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2007 yamaha v star 1100 service manual free download |
Yamaha V-Star Factory Service Repair by Linda Pong - Issuu
Table of Contents. Previous Page. Next Page. First edition, October All rights reserved. Any reproduction or unauthorized use without the 2007 yamaha v star 1100 service manual free download permission of Yamaha Motor Co. Page 3 It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo- torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Page 7 INFO This information will be needed to order spare parts. Page Important Information 5. Keep all parts away from any source of fire. Use only genuine Yamaha parts for all re- placements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Bend lock tabs asa series manual 5505 cisco the bolt or nut flats after the bolt or nut has been tightened to specification. Disconnect: S Connector 2. Check: S Connector Moisture!
Dry each terminal with an air blower. Connect and disconnect the terminals several times. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. Valve spring compressor This suzuki eiger 400 service manual free download is needed to remove and install the valve assemblies.
Page 16 This tool is needed when removing or instal- ling the damper spring. Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components. Yamaha bond No. Page 17 SPEC Page Chapter 2.
A Fasten the handlebar switch clamp 2007 yamaha v star 1100 service manual free download with holder. G Route the sidestand lead leads left and right to the C Clamp the wire harness with N Fasten the alarm lead with a Set the band at four notches, plastic band on the lid.
M Arrange the throttle position sensor connector, carburetor heater 2007 yamaha v star 1100 service manual free download and thermo switch connector between the starting circuit cutoff relay and high tension code. Q Clamp the taillight lead with Position the end of holder down mud guard clamp.
Page 54 INSP These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera- tion and a longer service life. The need for costly overhaul work will be greatly reduced.
This informa- tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Page 58 Final gear oil 24, km or 24 months whichever comes first. NOTE: S The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Install: S Ignitor plate NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver.
S When the valve clearance is to be measured or adjusted, the piston must be at top dead center TDC on the compression stroke. Remove: S tappet covers 1 7. Читать больше S camshaft sprocket cover rear cylinder 1 S camshaft sprocket cover front cylinder 8. Remove: S timing plug 1 S straight plug 2 9.
Measure: S valve clearance Out of specification! Turn the crankshaft counterclockwise. When the piston is at TDC on the compres- sion stroke, align either the camshaft sprock- et plate hole a with the stationary pointer b on the cylinder head.
When the camshaft sprocket plate hole or camshaft sprocket punch mark is aligned with the stationary pointer, the piston is at top dead center Measure the valve clearance again. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained. Install: 2007 yamaha v star 1100 service manual free download vacuum gauge 1 S engine tachometer 2 to the spark plug lead of cyl. Start the engine and let it warm up for several minutes.
Loosen the locknut 1. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Throttle cable free play is Direction increased. Measure: S spark plug gap a with a wire gauge Out of specification! Spark plug gap 0. Install: S spark plug 20 Nm 2. Check: S ignition timing a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed.
Install: S compression gauge 1 Compression gauge set: 6. Stand the motorcycle on a level surface. Start the engine, warm it up for several min- utes, and then адрес страницы it off. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. Install: S o-ring S engine oil filter cap Adjust: S h8 manual mechanism Engine side a. Triumph manual download in the adjusting screw 2 until it is lightly seated.
Unfiltered air will cause rapid wear of engine 2007 yamaha v star 1100 service manual free download and may damage the engine. S gaskets 3 Exhaust gas leaks! Check: S brake lever free play a Out of specification! Brake lever free play at the 2007 yamaha v star 1100 service manual free download of the brake lever 5 X 8 mm 2.
Adjust: S brake lever free play a. Check: S brake pedal position distance a from the top of the rider footrest приведу ссылку the top of the brake pedal Out of specification! Brake pedal position below the top of the rider footrest S Make sure that the motorcycle is upright. Check; S brake fluid level Below the minimum level mark a! Add the recommended brake fluid to the proper level. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.
Tighten the bleed screw and then release the brake lever or brake pedal. Repeat больше на странице e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose. Loosen the lower ring nut 4 2007 yamaha v star 1100 service manual free download then tighten по этому адресу to specification with a ring nut wrench 5. NOTE: Set the torque wrench at a right angle to the ring nut wrench.
Ring nut wrench Lower ring nut initial tightening Turn the adjusting knob 1 in direction a or! Spring preload is Direction increased suspension is harder. Spring 2007 yamaha v star 1100 service manual free download is Direction decreased suspension is softer. Page 90 No guarantee concerning handling characteristics can 2007 yamaha v star 1100 service manual free download given if a tire combination other than one approved by Yamaha is used on this motorcycle.
Front tire: Manufactur- Type S Align the mark 2 with the valve installation point. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. S Never remove the MF battery sealing caps. Voltage should be measured 30 min- utes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
Check: S battery breather hose and battery vent Obstruction! Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. Place a suitable stand under the frame and engine. Tighten the bolts in the following order. Remove: S camshaft sprocket cover S tappet covers 2.
2007 yamaha v star 1100 service manual free download
If over tighten the middle driven pinion gear nut, replace the collapsible col- lar and adjust the backlash. Stake the middle driven pinion gear shaft thread. Select: S middle drive gear shim -s 1 NOTE: Select the middle drive gear shim -s 1 by cal- culating the middle drive gear shim thickness and then measuring the middle gear backlash.
Middle drive pinion gear shim: Thickness mm 0. Page CARB Air filter case assembly Air ducts Cylinder head breather hose Disconnect Air chamber Disassemble the parts in the order listed. Jet needle set Starter plunger set Pilot screw Main air jet Pilot air jet 1 Pilot air jet 2 Throttle stop screw set For assembly, reverse the disassembly procedure.
Check: S fuel passages Obstruction! Wash the carburetor in a petroleumbased solvent. S Always use a new gasket. Measure: S fuel level a Out of specification! Fuel level above the line on the float chamber 4 X 5 mm a. Inspect: S throttle position sensor a. Disconnect the throttle position sensor cou- pler. Tighten the throttle position sensor screws.
NOTE: Remove the pocket tester leads and connect the throttle position sensor coupler. This is to reduce the output of the hy- drocarbons. When there is negative pressure around the ex- haust port, the reed valve opens and the sec- ondary air flows into the exhaust port. Inspect: Air filter S hose connections Orifice Poor connections! Properly connect. Carburetor joint near cylinder S hoses To the front cylinder head S reed valves To the rear cylinder head S air cut-off valve To the orifice S air filter Page CHAS Oil seals Bearings Collar For assembly, reverse the disassembly procedure.
NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Tighten: S spokes 3 Nm 0. Measure: S front wheel radial runout 1 S front wheel lateral runout 2 Over the specified limits! Clean the outside of the front wheel hub. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag be- tween the screwdriver and the wheel surface.
Remove the brake caliper. Hold the dial gauge at a right angle against the brake disc surface. Measure the deflection 2 — 3 mm below the edge of the brake disc. Lubricate: S wheel axle S oil seallips Recommended lubricant Lithium soap base grease 2.
S Adjust the front wheel static balance with the brake discs installed. Check: S front wheel static balance a. Turn the front wheel and make sure that it stays at each position shown. If the front wheel does not remain stationary at all of the positions, rebalance it. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Lubricate: S drive shaft splines Recommended lubricant Molydenum disulfide grease 2. Tighten the rear axle holder with specified torque. Rear axle end nut 23 Nm 2. Tighten the rear brake caliper bracket bolt with specified tightening torque. Brake caliper bracket bolt 40 Nm 4. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
Remove: S brake pads 1 along with the brake pad shims 3. Measure: S brake pad wear limit a Out of specification! Replace the brake pads as a set. Brake pad wear limit 0. Check: S brake fluid level Below the minimum lever mark a! Check: S brake lever operation Soft or spongy feeling! Bleed the brake system. Install: S brake pad shims onto the brake pads S brake pads S brake pad spring NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set.
Connect a clear plastic hose 1 tightly to the bleed screw 2. S brake fluid delivery passages 2 brake master cylinder body Obstruction! Blow out with compressed air. S Never use solvents on internal brake com- ponents. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
S 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 perfor- mance. Brake fluid Drain Brake hose holder Union bolt Caliper piston seals Bleed screw For assembly, reverse the disassembly procedure. NOTE: Before removing either brake caliper, drain the brake fluid from the entire brake system.
Remove: S brake hose holder S union bolt 1 S copper washers 2 S brake hose Remove: S brake caliper pistons 1 S brake caliper pistons seals 2 a. Replace the brake caliper piston assembly. Replace the brake cali- per. S brake fluid delivery passages brake caliper body Obstruction! Therefore, always clean up any spilt brake fluid immediately.
Check: S brake fluid level Below the minimum level mark a! Oil lock piece Outer tube For assembly, reverse the disassembly procedure. S If the front fork leg protector must be removed, always install a new one. Blow out all of the oil pas- sages with compressed air.
S oil lock piece 2 Damage! Tighten: S damper rod bolt 1 30 Nm 3. Page with the specified amount of the recom- mended fork oil Quantity each front fork leg 0. Other oils may have an adverse effect on front fork performance. S Before installing the cap bolt, apply grease to the O-ring.
S Temporarily tighten the cap bolt. Cable guide Handlebar holders lower For installation, reverse the removal procedure. Remove: S handlebar grip left 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. Apply a light coat of rubber adhesive onto the left end of the handlebar. Slide the handlebar grip over the left end of the handlebar. Wipe off any excess rubber adhesive with a clean rag.
Clutch cable free play at the end of the clutch lever 5 X 10 mm 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 Remove the bearing reces from the steering head pipe with a long rod 1 and hammer. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. Install a new rubber seal and new bearing re- ces. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand following information.
Replace the rear shock absorber assembly. Lubricate: S spacers S bearings Recommended lubricant Molybdenum disulfide grease 3. Install: S rear shock absorber assembly Rear shock absorber assembly upper nut 40 Nm 4. Install: S relay arm S left connecting arm S right connecting arm Rear-shock-absorber-assembly lower nut 1 48 Nm 4. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration, or sus- B.
Improper gear lash tained speeds. Damaged gear teeth surging or transmissionrelated D. Broken drive shaft Investigate any unusual noises. The following noises may indicate a me- chanical defect: a.
Check: S final drive oil Large amount of metal particles! Check for bearing seizure. Secure the final drive assembly in a vise. Remove: S final drive oil drain bolt 3. Drain: S final drive oil from the final drive assembly 4. Measure: S ring gear backlash Out of specification! Reinstall the bolt, special tool, and dial gauge.
Repeat steps d to h three more times for a total of four measurements. If any of the readings are over specification, adjust the ring gear backlash. If it is necessary to increase the ring gear backlash by more than 0. If it is necessary to reduce the ring gear back- lash by more than 0.
After all of the bolts and nuts are fully loosened, and remove them. Remove: S collar 1 S oil seal 2 S bearing 3 with an appropriate press tool 4 and an ap- propriate support for the final drive housing 2. Check: S bearing Damage! Install: S gear coupling S self-locking nut Nm Install: S ring gear bearing housing along with the ring gear, but without the thrust washer 5. Page Checking The Drive Shaft 1. Lubricate: S drive shaft splines Recommended lubricant Molybdenum disulfide grease 2.
Apply: S sealant onto both final drive housing mating sur- faces Yamaha bond No. Install: S drive shaft to the final drive pinion gear Tighten: S final bearing housing nuts 42 Nm 4. Page — ELEC If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Repair or replace the switch.
Improperly connected! Incorrect continuity reading! Replace the switch. Repair or replace the bulb, bulb socket or both. Check: S bulb socket for continuity with the pocket tester No continuity! Battery S Check the condition of the battery. The ignition system fails to operate no spark or intermittent spark. Check: Min. S Disconnect the spark plug cap from the spark plug. Main switch S Check the main switch for continuity.
S Is the main switch OK? Replace the main switch. Secondary coil resistance Starting circuit cut-off relay diode S Remove the relay unit from the wire har- ness. S Check for continuity as follows: SKy blue Continu The starter motor fails to turn.
Starting circuit cutoff relay 5. Starting circuit cutoff relay Diode S Disconnect the relay unit from the coupler. Starter relay 8. Engine stop switch S Check the engine stop switch for continuity.
S Is the engine stop switch OK? Start switch S Check the start switch for continuity. S Is the start switch OK? Replace right handlebar switch. Diode S Check the diode for continuity.
S Is the diode OK? Replace the diode. Starter motor lead Starter motor assembly For installation, reverse the removal procedure. Disassembling the starter motor Disassembly the pats in the order listed. Check: S commutator Dirt! Clean with grit sandpaper. Measure: S commutator diameter a Out of specification! Replace the starter motor. Measure: S mica undercut a Out of specification! Scrape the mica to the proper measurement with a hacksaw blade Measure: S brush length a Out of specification!
Replace the brushes as a set. Measure: S brush spring force Out of specification! Replace the brush springs as a set. Bruch spring force 7.
The battery is not being sharged. Check: 1. S Is the charging voltage within specification? The charging circuit is OK. Open-circuit voltage Check: Dimmer switch 1. The headlight and the high beam indicator S Check the dimmer switch for continuity.
S Is the dimmer switch OK? Voltage S Connect the pocket tester 20 V to the meter assembly coupler wire harness side as shown. Tester positive probe! Voltage 2. S The forn fails to sound. The horn fails to sound. S Disconnect the black connector at the horn terminal. Horn switch S Connect a jumper lead to the horn terminal S Check the forn switch for continuity. S Pull in the brake lever or push down on the 1. Turn signal switch Tester negative probe! S Is the turn signal switch OK? Replace the left han- dlebar switch.
S Connect the pockt tester DC 20V to the me- S Measure the voltage 12 V of chocolate ter assembly coupler wire harness side as dark green at the turn signal light connec Oil level switch 4. Ignition fuse The ignitor unit includes the control unit for the Engine stop switch fuel pump. The fuel pump fails to operate. Starting circuit cutoff relay fuel pump relay 6.
Fuel pump resistance S Disconnect the fuel pump coupler from the S Remove the relay unit from the wire har- wire harness. Be extreme- ly careful and note the following points: S Stop the engine before refuelling. S Do not smoke and keep away from open flames, sparks, or any other source of fire. The carburetor heater fails to operate. Carburetor heater relay S Remove the carburetor heater relay from the wire harness.
Sky blue terminal Carburetor heater S Remove the carburetor heater from the car- buretor body. S Connect the pocket tester to the carburetor heater. Heater terminal Tester — lead! Heater body S Measure the heater resistance. S Is the wire harness OK? S Turn the rear wheel slowly.
S Check the tester voltage 0V - 5V - 0V. S Is the speed sensor OK? Replace the ignitor Replace the speed unit. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. Position the end of right side. This manual is also suitable for: xvs xvsl. Woodruff key 2. Chain guide bolt Primary drive nut 3. Cam chain drive assembly Lockwasher 4. Cam chain Keyed washer 5. Front chain guide Timing gear 6.
Retainer bolt Preload the cam chain drive assembly as follows: a. Page The following procedures describe how Top view to check valve components and determine the needed service. A valve spring compressor Yamaha part No.
YM or , or equivalent, is needed to remove and install the valves. Insert a bore protector between the valve assem- bly and the bore. Install a valve spring compressor squarely over the valve retainer.
Make sure the opposite end of the com- pressor rests against the valve head. Label the set so you will know what cylinder it came from and whether it is an in take or an exhaust valve. This keeps parts from getting mixed up and makes installation simpler. Do not mix components from different valve assemblies or excessive wear may occur. Compress the valve springs with a valve spring compressor and install the valve keepers Figure Page This procedure requires the following special tools lapping with fine carborendum paste, however, lap- and should be entrusted to a Yamaha dealership or ping is inferior to precision grinding.
Install new circlips onto the new valve guides, and place the valve guides in a freezer overnight. Remove and discard the valve guide and circlip. Never reinstall a valve guide or circlip. They are no longer true and are not within tolerance. After the cylinder head cools, check the guide bore for carbon or other contamination. Clean the bore thoroughly. Reface the valve seats as described in this chap- ter.
Install the intake manifold. When servicing a rear cylinder head, install the exhaust manifold with a new exhaust gasket. The following procedure is provided if you choose to perform this task yourself. Check the seat by performing the leakage test described in the Cylinder Head section earlier in this chapter. If fluid leaks past any of the seats, disassemble that valve assembly and repeat the lapping procedure Valve lapper until there are no leaks.
Cylinder bolt 2. Cylinder 3. Compression ring 4 Oil ring 5. Piston pin circlip 6. Piston 7. Base gasket 8. Dowel 9. Front cam chain guide Piston pin Follow the break-in procedure in Chapter Five if the cylinder block was rebored or honed, or if a new piston or piston rings were installed.
Inspection The following procedure requires the use of highly specialized and costly measuring instru- ments. Remove the cylinder head and cylinder as de- scribed in this chapter. Lightly mark the top of the piston front or rear so it can be installed in the correct cylinder during installation. Do not drive out the piston pin. This could damage the pis- ton pin, connecting rod or piston. Remove the piston from the connecting rod and remove the remaining circlip from the piston.
Dis- card both piston pin circlips. Install the second piston pin circlip Figure into the groove in the piston. Check the piston skirt B, Figure for gall- ing and abrasion, which may have been caused by Specified distance piston seizure.
If a piston shows signs of partial sei- zure bits of aluminum build-up on the piston skirt , replace the piston to reduce the possibility of engine noise and further piston seizure. Measure the inside diameter of the piston pin bore in the piston with a small bore gauge Figure Calculate piston pin-to-piston clearance by sub- tracting the piston pin outside diameter from the piston pin bore inside diameter.
If the clearance is outside the range specified in Table 2, replace the piston pin if the piston bore inside diameter is within specification. Inspect the grooves carefully for burrs, nicks or broken and cracked lands.
Recondition or replace the piston if necessary. Roll each ring around its piston groove as shown in Figure to check for binding. Minor binding may be cleaned up with a fine-cut file. Install the oil control ring assembly into the bot- tom ring groove. Displacement cc Compression ratio 8. Service limit mm in. Valve head diameter Intake Exhaust pipe-to-manifold bolts rear cylinder — Flywheel nut — Intake manifold bolts — Oil delivery pipe banjo bolt — Primary drive nut — Rear chain guide bolt — External gearshift mechanism.
Crankcase assembly. Connecting rods. Alternator and starter clutch. Frame 8. Engine bracket lower Engine bracket upper 2. Cylinder head bracket bolt through bolt through bolt 3. Front frame member nut 9. Upper rear engine Rear frame member bolt 4.
Rear engine through bolt mounting bolt Page Removal are no longer in place. Remove the cylinder head covers from each engine from the frame. Though this is cylinder head Chapter Four. Note that the bolt with two oil holes B, Figure 5 se cures the oil pipe to the cylinder head.
Remove the removable frame member as follows: a. Remove the nuts from the upper frame mem- ber bolts Figure 13 and remove the bolts. Remove the lower frame member bolts B, Figure 3 and lift the removable frame mem- ber from the frame. Page While the engine is removed for service, check all of the frame engine mounts for cracks or other damage.
If any cracks are detected, take the chassis assembly to a Yamaha dealership for further exami- nation. Installation Install the front engine bracket as follows: 1. Install the starter, speed sensor and horn Chap- ter Nine. Route the oil level switch wire A, Figure 3 along the path noted during removal and connect the bullet connector to its harness mate.
Install the right and left side covers, toolbox panel, frame neck covers and the sidestand Chapter Fourteen. Dowel 2. Gasket 3. Wire clamp 4. Stator mounting bolt 6. Alternator cover 7. Alternator cover bolt Remove the sidestand, toolbox cover and right side cover Chapter Fourteen. Roll the boot on the toolbox panel from the elec- trical connectors. Disconnect the three-pin stator connector A, Figure 21 and the two-pin pickup coil connector B from their respective mates on the wiring harness. Page See Chapter Nine for stator and pickup coil re- moval and inspection procedures.
Sheave holder: part No. YS or Bolt 9. Timing gear 2. One-way clutch housing Snap ring 3. One-way clutch Flywheel Bearing 5.
Starter wheel gear 6. Nut Starter idler gear assembly 7. If the timing mark on the rear cam sprocket does not align with the pointer on the rear head, rotate the engine one turn clockwise. Remove the alternator cover as described in this chapter. NOTE Install the sheave holder so it sits completely flat against the flywheel.
If necessary, lift the timing gear A, Figure 35 from the back of the flywheel. Remove each pin and spring Figure 36 from the slots in the flywheel. Installation 1. Insert a pin into each spring Figure Position the flywheel so the two marked teeth A, Figure 41 align with the Woodruff key in the crankshaft. If either part is worn or dam aged, replace the starter clutch assembly.
The one-way clutch is faulty if it fails either test. Replace the starter clutch assembly. Inspect the teeth A, Figure 48 of the starter wheel gear. Replace the gear if any teeth are worn, broken or missing. Inspect the bearing surface B, Figure 48 of the starter wheel gear for nicks or scratches. Replace the wheel gear if it shows signs of wear. If necessary, remove the oil delivery pipe mount- ing bolt C, Figure 53 at each end of the pipe, and remove the oil delivery pipe D from the crank- case.
Watch for the O-ring Figure 54 behind the fitting on each end of the pipe. Primary body 2. Oil strainer 3. Indexing pin 4. Outer rotor 5. Inner rotor 6. Secondary body 7. Outer rotor 8. Inner rotor 9. Drive pin Pump shaft Snap ring Oil pump cover Turn the pump over and lift the primary pump body Figure 59 from the pump. NOTE This pump has two sets of rotors: a thick set that fits in the primary body and a thin set for the secondary body.
Keep each set of rotors together with its respective body. Remove the shaft Figure 67 from the pump cover. Assembly 1. Coat all parts with fresh oil prior to assembly. Install the pump shaft Figure 67 into the pump cover. The end with the holes enters from the out- board side of the cover. Clean all parts in solvent and dry them thor- oughly with compressed air. Inspect the primary body A, Figure 68 for cracks and inspect the primary body rotors B for wear or abrasion.
Inspect the strainer C, Figure 68 for tears or other damage that will allow contaminants into the pump. Page If necessary, replace the chain along with both the drive and driven sprocket. Crankcase separating tool part No. YUA or Remove the mounting screw, and lift the shift also indicate the crankcase bolt tight ening sequence. See Figure Before removing the crankcase bolts, draw an outline of each case half on a piece of cardboard.
These bolts must be reinstalled in their original locations during as sembly. Remove the two dowels A Figure 77 from the crankcase mating surface. Remove the O-ring and its short collar B, Figure 77 from the boss beneath the crank- shaft.
Remove the O-ring from the crankcase mat- ing surface above the middle drive shaft. Page Install each shift fork with the letter tools are not available, have a facing up toward the right side of the Yamaha dealership or other qualified engine. Install the left shift fork into the countershaft 4. Page Do not add so much oil that it will drip from the bearing when the case half is turned over.
Apply a light coat of Yamaha Bond No. ACC or or on equivalent sealant to the mating surface of the left crankcase half. Turn the crankcase over and install the left crankcase bolts. If there is any binding, stop and correct the cause before proceeding. Before heating the crankcase, remove the middle drive shaft assembly and middle driven shaft as- sembly Chapter Seven.
Do Puller not heat the crankcase with a torch. Connecting rod 2. Connecting rod bolt 3. Connecting rod bearing 4. Main bearing 5. Oil pump drive sprocket 6. Crankshaft 7. Nut 8. If the side clearance is still outside the specified range, replace the crankshaft. Use V-blocks and a dial gauge to check the crankshaft runout Figure If the runout ex- ceeds the specification in Table 1, replace the crankshaft.
The connecting rod must be installed so this side faces the left crankshaft end the tapered end. Install rod and cap. Be sure the weight marks Figure 99 on the side of the rod and cap align. Between to miles km of for further service. Alternator cover bolts — Connecting rod nuts — Crankcase stud 10 mm — 12 mm — Crankcase bolts 6 mm — 10 mm — Engine mounting hardware Cylinder head bracket bolts — Replace any part that is dam- Refer to Figure 1.
Oil filter cover bolt 8. Clutch cover bolt 2. Oil filter outer cover 9. Wire clamp 3. Air filter housing bracket O-ring 4. Cap bolt Clutch cover 5. Cap Gasket 6. Install the wire clamps behind the bolts A, Figure 2 noted during removal. Apply Yamaha Bond or an equivalent sealant to the threads of the two indicated bolts C, Figure 2. Oil will leak past these bolts if the threads are not sealed.
Retaining wire Clutch nut 2. Clutch plate No. Lock plate 3. Clutch boss spring Clutch spring bolt 4. Plate seat Spring plate 5. Clutch boss Clutch spring 6. Remove the pressure plate B, Figure Remove the washer Figure 11 and the release bearing Figure 12 from pushrod No. Remove pushrod No. However, do not use a steel washer. Steel will damage the gear teeth.
If a clutch holder is not available, stuff a shop cloth, copper penny, or brass washer Figure 18 between the primary drive gear and the primary driven gear on the clutch housing. Lift the other end from the hole and remove the retaining wire from the clutch hub. Remove clutch plate No. The last item installed should be friction disc. Make sure the marked tab on each friction disc sits in the marked slots on the clutch housing as shown in Figure If necessary, remove the fric- tion discs and clutch plates.
Check the inner splines Figure 30 on the clutch plates. Minor roughness can be cleaned with an oilstone or fine file. If any one plate has excessive roughness or wear, re- place all the clutch plates as a set. They must be smooth for chatter-free operation. If there is any excessive damage, replace the compo- nents. Inspect the posts B, Figure 32 for wear or galling. If there is any excessive damage, re- place the clutch boss. Pushrod No. O-ring 3. Adjuster 4. Push screw 5. Ball assembly 6.
Housing 7. Oil seal 8. Pin 9. Clutch lever Spring 1. Remove the alternator cover as described in Chapter Five. Apply grease to the balls in the ball assembly A, Figure Lower the ball assembly A, Figure 41 onto the push screw B.
Seat the balls in the detents. Invert the assembly and install it into the housing on the inboard side of the alternator cover Figure Remove the mounting bolts A, Figure 45 , and pull the clutch adjuster cover B from the alternator cover. Disconnect the clutch cable Figure 46 from the clutch lever.
Pull the clutch cable end from the port in the alternator cover. Before removing the primary drive gear, set the front cylinder to top dead center on the compression stroke, The Yamaha sheave holder part No.
YU and note the position of the timing or , or an equivalent flywheel holder, marks on the cam sprocket plate and is needed to service the primary drive gear. Remove the cylinder head and the cam chain drive assembly from the front cylinder Chapter Four. Remove the clutch as described in this chapter. Bend the ears of the lockwasher A, Figure 50 away from the primary gear nut. Push the springs as far apart as possible.
Install the cam chain drive assembly and the cylinder head as described in Chapter Four. Install the clutch as described in this chapter. Loosen the shift lever clamp bolt B, Figure 2. Remove the footrest bracket bolts Figure 3.
Locknut 2. E-clip Shift rod 3. Stopper lever spring Snap ring 4. Stopper lever Shift pedal 5. Collar XVSA models 6.
Wave washer 7. Shift shaft spring XVSA models 8. Install the shift lever so the index mark A, Figure 2 on the shift shaft aligns with the slot in the shift lever. Slide the end of the shift shaft into the crankcase boss B, Figure 6 until the assembly bottoms. The arms of the shift shaft spring C, Figure 4 must straddle the post in the crankcase.
Retainer screw 6. Neutral pin 2. Shift fork shaft 7. Bearing retainer 8. Pin 20 mm 3. Shift fork shaft 9. Pin 16 mm 4. Shift fork Shift cam 5. Check the pins B, Figure 12 and shift cam ramps C for wear. Gear b. Middle drive gear Countershaft first gear Mainshaft fourth gear 3.
Countershaft fourth gear Splined washer 4. Snap ring 5. Splined washer Mainshaft second-third 6. Install fourth gear A, Figure 19 onto the mainshaft, and slide it up against first gear. Make sure the engagement dogs on the gear face away from first gear. Install a splined washer B, Figure 19 and a new snap ring C.
If it is still installed, remove the middle drive gear Figure 23 from the countershaft. Remove first gear, then remove fourth gear. Remove the snap ring and the splined washer. Remove the countershaft third gear. Install first gear Figure 30 so its flat side faces out. Install the middle drive gear Figure 23 so its splines engage those on the countershaft.
Mesh both assembled transmission shafts to- gether with the middle driven gear Figure Make sure all gears mate properly. Have these tools on hand before beginning this procedure.
Bearing retainer 2. Spring retainer 3. Spring seat 4. Damper spring 5. Damper cam male 6. Damper cam female 7. Middle drive shaft nut 8. Bearing 9. Middle drive shaft shims Middle drive shaft Apply engine oil to the teeth of the middle drive shaft and install the middle drive shaft assembly into the crankcase. Turn the bearing retainer A, Figure 40 until it is in place.
Inspect the internal splines on the male and fe- male sides of the damper cam. The Yamaha universal joint holder part No. Inspect the damper spring for wear, cracks or YM or , or its equivalent, is damage. Bearing Speed sensor bracket 2. Middle driven shaft Bolt 3. Rotor 4. Collapsible collar Drive yoke 5. Collar Washer 6.
O-ring Middle driven shaft nut 7. Remove the driven yoke C, Figure 46 from the drive yoke B. Hold the drive yoke with the universal joint holder A, Figure 48 and loosen the middle driven shaft nut B. Install the universal joint holder A, Figure 48 onto the drive yoke and install the middle gear backlash band Figure 49 onto the middle drive shaft assembly. Install the bearing housing bolts A, Figure 45 They may also be damaged. Dur- NOTE ing inspection, compare measurements to the speci- During removal, label each hose and fications in the tables at the end of this chapter.
Fuel tank 6. Seat bracket bolt 2. Fuel hose 7. Passenger seat 3. Fuel tank bolt 8. Nut 4. Meter connector 5. Seat bracket 8. Raise the fuel tank bracket and support the tank. Pull the meter connector B, Figure 5 from be- neath the ignitor panel and disconnect the pin meter connector A, Figure 6 from its harness Pull the tank bracket rearward until the tank is free of the damper A, Figure 7 on each side of the frame. Remove the fuel tank. Installation is the reverse of removal.
O-ring 2. Fuel valve body 3. Clamp 4. Fuel hose 5. Valve packing 6. Valve seal 7. Lever 8. Wave washer 9. Plate Pan head screw Screw 3. Drain the fuel from the tank into a clean, sealable b. Cover bolt Surge tank base Air filter housing 2.
Air filter cover Air filter housing bracket lower 3. Air filter Air filter housing duct Cylinder head 4. Remove the cover bolts A, Figure 10 and pull the air filter cover B from the housing. Lift the air filter A, Figure 11 from the posts in the air filter housing. Loosen the clamp B, Figure 11 that secures the surge tank duct to the back of the air filter housing.
Remove the plug A, Figure 15 from the drain hose on the air filter housing. Clean out accumu- lated moisture or dirt. If necessary, blow the hose clear with compressed air. Inspect all components of the air filter housing assembly.
If removed, install the cylinder head breather hose Figure 20 onto the surge tank fitting so the dots on the hose face forward. Make sure the clamp A, Figure 19 on each car- buretor duct is loose and the carburetor breather hose B faces up. At full throttle, the carburetor venturi is fully open and the needle is lifted far enough to permit the main jet to flow at full capacity. The choke circuit is a bystarter system. If necessary, turn the pull cable adjuster C, Figure 26 to create addi- tional slack.
Loosen the cable clamp screw A, Figure 27 and disconnect the choke cable end B from the choke linkage. Route the throttle cables and choke cable along their original paths. These cables must not be twisted, kinked or pinched.
Secure the cables in the holder B, Figure 7. Connect each hose to the fitting noted during removal and route the hose along its original path.
Remove the cotter pin A, Figure 35 and washer. Remove the throttle arm B, Figure 35 from the throttle shaft on the front carburetor. Remove the mounting screw A, Figure 36 and lift the choke linkage B from the starter plunger on the rear carburetor. Throttle position 1. Screw 2. Choke cable bracket sensor TPS Carburetor heater 3.
Top cover 4. Spring Ground terminal 5. Needle retainer Pilot jet 6. Jet needle Spacer 7. If the carburetors were not separated, disconnect the carburetor heater wires by performing Steps in Separation in this section.
Remove the top cover as follows: a. Remove the top cover screws A, Figure When servicing the rear carburetor, remove the choke cable bracket B, Figure 41 from the top cover. Remove the carburetor heater A, Figure 48 and its washer from the bottom of the carburetor body. When servicing the rear carburetor, also re- move the heater ground terminal B, Figure Remove the mounting screws A, Figure 49 and lift the float bowl B from the carburetor body.
Remove the screw A, Figure 53 and pull the valve seat B from the carburetor body. Remove the pilot jet Figure Remove the starter jet Figure 55 and spacer. Remove the main jet Figure Install the float pin B, Figure 51 and secure it with the screw A. Install a new float bowl O-ring Figure 50 and set the float bowl onto the bottom of the carburetor B, Figure If removed, install the starter plunger B, Fig- ure Assemble the coasting enricher, if it was disas- sembled, as follows: a.
Install the coasting enricher diaphragm B, Figure 40 onto the carburetor Figure Install the spring A, Figure 40 into the cen- ter of the diaphragm. Inspect the vacuum piston B, Figure 61 for scoring and wear. Replace it if necessary. Inspect the diaphragm on the vacuum piston for tears, cracks or other damage.
Page Fuel Level If a pilot screw must Drill stop be removed, perform the procedure as described, then have a Yamaha deal Plug ership perfom the final adjustment. Page Fuel level inspection re- quires a special fuel level gauge Yamaha part No. Reinstall the carburetor assembly and re- YMA or Perform the test in the listed sequence. Connect the positive lead of an ohmmeter to the yellow terminal Figure 77 on the sensor side of the connector and connect the negative lead to the black terminal. With the throttle fully closed, rotate the sensor body B, Figure 78 until the resistance is within the fully closed range specified in Table 2.
Disconnect the four-pin harness connector from the carburetor heater relay and remove the relay. Thermo Switch Test 1. Disconnect the two-pin thermo switch connector B, Figure 75 from its harness mate.
Replace the thermo switch if the test results are not within the above specifications. Carburetor Heater Test 1. Disconnect the electrical lead from the carbure- tor heater and remove the heater from the carbure- tor. Tie a piece of heavy string or cord to the ends of the throttle cable at the carburetor. Starting at the choke lever, carefully pull the cable from the motorcycle, following the path of the original cable.
Lubricate the new cable as described in Chap- ter Three. Untie the string from the old cable and tie it to the carburetor end of the new cable. Position the filter so its arrow points toward the fuel pump. Check the hose clamps for damage; replace them if necessary. After installation is complete, thoroughly check for leaks.
Disconnect the electrical lead from the negative battery terminal. Remove the fuel tank and surge tank as de- scribed in this chapter. Remove the frame neck cover Chapter Four- teen. Remove the starting circuit cutoff relay C, Fig- ure 75 from the mounting tang and disconnect the connector from the relay. Vacuum hose to rear cylinder intake manifold 2. Orifice 3. AIS air filter 4.
Air filter housing 5. Air cut valve 6. Reed valve 7. Housing 8. Bracket 9. AIS output hose AIS pipe to rear cylinder Remove the toolbox cover and the side cover from the left side as described in Chapter Fourteen. Release the hose clamp Figure 96 and discon- nect the AIS pipe from its fitting on each cylinder head. Replace any component that is worn, damaged or out of specification. Fitting 2. Solenoid valve 3.
Rollover valve 4. Clamp 5. Label each hose before removal so they can be easily identified during assembly. Remove the toolbox cover and the side cover from the left side of the motorcycle. Hanger bolt 9. Exhaust manifold 2. Muffler assembly Nut 3. Muffler gasket Front exhaust pipe 4.
Clamp screw Exhaust cover 5. Rear exhaust pipe Nut 6. Bolt Loosen the muffler clamp screw A, Figure on each muffler. Remove the muffler hanger bolts B, Figure Pull the muffler assembly rearward. Separate each muffler from its respective exhaust pipe and remove the muffler assembly. After installation is complete, start the engine and make sure there are no exhaust leaks. Correct any leak prior to riding the bike.
Charging system. Ignition system. The ammeter should read less than 0. If the amperage is greater, there is a current draw on the system that will discharge the battery.
Charging Voltage Test 1. Connect an engine tachometer to the spark plug lead on the No. Apply a medium-strength threadlocking compound to the threads of the stator mount- ing screws C, Figure 7 and the pickup coil mounting screws B. Alternator cover bolt vides longer component life and delivers a strong, tion coil and the magnetic field within the coil col- reliable spark throughout the entire range of engine lapses. Never connect the battery backwards.
If the bat- tery polarity is incorrect, the voltage regulator, al- ternator and ignitor unit will be damaged. Do not disconnect the battery while the engine is running. Keep all connections between the various units clean and tight.
Remove the fuel tank, air filter housing and surge tank as described in Chapter Eight, and the re- move the frame neck cover Chapter Fifteen. Disconnect the electrical lead from the negative battery terminal A, Figure 1. Page Before purchasing a new ignitor unit, have the system checked by a Yamaha dealership or another qualified shop. Most motorcycle dealerships will not accept returns on electrical components.
Apply a dielectric compound to the electrical connectors prior to reconnecting them. Make sure the electrical connections are free of corrosion and are completely coupled to each other. Tighten the screws securely. Install all removed items. Case bolt Armature 2.
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Sign up for free Log in. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical or- der refer to the numbers in the illustration.
A Right crankcase S Make sure that the crankcase separating tool is centered over the crankshaft assembly. Crankcase separating tool EB To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions.
Clean the big end bearings, crankshaft pins, and the inside of the connecting rod halves. Connecting rod nut 48 Nm 4. Remove the connecting rod and big end bearings. Measure the compressed Plastigauge width 1 on each crankshaft pin.
If the clearance is out of specification, select replacement big end bearings. Check: S bearings Clean and lubricate the bearings, then rotate the inner race with your finger Rough movement! Apply: S engine oil onto the main journal bearings S sealant onto the crankcase mating surfaces Yamaha Bond No. Tighten: S crankcase bolts follow the proper tightening sequence NOTE: The numbers embossed on the crankcase indi- cate the crankcase tightening sequence.
Replace the shift fork. Check: S shift fork guide bar Roll the shift fork guide bar on a flat surface. Measure: S main axle runout with a centering device and dial gauge Out of specification!
Replace the main axle. Main axle runout limit 0. Measure: S drive axle runout with a centering device and dial gauge Out of specification! Replace the drive axle. Bearing For installation, reverse the removal procedure. Remove: S bearing retainer S middle drive shaft assembly a. Straighten the thread on the bearing retainer. Attach the bearing retainer wrench 1. Bearing retainer wrench: c.
Remove the bearing retainer and middle drive shaft assembly. Remove: S universal joint a. Remove the circlips 1. Place the universal joint in a press. With a pipe of the proper diameter positioned beneath the universal joint driven yoke as shown, press the bearing into the pipe. Check: S O-ring S oil seal Damage! Replace the defective part -s. Check: S universal joint movement Rough movement! Replace the universal joint.
Tighten: S middle drive shaft nut 1 Nm Install: S shim S middle drive shaft assembly 3. Install: S bearing retainer Install steps: S Attach the bearing retainer wrench 1. Bearing retainer wrench: S Tighten the bearing retainer. Bearing retainer: Nm If over tighten the middle driven pinion gear nut, replace the collapsible col- lar and adjust the backlash.
Stake the middle driven pinion gear shaft thread. Select: S middle drive gear shim -s 1 NOTE: Select the middle drive gear shim -s 1 by cal- culating the middle drive gear shim thickness and then measuring the middle gear backlash.
Middle drive pinion gear shim: Thickness mm 0. Page CARB Air filter case assembly Air ducts Cylinder head breather hose Disconnect Air chamber Disassemble the parts in the order listed. Jet needle set Starter plunger set Pilot screw Main air jet Pilot air jet 1 Pilot air jet 2 Throttle stop screw set For assembly, reverse the disassembly procedure. Check: S fuel passages Obstruction! Wash the carburetor in a petroleumbased solvent.
S Always use a new gasket. Measure: S fuel level a Out of specification! Fuel level above the line on the float chamber 4 X 5 mm a. Inspect: S throttle position sensor a. Disconnect the throttle position sensor cou- pler. Tighten the throttle position sensor screws.
NOTE: Remove the pocket tester leads and connect the throttle position sensor coupler. This is to reduce the output of the hy- drocarbons. When there is negative pressure around the ex- haust port, the reed valve opens and the sec- ondary air flows into the exhaust port. Inspect: Air filter S hose connections Orifice Poor connections! Properly connect. Carburetor joint near cylinder S hoses To the front cylinder head S reed valves To the rear cylinder head S air cut-off valve To the orifice S air filter Page CHAS Oil seals Bearings Collar For assembly, reverse the disassembly procedure.
NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Tighten: S spokes 3 Nm 0. Measure: S front wheel radial runout 1 S front wheel lateral runout 2 Over the specified limits! Clean the outside of the front wheel hub. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag be- tween the screwdriver and the wheel surface.
Remove the brake caliper. Hold the dial gauge at a right angle against the brake disc surface. Measure the deflection 2 — 3 mm below the edge of the brake disc. Lubricate: S wheel axle S oil seallips Recommended lubricant Lithium soap base grease 2. S Adjust the front wheel static balance with the brake discs installed. Check: S front wheel static balance a. Turn the front wheel and make sure that it stays at each position shown. If the front wheel does not remain stationary at all of the positions, rebalance it.
NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Lubricate: S drive shaft splines Recommended lubricant Molydenum disulfide grease 2. Tighten the rear axle holder with specified torque. Rear axle end nut 23 Nm 2. Tighten the rear brake caliper bracket bolt with specified tightening torque. Brake caliper bracket bolt 40 Nm 4. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary.
S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly. Remove: S brake pads 1 along with the brake pad shims 3.
Measure: S brake pad wear limit a Out of specification! Replace the brake pads as a set. Brake pad wear limit 0. Check: S brake fluid level Below the minimum lever mark a! Check: S brake lever operation Soft or spongy feeling! Bleed the brake system. Install: S brake pad shims onto the brake pads S brake pads S brake pad spring NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set.
Connect a clear plastic hose 1 tightly to the bleed screw 2. S brake fluid delivery passages 2 brake master cylinder body Obstruction! Blow out with compressed air. S Never use solvents on internal brake com- ponents.
Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S 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 perfor- mance. Brake fluid Drain Brake hose holder Union bolt Caliper piston seals Bleed screw For assembly, reverse the disassembly procedure. NOTE: Before removing either brake caliper, drain the brake fluid from the entire brake system.
Remove: S brake hose holder S union bolt 1 S copper washers 2 S brake hose Remove: S brake caliper pistons 1 S brake caliper pistons seals 2 a.
Replace the brake caliper piston assembly. Replace the brake cali- per. S brake fluid delivery passages brake caliper body Obstruction! Therefore, always clean up any spilt brake fluid immediately.
Check: S brake fluid level Below the minimum level mark a! Oil lock piece Outer tube For assembly, reverse the disassembly procedure. S If the front fork leg protector must be removed, always install a new one. Blow out all of the oil pas- sages with compressed air. S oil lock piece 2 Damage! Tighten: S damper rod bolt 1 30 Nm 3. Page with the specified amount of the recom- mended fork oil Quantity each front fork leg 0. Other oils may have an adverse effect on front fork performance.
S Before installing the cap bolt, apply grease to the O-ring. S Temporarily tighten the cap bolt. Cable guide Handlebar holders lower For installation, reverse the removal procedure. Remove: S handlebar grip left 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. Apply a light coat of rubber adhesive onto the left end of the handlebar. Slide the handlebar grip over the left end of the handlebar. Wipe off any excess rubber adhesive with a clean rag.
Clutch cable free play at the end of the clutch lever 5 X 10 mm 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 Remove the bearing reces from the steering head pipe with a long rod 1 and hammer. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. Install a new rubber seal and new bearing re- ces. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand following information.
Replace the rear shock absorber assembly. Lubricate: S spacers S bearings Recommended lubricant Molybdenum disulfide grease 3. Install: S rear shock absorber assembly Rear shock absorber assembly upper nut 40 Nm 4. Install: S relay arm S left connecting arm S right connecting arm Rear-shock-absorber-assembly lower nut 1 48 Nm 4.
A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration, or sus- B. Improper gear lash tained speeds. Damaged gear teeth surging or transmissionrelated D.
Broken drive shaft Investigate any unusual noises. The following noises may indicate a me- chanical defect: a. Check: S final drive oil Large amount of metal particles! Check for bearing seizure. Secure the final drive assembly in a vise. Remove: S final drive oil drain bolt 3. Drain: S final drive oil from the final drive assembly 4. Measure: S ring gear backlash Out of specification! Reinstall the bolt, special tool, and dial gauge.
Repeat steps d to h three more times for a total of four measurements. If any of the readings are over specification, adjust the ring gear backlash. If it is necessary to increase the ring gear backlash by more than 0. If it is necessary to reduce the ring gear back- lash by more than 0. After all of the bolts and nuts are fully loosened, and remove them. Remove: S collar 1 S oil seal 2 S bearing 3 with an appropriate press tool 4 and an ap- propriate support for the final drive housing 2.
Check: S bearing Damage! Install: S gear coupling S self-locking nut Nm Install: S ring gear bearing housing along with the ring gear, but without the thrust washer 5.
Page Checking The Drive Shaft 1. Lubricate: S drive shaft splines Recommended lubricant Molybdenum disulfide grease 2. Apply: S sealant onto both final drive housing mating sur- faces Yamaha bond No.
Install: S drive shaft to the final drive pinion gear Tighten: S final bearing housing nuts 42 Nm 4. Page — ELEC If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Repair or replace the switch. Improperly connected! Incorrect continuity reading! Replace the switch. Repair or replace the bulb, bulb socket or both. Check: S bulb socket for continuity with the pocket tester No continuity! Battery S Check the condition of the battery.
The ignition system fails to operate no spark or intermittent spark. Check: Min. S Disconnect the spark plug cap from the spark plug. Main switch S Check the main switch for continuity. S Is the main switch OK? Replace the main switch. Secondary coil resistance Starting circuit cut-off relay diode S Remove the relay unit from the wire har- ness.
S Check for continuity as follows: SKy blue Continu The starter motor fails to turn. Starting circuit cutoff relay 5. Starting circuit cutoff relay Diode S Disconnect the relay unit from the coupler. Starter relay 8. Engine stop switch S Check the engine stop switch for continuity. S Is the engine stop switch OK? Start switch S Check the start switch for continuity. S Is the start switch OK? Replace right handlebar switch. Diode S Check the diode for continuity.
S Is the diode OK? Replace the diode. Starter motor lead Starter motor assembly For installation, reverse the removal procedure. Disassembling the starter motor Disassembly the pats in the order listed.
Check: S commutator Dirt! Clean with grit sandpaper. Measure: S commutator diameter a Out of specification! Replace the starter motor. Measure: S mica undercut a Out of specification! Scrape the mica to the proper measurement with a hacksaw blade Measure: S brush length a Out of specification! Replace the brushes as a set. Measure: S brush spring force Out of specification! Replace the brush springs as a set. Bruch spring force 7. The battery is not being sharged. Check: 1.
S Is the charging voltage within specification? The charging circuit is OK. Open-circuit voltage Check:
