin. Piston ring compressor

YM-8037 90890-05158

This tool is used to compress the piston rings when installing the piston into the cylinder. Damper spring compressor

YM-33286 90890-04090

This tool is needed when removing or installing the damper spring. Middle drive gear holder This tool is needed to remove and install the middle drive pinion gear. This tool is also used for the gear backlash adjustment. Middle drive gear holder

Limit 0.15 mm SSS

Measuring point H Piston off-set Piston pin bore inside diameter Piston pin outside diameter Piston rings: Top ring:
4 mm 0 mm 19.004 X 19.015 mm 18.991 X 19.000 mm
SSS SSS 19.045 mm 18.975 mm
Type Dimensions (B T) End gap (installed) Side clearance (installed) 2nd ring:
Barrel 3.1 1,0 mm 0.20 X 0.35 mm 0.03 X 0.07 mm

SSS SSS 0.55 mm 0.12 mm

Type Dimensions (B T) End gap (installed) Side clearance Oil ring:
Taper 3.1 1.2 mm 0.35 X 0.50 mm 0.02 X 0.06 mm

SSS SSS 0.8 mm 0.12 mm

Dimensions (B T) End gap (installed)

3.1 2.5 mm 0.3 X 0.9 mm

MAINTENANCE SPECIFICATION
Item Connecting rod: Oil clearance Color code (corresponding size) Crankshaft: Standard 0.021 X 0.039 mm 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 6 Pink

Limit 0.09 mm SSS

Crank width A Assembly width B Runout limit C Big end side clearance D Big end radial clearance Journal oil clearance Color code (corresponding size) Ballancer: Ballancer drive method Clutch: Friction plate thickness Quantity Friction plate wear limit Clutch plate thickness Quantity Warp limit Clutch spring free length Quantity Minimum length Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Push rod bending limit
83.92 X 83.97 mm 242.72 X 243.17 mm SSS 0.160 X 0.264 mm 0.021 X 0.039 mm 0.020 X 0.038 mm 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 6 Pink 7 Red Gear 2.9 X 3.1 mm 8 SSS 2.2 X 2.4 mm 7 SSS 7 mm 1 SSS 0.10 X 0.37 mm 0.017 X 0.053 mm Hydraulic inner push SSS
SSS SSS 0.03 mm SSS SSS 0.1 mm SSS
SSS SSS 2.8 mm SSS SSS 0.2 mm SSS SSS 6.5 mm SSS SSS SSS 0.5 mm
Item Transmission: Main axle runout limit Drive axle runout limit Shifter: Shifter type Guide bar bending limit Carburetor: I.D.mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Fuel level Engine idle speed Intake vacuum Fuel pump: Type Model/manufacturer Consumption amperage Output pressure SSS SSS Guide bar SSS 5JC#1, 2 : #122.5 #3 : #117.5 #4 : #120 #110 5DL41-54 P-0 #85 1.1 #15 0.8 0.8 0.8 1.5 #35 0.5 #mm 950 X 1,050 r/min 36 kPa (270 mmHg) Electrical type 4NK/MITSUBISHI 1A 15 X 20 kPa (0.2 kg/cm2, 0.2 bar) Paper type Trochoid type 0 X 0.12 mm 0.03 X 0.08 mm 80 X 120 kPa (0.8 X 1.2 kg/cm2, 0.8 X 1.2 bar) 440 X 560 kPa (4.4 X 5.6 kg/cm2, 4.4 X 5.6 bar) 58 kPa (0.58 kg/cm2) at 1,000 r/min Standard

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

EAS00136

ADJUSTING THE SHIFT PEDAL 1. Check: S shift pedal position Check the shift pedal rod length a. If the position is incorrect ! Adjust. Shift pedal rod length: 26.8 mm
ADJUSTING THE SHIFT PEDAL/CHECKING THE FINAL DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OIL
2. Adjust: S shift pedal position
a. Loosen both locknuts 1. b. Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position. Direction a ! Shift pedal is raised. Direction b ! Shift pedal is lowered. S Tighten both locknuts.

EAS00144

CHECKING THE FINAL DRIVE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Remove: S final drive housing oil filler bolt 1 3. Check: S final drive oil level The final drive oil level should be to the bottom brim 2 of the filler hole. Below the bottom brim ! Add the recommended final drive oil to the proper level. Recommended final drive oil SAE 80 hypoid gear oil graded GL-4, GL-5 or GL-6 or multi-purpose SAE 80W 90 hypoid gear oil 4. Install: S final drive housing oil filler bolt

23 Nm (2.3 mSkg)

EAS00145
CHANGING THE FINAL DRIVE OIL 1. Place a container under the final drive housing. 2. Remove: S final drive housing oil filler bolt 1 S final drive housing oil drain bolt 2 Completely drain the final drive housing of its oil. 3. Check: S final drive housing oil drain bolt gasket Damage ! Replace.
CHANGING THE FINAL DRIVE OIL/ CHECKING AND ADJUSTING THE STEERING HEAD
4. Install: S final drive housing oil drain bolt 5. Fill: S final drive housing (with the specified amount of the recommended final drive oil) Quantity 0.2 L Refer to CHECKING THE FINAL DRIVE OIL LEVEL.

EAS00146

CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface.
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. Check: S steering head Grasp the bottom of the front fork legs and gently rock the front fork. Looseness or binding ! Adjust the steering head. 3. Remove: S front cowling Refer to FRONT COWLING. 4. Remove: S handlebar 1
5. Loosen S upper bracket pinch bolts 1 6. Remove S steering stem nut 2 S upper bracket 3
CHECKING AND ADJUSTING THE STEERING HEAD
7. Adjust: S steering head

CAMSHAFTS

Job/Part Spark plug caps Coolant hoses (to cylinder head) Chrome cylinder head covers Spark plugs Bolts (cylinder head covers) Cylinder head covers Gaskets (cylinder head covers)
Qty 2 Disconnect Disconnect

40 (32)

20 (4)

12 (8)

7 Nm (0.7 mSkg)

12 (2)

Job/Part Removing the camshafts Cylinder head covers Crankcase cover plate Timing plug Cap bolts (tensioners) Timing chain tensioners Gaskets Timing chain guides (metal and rubber) Bolts (camshaft sprockets) Camshaft caps Camshafts (intake and exhaust) Camshaft sprockets
Remarks Remove the parts in the order listed. Refer to CYLINDER HEAD COVERS.
Refer to REMOVING/INSTALLING THE CAMSHAFTS.

EAS00201

REMOVING THE CAMSHAFTS Rear cylinder head 1. Remove: S spark plugs S cylinder head cover S gasket (cylinder head cover) NOTE: Loosen each bolt 1/4 of a turn in a crisscross pattern. After all the bolts are loosened, remove them. 2. Remove: S crankcase cover plate 1 S timing plug 2 3. Align: S and I marks on the generator rotor (with the stationary pointer on the crankcase cover) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the and I marks a with the stationary pointer b. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
4. Loosen: S cap bolt 1 5. Remove: S timing chain tensioner 2 S gasket
6. Remove: S timing chain guide (exhaust side) 1 S camshaft caps (#2) 2
7. Remove: S camshaft sprocket bolts Hold the camshaft with a 22 mm wrench.
8. Remove: S camshaft caps
To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the outside in. NOTE: When loosening the camshaft cap bolts, make sure that the camshaft lobes do not touch the valve lifters.
9. Remove: S intake camshaft S exhaust camshaft NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire to it. 10. Remove: S camshaft sprockets

Front cylinder head

NOTE: When removing the front cylinder camshafts, repeat the rear cylinder camshaft removal procedure. However, note the following points. 1. Turn: S crankshaft NOTE: From the and I marks, turn the crankshaft counterclockwise 430_ (i.e., 360_ plus an additional 70_). 2. Align: S mark (with the stationary pointer)

EB401401

CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Replace the camshaft. 2. Measure: S camshaft lobe dimensions a and b Out of specification ! Replace the camshaft. Camshaft lobe dimension limit Intake a 35.65 mm b 27.85 mm Exhaust a 35.65 mm b 27.85 mm

3. Install: S timing chain tensioner
a. Remove the cap bolt 1 , washer 2 and spring 3. b. Release the timing chain tensioner one-way cam 4.
c. Install the timing chain tensioner 5 and gasket 6 onto the cylinder block.
Always use a new gasket. Timing chain tensioner bolt 12 Nm (1.2 mSkg) d. Install the spring 3 , washer 2 , and cap bolt 1. Cap bolt 20 Nm (2.0 mSkg)
4. Turn: S crankshaft (several turns counterclockwise) 5. Check: S TDC mark a Make sure that the TDC mark on the generator rotor is aligned with the crankcase edge b. S camshaft timing punch mark c (o: small hole) Make sure hat the punch marks in the camshafts are aligned with the marks d on the camshaft caps. Out of alignment ! Adjust. Refer to the camshaft installation steps above.
6. Tighten: S camshaft sprocket bolts
Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. 7. Install: S camshaft caps I-S camshaft caps E-S timing chain guide (top side) 3
S timing chain guide (exhaust side) 4
8. Lubricate: S timing chain S camshaft sprockets S camshafts S valve pads Recommended lubricant Engine oil
Front cylinder NOTE: When installing the front cylinder camshafts, repeat the rear cylinder camshaft installation procedure. However, note the following points. 1. Install: S exhaust camshaft S intake camshaft a. From the and I marks, turn the crankshaft counterclockwise 430_ (i.e., 360_ plus an additional 70_). b. When piston #2 is at TDC on the compression stroke, align the mark a with the crankcase edge b.
c. Install the camshaft sprockets onto the camshafts. Refer to the camshaft sprocket installation steps below. NOTE: Make sure that the FRONT marks 1 on the camshaft sprockets face away from the IN 2 and EX marks 3 on the camshafts. d. Turn the camshafts by hand so that the camshaft timing marks (o: big hole) face up. 2. Install: S intake camshaft sprocket S exhaust camshaft sprocket (onto the camshafts)
a. Align the mark a on the generator rotor with the crankcase edge b. b. Install the camshaft sprocket with the FRONT mark facing out, and then finger tighten the camshaft sprocket bolts. c. Turn the intake and exhaust camshafts and align the camshaft timing marks c (o: big hole) with the camshaft cap marks d. 3. Measure: S valve clearance Out of specification ! Adjust. Refer to ADJUSTING THE VALVE CLEARANCE in CHAPTER 3. 4. Install: S timing mark accessing screw 1 S crankshaft end cover 2
CYLINDER HEADS CYLINDER HEADS

22 (2)

Job/Part Removing the cylinder heads Engine assembly Cylinder head covers Camshafts Lock pins Water jacket joints Oil delivery pipes Cylinder heads Timing chain dampers Gaskets (cylinder heads) Dowel pins

EAS00365

CHECKING THE RELIEF VALVE 1. Check: S relief valve body S relief valve 1 S spring 2 Damage/wear ! Replace the defective part(-s).

EAS00367

CHECKING THE OIL GALLERY PIPES The following procedure applies to all of the oil gallery pipes. 1. Check: S oil gallery pipe 1 Damage ! Replace. Obstruction ! Wash and blow out with compressed air.

EAS00368

CHECKING THE OIL STRAINER 1. Check: S oil strainer 1 S oil strainer housing 2 Damage ! Replace. Contaminants ! Clean with engine oil.
INSTALLING THE OIL GALLERY PIPES 1. Install: S oil gallery pipe 1 S oil pipe 2

Always use new O-rings.

2. Bend: S bracket tabs 1

EAS00375

ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S oil pump shaft 1 (to the oil pump cover 2 ) S pin 3 S inner rotor 4 S outer rotor 5 S pin 6 S oil pump housing S screw
NOTE: When installing the inner rotor, align the pin 3 in the oil pump shaft with the groove a on the inner rotor 4. 3. Check: S oil pump operation Refer to CHECKING THE OIL PUMP.

EAS00376

INSTALLING THE OIL PUMP 1. Install: S oil pump Nm (1.0 mSkg)
After tightening the bolts, make sure that the oil pump turns smoothly.

EAS00378

INSTALLING THE OIL STRAINER 1. Install: S oil strainer housing 1 2. Install: S oil strainer cover 2 S relief valve NOTE: The arrow a on the oil strainer cover must point towards the rear of the engine.

EAS00380

INSTALLING THE OIL PAN 1. Install: S dowel pins S gasket (New) S oil pan Nm (1.0 mSkg) S oil level switch 2

S engine oil drain bolt

Always use new copper washers. NOTE: S Tighten the oil pan bolts in stages and in a crisscross pattern. S Lubricate the oil level switchs O-ring with engine oil.

CRANKCASE CRANKCASE

21 (4)

13 (3)

Job/Part Crankcase separation Engine assembly Cylinder head Water pump Clutch assembly Shift shaft, stopper lever Clutch release cylinder AC Magneto Oil pan and oil pump assembly

Do not attempt to straighten a bent shift fork guide bar.
3. Check: S shift fork movement (on the shift fork guide bar) Rough movement ! Replace the shift forks and shift fork guide bar as a set.

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum. S shift drum bearing 1 Damage/pitting ! Replace. S shift drum segment 2 Damage/wear ! Replace.

EAS00425

CHECKING THE TRANSMISSION 1. Measure: S main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main axle. Main axle runout limit 0.08 mm 2. Measure: S drive axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the drive axle. Drive axle runout limit 0.08 mm
3. Check: S transmission gears Blue discoloration/pitting/wear ! Replace the defective gear(-s). S transmission gear dogs Cracks/damage/rounded edges ! Replace the defective gear(-s). 4. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. 5. Check: S transmission gear movement Rough movement ! Replace the defective part(-s). 6. Check: S circlips Damage/bends/looseness ! Replace.

EAS00426

INSTALLING THE SHIFT FORKS 1. Install: S shift forks 1 S shift fork guide bars 2 NOTE: The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: R, C, L.
2. Install: S shift cam 1 S shift cam retainer 2
NOTE: S Apply LOCTITER #648 to the shift cam retainer screws. S Rotate the shift cam to the neutral position.
3. Install: S neutral switch 1
NOTE: Apply grease to the neutral switch.

Always use a new O-ring.

EAS00428
INSTALLING THE TRANSMISSION 1. Install: S main axle assembly 1 S drive axle assembly 2 NOTE: S Make sure that the bearing circlips 3 are inserted into the grooves in the lower crankcase. S The bearing pin 4 are inserted into the grooves in the lower crankcase. 2. Check: S transmission Rough movement ! Repair. NOTE: Oil each gear, shaft, and bearing throughly.

MIDDLE GEAE MIDDLE GEAE

90 Nm (9.0 mSkg)

110 Nm (11.0 mSkg)

Job/Part Removing the middle gear Crankcase separation Drive axle assembly Nut Washer Universal joint (yoke) Dust seal Middle driven gear housing Shims O-ring Bearing Collapsible collar Spacer Bearing Middle drive shaft Retainer
Remarks Remove the parts in the ordr listed. Refer to CRANKCASE. Refer to TRANSMISSION. Refer to DISASSEMBLING/ ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY.
Refer to DISASSEMBLING/ ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY.

7. Select: S shim(-s) 1

a. Shims can only be selected in 0.05 mm increments, therefore round off to the hundredths digit of the calculated thickness and select the appropriate shim(-s) with the following chart. b. For example, the clearance between the crankcase and the middle driven shaft bearing housing is 0.42 mm. Therefore, the chart instructs you to round off the 2 to 0. Thus, you should use one 0.40 mm shim. Hundredths 0, 1, 2 3, 4, 5, 6, 7 8, 9 Rounded value 10
Shims are supplied in the following thicknesses. Middle drive gear shim Thickness (mm) 0.10, 0.15, 0.20, 0.30, 0.40, 0.50
8. Loosen: S middle driven shaft bearing housing bolts 9. Install: S shim(-s)R 10. Tighten: S middle driven shaft bearing housing bolts

30 Nm (3 mSkg)

11. Measure: S middle gear backlash Out of specification ! Refer to MEASURING THE MIDDLE GEAR BACKLASH. 12. Install: S bearing retainers 1
S Apply LOCTITER on to the retainer screws. S After tightening the bearing retainer screws, stake them with a center punch.

CONTENTS COOLING SYSTEM

RADIATOR. 5-1 CHECKING THE RADIATOR. 5-2 INSTALLING THE RADIATOR. 5-3 THERMOSTAT. THERMOSTAT HOUSING. CHECKING THE THERMOSTAT. ASSEMBLING THE THERMOSTAT. INSTALLING THE THERMOSTAT. WATER PUMP. DISASSEMBLING THE WATER PUMP. CHECKING THE WATER PUMP. ASSEMBLING THE WATER PUMP. INSTALLING THE WATER PUMP. 5-5 5-6 5-7 5-7 5-8 5-9 5-11 5-11 5-13 5-14

RADIATOR

COOLING SYSTEM

2 Nm (0.2 mSkg)

12 (3)

40 (2)

Job/Part Removing the radiator Rider seat, fuel tank
Remarks Remove the parts in the order listed. Refer to RIDER AND PASSENGER SEATS and FUEL TANK in CHAPTER 3. Refer to CHANGING THE COOLANT in CHAPTER 3.
Coolant 7 Steering head side covers Lower radiator bolts Radiator hose clamps (upper and lower) Thermo unit lead Fan lead Radiator Fan motor 1
Loosen Disconnect Disconnect

EAS00455

CHECKING THE RADIATOR 1. Check: S radiator fins Obstruction ! Clean. Apply compressed air to the rear of the radiator. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: S radiator hoses S radiator pipes Cracks/damage ! Replace.
3. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. Radiator cap opening pressure 95 X 125 kPa (0.95 X 1.25kgf/cm2, 0.95 X 1.25 bar) a. Install the radiator cap tester 1 to the radiator cap. Radiator cap tester YU-24460-01, 90890-01325 b. Apply the specified pressure for ten seconds and make sure that there is no drop in pressure. 4. Check S radiator fan Damage ! Replace. Malfunction ! Check and repair. Refer to COOLING SYSTEM in chapter 8.

EAS00486

CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace.
2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleumbased solvent. Do not use any caustic-carburetorcleaning solution. b. Blow out all of the passages and jets with compressed air.
3. Check: S float chamber body Dirt ! Clean. 4. Check S float chamber rubber gasket 1 Cracks/damage/wear ! Replace.
5. Check: S float Damage ! Replace.
6. Check: S needle valve 1 S needle valve seat 2 Damage/obstruction/wear ! Replace the needle valve, needle valve seat and O-ring as a set. 7. Check: S O-ring 3 Damage/wear ! replace the needle valve, needle valve seat and O-ring as a set.
8. Check: S piston valve 1 Damage/scratches/wear ! Replace. S rubber diaphragm 2 Cracks/tears ! Replace.
9. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder Cracks/damage ! Replace.
10. Check: S jet needle kit 1 S needle jet 2 S main jet 3 S pilot jet 4 S pilot screw 5 Bends/damage/wear ! Replace. Obstruction ! Clean. Blow out the jets with compressed air.
11. Check: S piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness ! Replace the piston valve.
12. Check: S fuel feed pipes S hose joint Cracks/damage ! Replace. Obstruction ! Clean. Blow out the pipes with compressed air.
13. Check: S fuel feed hoses S fuel hoses Cracks/damage/wear ! Replace. Obstruction ! Clean. Blow out the hoses with compressed air.

EAS00489

ASSEMBLING THE CARBURETORS The following procedure applies to both of the carburetors.
S Before assembling the carburetors, wash all of the parts in a petroleum-based solvent. S Always use a new gasket. 1. Install: S piston valve holder
2. Install: S needle jet 1 S pilot jet S main jet NOTE: Align the slot a on the needle jet with the projection b on the carburetor body.
3. Measure: S float height a Out of specification ! Adjust. Float height 8.0 X 9.0 mm
a. Hold the carburetor upside down. b. Measure the distance from the mating surface of the float chamber (with the gasket removed) to the top of the float. NOTE: The float arm should rest on the needle valve without depressing it. c. If the float height is not within specification, inspect the needle valve seat and needle valve. d. If either the needle valve seat or needle valve is worn, replace them both. e. If both the needle valve seat and needle valve are fine, adjust the float height by bending the float tang 1. f. Check the float height again.
4. Install: S coasting enricher diaphragm 1 S coasting enricher spring 2 S coasting enricher cover 3 NOTE: Align the tab a on the coasting enricher diaphragm with the recess b in the carburetor body.

INSTALLING THE FRONT FORK LEGS. 7-55 HANDLEBAR. HANDLEBAR. REMOVING THE HANDLEBAR. CHECKING THE HANDLEBAR. INSTALLING THE HANDLEBAR. STEERING HEAD. STEERING HEAD. REMOVING THE LOWER BRACKET. CHECKING THE STEERING HEAD. INSTALLING THE STEERING HEAD. REAR SHOCK ABSORBER. REAR SHOCK ABSORBER ASSEMBLY. REMOVING THE REAR SHOCK ABSORBER ASSEMBLY. CHECKING THE REAR SHOCK ABSORBER ASSEMBLY. INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY. SWINGARM. SWINGARM. REMOVING THE SWINGARM. CHECKING THE SWINGARM. INSTALLING THE SWINGARM. SHAFT DRIVE. SHAFT DRIVE. TROUBLESHOOTING. CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND INSPECTING THE SHAFT DRIVE FOR LEAKS. FINAL DRIVE ASSEMBLY AND DRIVE SHAFT. FINAL DRIVE ASSEMBLY AND DRIVE SHAFT. MEASURING THE RING GEAR BACKLASH. ADJUSTING THE RING GEAR BACKLASH. MEASURING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE. ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE. FINAL DRIVE. FINAL DRIVE ASSEMBLY. DISASSEMBLING THE FINAL DRIVE ASSEMBLY. REMOVING AND INSTALLING THE RING GEAR BEARINGS. ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR. 7-56 7-56 7-58 7-58 7-59 7-61 7-61 7-63 7-63 7-64 7-66 7-66 7-68 7-68 7-69 7-70 7-70 7-72 7-72 7-73 7-74 7-74 7-74 7-77 7-78 7-78 7-79 7-80 7-81 7-81 7-83 7-83 7-85 7-86 7-87
CHECKING THE DRIVE SHAFT. 7-91 INSTALLING THE DRIVE SHAFT. 7-91
FRONT WHEEL AND BRAKE DISCS

EAS00514

25 Nm (2.5 mSkg) 78 Nm (7.8 mSkg)
19 Nm (1.9 mSkg) 40 Nm (4.0 mSkg)
Job/Part Removing the front wheel and brake discs
Securely support the motorcycle so there is no danger of it falling over. 1 Front brake calipers/brackets (left and right) 2/2 NOTE: Do not depress the brake lever when the wheel is off of the motorcycle as the brake pads will be forced shut. 1 Loosen Elevate the front wheel. Place a suitable stand under the engine.
Pinch bolt(front wheel axle) Front wheel axle Front wheel

Order 7 8

Job/Part Collars Brake disc cover (left) Brake discs Brake disc cover (right-with weight)
Refer to INSTALLING THE FRONT WHEEL. For installation, reverse the removal procedure.

EAS00518

FRONT WHEEL
Job/Part Disassembling the front wheel
Oil seals Bearings Spacer

EAS00521

Handlebar Front cowling Front wheel, front forks Leads (to the front cowling body) Chrome flasher bracket cover

Order 17

Job/Part Flasher light bracket assembly Brake hose joint Brake hose guide Steering stem nut Upper bracket Lock washer Upper ring nut Rubber washer Lower ring nut Bearing cover Bearing (upper) Bearing races Lower bracket Bearing (lower) Rubber seal
Refer to REMOVING THE LOWER BRAKET/INSTALLING THE STEERING HAND.

EAS00679

REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface.
2. Remove: S upper ring nut 1 S lower ring nut 2 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, then remove the upper ring nut with the ring nut wrench. Exhaust and steering nut wrench 90890-01268 Ring nut wrench YU-33975, 90890-01403
Securely support the lower bracket so that there is no danger of it falling.

EAS00682

CHECKING THE STEERING HEAD 1. Wash: S bearing Recommended cleaning solvent Kerosine
2. Check: S bearing 1 S bearing races Damage/pitting ! Replace.
3. Replace: S bearing balls S bearing races
a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new dust seal and new bearing races.
If the bearing race is not installed properly, the steering head pipe could be damage. NOTE: S Always replace the bearing balls and bearing races as a set. S Whenever the steering head is disassembled, replace the dust seal.
4. Check: S upper bracket S lower bracket (along with the steering stem) Bends/cracks/damage ! Replace.

EAS00683

INSTALLING THE STEERING HEAD 1. Lubricate: S upper bearing S lower bearing S bearing races Recommended lubricant Lithium soap base grease
2. Install: S lower ring nut 1 S rubber washer 2 S upper ring nut 3 S lock washer 4 Refer to INSPECTING THE STEERING HEAD in chapter 3.
3. Install: S upper bracket S steering stem nut
NOTE: Temporarily tighten the steering stem nut. 4. Install: S front fork legs Refer to FRONT FORK. NOTE: Temporarily tighten the upper and lower bracket pinch bolts.
REAR SHOCK ABSORBER ASSEMBLY

EAS00685

59 Nm (5.9 mSkg)
50 Nm (5.0 mSkg) 50 Nm (5.0 mSkg)
Job/Part Removing the rear shock absorber assembly
Securely support the motorcycle so there is no danger of it falling over. Rear fender and rear wheel Muffler 5 Bolt (shock absorber-frame) Bolt (shock absorber-relay arm) Rear shock absorber Bolt (connecting arm-relay arm) Bolt (connecting arm-swingarm)

Refer to REAR WHEEL AND BRAKE DISC. Refer to ENGIEN REMOVAL in CHAPTER 4. 1 1
Refer to REAR SHOCK ABSORBER ASSEMBLY.

Order 8

Job/Part Connecting arms Bolt (relay arm -frame) Relay arm

EAS00690

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface.
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 rear wheel is elevated. 2. Remove: S rear shock absorber assembly

EAS00695

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM 1. Check: S rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly. S bushings Damage/wear ! Replace. S bolts Bends/damage/wear ! Replace. 2. Check: S relay arm Cracks/damage ! Replace.
3. Check: S connecting arms Cracks/damage ! Replace.

EAS00698

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: S spacers S bearings Recommended lubricant Molybdenum disulfide grease 2. Install: S rear shock absorber assembly Rear shock absorber assembly upper nut Nm (5.9 mSkg) Rear shock absorber assembly lower nut Nm (5.0 mSkg) Relay-arm-to-frame-nut Nm (5.0 mSkg) NOTE: S When installing the rear shock absorber assembly, lift up the swingarm. S Install the connecting arm front bolt from the right.

SWINGARM

EAS00701

100 Nm (10.0 mSkg)

42 Nm (4.2 mSkg)

16 Nm (1.6 mSkg)

Job/Part Removing the swingarm
Securely support the motorcycle so there is no danger of it falling over. Rear fender and rear wheel Rear shock absorber 5 Speedometer sensor Final gear case Drive shaft Brake hose holder Speedometer sensor leads 1 Refer to REAR WHEEL AND BRAKE DISC. Refer to REAR SHOCK ABSORBER ASSEMBLY.
Unhook from the cable guide.

Order 6 7

Job/Part Pivot shafts (right and left) Swingarm
Refer to REMOVING THE SWINGARM. For installation, reverse the removal procedure.

EAS00702

REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface.

AUDIO SYSTEM AUDIO SYSTEM
Main switch Battery Fuse (main) Fuse (back up)

AUDIO SYSTEM

Fuse (audio) MCU Speaker (front) Speaker (front) Speaker (rear) Rear remoto controller Fuse (front DC outlet) Fuse (rear DC outlet) DC outlet (front) DC outlet (rear)
AUDIO SYSTEM AUDIO SYSTEM CIRCUIT OPERATION
The audio system circuit consists of the front/rear remote controllers, front/rear speakers, tape deck, and main control unit (MCU).
Battery Fuse (main) Main switch Fuse (back up) Fuse (audio) Main control unit Front remoto controller Rear remoto controller Front speakers Rear speakers
FM / AM antenna Tape deck Fuse (front DC outlet) Fuse (rear DC outlet) DC outlet (front) DC outlet (rear) Front headset (option) Rear headset (option) CD changer (option)
REMOVAL 1. Disconnect: S Front remote control coupler (from the main control unit) S Tape deck coupler (from the main control unit)
When disconnect a coupler, be sure to push on the coupler as shown, and pull it out straight. If the coupler is twisted when disconnecting, the inner pins may be damaged.
INSTALL 1. Connect: S Front remote control coupler (to the main control unit) S Tape deck coupler (to the main control unit)
When connecting a coupler, be sure to align projection 1 with indent 2 and push inward straightly. If the coupler is twisted when connecting, the inner pins may be damaged.
AUDIO SYSTEM does not operation Check: 1. Fuses 2. Ground 3. MCU 4. Wiring connections (of the entire audio system) NOTE: S Before troubleshooting, remove the following part(-s): 1) Front cowlling 2) Trunk S Troubleshoot with the following special tool(-s). Pocket tester YU-03112, 90890-03112 1. All AUDIO system does not operation. 1. Fuse S Check the main back up and audio fuse for continuity. Refer to CHECKING THE FUSES in CHAPTER 3. S Is the main back up and audio fuse OK? YES NO Replace the fuses. 2. Ground lead S Check the ground lead 1. S Check the wiring. S Check the ground. 3. MCU coupler
S Check the connection of MCU 18P connector. Refer to checking the connection. S Is the MCU connector OK? YES Correct the connector. 4. MCU back up S Disconnect the MCU 18P connector from the wire harness. S Connect the pocket tester (20 V DC) to the MCU 18P connector as shown. Back up Tester positive probe ! red/green 1 Tester negative probe ! ground Audio Tester positive probe ! brown/white 2 Tester negative probe ! ground NO MCU
S Measure the voltage (12 V) on the MCU 18P connector. S Is the voltage within specification? YES NO Correct the wiring. 5. Wiring connections S Check the wiring (blue/green) of MCU X front remote controller.