Oil Pumps And Timing Chain Note
With the engine mounted, the oil pump can be maintained by removing the following parts. Engine guard Exhaust pipes Dowel pins 0 Collar (2) (with O-ring) Gasket (3) (oil pump cover) 3. Remove Circlips 0 Oil pump gears 5. Remove Dowel pin 0 Gaskets (2) (oil pumps) Timing chain (3) With the engine mounted, the balancer weights can be maintained by removing the following parts. Engine guard Exhaust pipes Crankcase cover (left) CDI rotor Starter drives Crankcase cover (T) (upper) NOTE _ Working in...
Throttle Cable Free Play Adjustment
If the free play cannot be adjusted here, adjust it at the throttle grip side of the cable. Loosen the locknut (5). Turn the adjuster (6.) in or out until the specified free play is obtained. Turning out- Free play is decreased. After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster. Air filter case Fuel tank Seat yn Bolt (air filter case) 7 Nm (0.7 m kg, 5.1 ft-lb) Bolts (fuel tank, seat) 1. Remove Side cowling Side covers Seat Fuel tank...
Rear Shock Absorber Adjustment
Securely support the motorcycle so there is no danger of it falling over. 1. Elevate the rear wheel by placing a suitable stand under the engine. Adjustment steps Loosen the locknut (J). Turn the adjuster (2) in or out. Turning in - Spring preload is increased. Turning out- Spring preload is decreased. The length of the spring (installed) changes 1.0 mm (0.04 in) per turn of the adjuster. Never attempt to trun the adjuster beyond the maximum or minimum setting. When adjusting, use the special...
Transmission And Shifter
Screws 0 (bearing retainer) Use the torx wrench (T30). Screws (bearing retainer) 12 Nm (1.2 rn-kg, 8.7 ft-lb) Apply LOCTITE 5. Apply Engine oil (onto guide bars) Shift cam (T) Shift fork C (2) Shift fork L Shift fork R (4) Spring (5) Guide bars (6) NOTE _ Install the shift forks with the embossed mark on each shift fork facing right side of the engine. Install the guide bar with the cut-out end (7) facing the right side of the engine. Stopper ring (T) (bearing) (onto clutch side) Align the...
Headlight Blub Replacement
Disconnect Headlight leads T Keep flammable products or your hands away from the bulb while it is on, it will be hot. Do not touch the bulb until it cools down. 4. Install Bulb new Secure the new bulb with the bulb holder. Avoid touching glass part of bulb. Also keep it free from oil otherwise, transparency of glass, bulb life and illuminous flux will be adversely affected. If oil gets on bulb, clean it with a cloth moistened thoroughly with alcohol or lacquer thinner. ENGINE SIDE COVERS,...
For Electrical Components
Dynamic spark tester P N 90890-03144 This instrument is necessary for checking the ignition system components. This instrument is invaluable for checking the electrical system. GENERAL MAINTENANCE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS LUBRICATION POINT AND GRADE OF LUBRICANT LUBRICATION DIAGRAM COOLANT CABLE
Awarning
Securely support the motorcycle so there is no danger of it falling over. 1. Elevate the rear wheel by placing a suitable stand under the engine. Adjustment steps Loosen the locknut J . Turn the adjuster 2 in or out. Turning in - Spring preload is increased. Turning out- Spring preload is decreased. The length of the spring installed changes 1.0 mm 0.04 in per turn of the adjuster. Never attempt to trun the adjuster beyond the maximum or minimum setting. When adjusting, use the special wrench...
Periodic Maintenancelubrication Intervals
Adjust if necessary. Check condition. Clean or replace if necessary. Check idle speed starter operation. Adjust if necessary. Check fuel hose for cracks or damage. Replace if necessary. Replace Warm engine before draining See NOTE Check operation fluid leakage See NOTE. Correct if necessary. Check operation. Adjust if necessary. Check swingarm assembly for looseness. Correct if necessary. Moderately repack. Check operation. Moderately repack. Check balance damage runout...
Engine Oil Replacement Clutch Adjustment
10-15 mm 0.4-0.6 in At clutch lever end Bolts protector engine 7 Nm 0.7 m 'kg, 5.1 ft-lb Clutch cable free play a Out of specification- Adjust. Adjustment steps Loosen the locknuts 1 . Trun the adjusters C2 in or out until the specified free play is obtained. Turning in Free play is increased. Turning out Free play is decreased.
Change Pedal Adjustment Drive Chain Slack Adjustment
Change pedal position When looking at the side view the top of the change pedal should be even with the top of the footrest 1 . Also align slot A of shift lever with punch mark on the shaft. Adjustment steps Loosen both locknuts Turn the adjuster rod justment is suitable. Tighten the both locknuts DRIVE CHAIN SLACK ADJUSTMENT NOTE _ Before checking and or adjusting, rotate the rear wheel several revolutions and check slack at several points to find the tightest point. Check and or adjust the...
Exhaust System Inspection Coolant Level Inspection
Exhaust pipe 1 Muffler D Crack Damage- Replace. Gasket 3 Exhaust gas leaks Replace. Bolt rear footrest bracket right 20 Nm 2.0 m-kg, 14 ft-lb Position the motorcycle straight up when inspecting the coolant level. 1. Place the motorcycle on a level surface. Place the motorcycle on its centerstand, if a cen-terstand is equipped. If not, place a suitable stand under the motorcycle.
Engine
The valve clearance must be adjusted when the engine is cool to the touch. Adjust the valve clearance when the piston is at the Top Dead Center T.D.C. on compression stroke. Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap...
Rear Brake Adjustment
Brake pedal height a Out of specification- Adjust. 15 mm 0.6 in Below top of footrest. 15 mm 0.6 in Below top of footrest. Adjustment steps Loosen the locknut 0 Turn the adjuster 2 in or out until the specified pedal height is obtained. Turning in- Pedal height is increased. Turning out- Pedal height is decreased. After adjusting the brake pedal height, visually check the adjuster end. The adjuster end must appear within 6.25 mm 0.25 in . Make sure that the brake does not drag after adjusting...
Carburetor Synch Ron Izationtimig sp Chain Adjustmentidle Speed Adjustment
Air filler case Fuel tank Seat V 3olt air filter case W 7 Nm 0.7 m-kg, 5.1 ft-lb Bolts fuel tank, seat 1.Start the engine and let it warm up. 2. Attach Engine Tachometer To spark plug lead. Engine idle speed Out of specification- Adjust. Engine idle speed 1,100-1,200 r min Turn the throttle stop screw T in or out until specified idle speed is obtained. Turning in Idle speed becomes higher. Turning out- ldle speed becomes lower. After adjusting the engine idle speed, the throttle cable free...
Engine Oil Level Inspection Engine Oil Replacement
Engine oil also lubricates the clutch and additives could cause clutch slippage. Do not allow foregin material to enter the oil tank. 4. Start the engine and let it warn up until the oil temperature rises to approximately 60 C 140 F 5. Idle the engine more than 10 second while keeping the motorcycle upright. Then stop the engine and inspect the engine oil level once again. Never attempt to remove the oil tank cap just after high speed operation. The heated...
Compression Pressure Measurement
Compression pressure Above the maximum pressure- Inspect cylinder head, valve surface, and piston crown for carbon deposists. Below the minimum pressure- Squirt a few drops of oil into affected cylinder and measure again. Follow the table below. Compression pressure with oil introdued into cylinder Defective ring s , valves, cylinder head gasket or piston is possible. Compression Pressure at Sea Level Standard 950 kPa 9.5 kg cm2, 135 psi Minimum 910 kPa 9.1 kg cm2, 129 psi Maximum Crank over...
Spark Plug Inspection Ignition Timing Check
Air filter case Fuel tank Seat Carburetor synchronization, engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 2. Attach Timing light Inductive tachometer P N 90890-03109 Inductive tachometer P N 90890-03113 Warm up.the engine and let it at the specified speed.
Engine Oil Replacement
Drain bolt 2 oil strainer case Drain plug 3 oil pan Drain the crankcase and oil tank of their oil. 5. If the oil filter is replaced with oil change, perform the following. Oil filter replacement steps Remove the oil filter cover and oil filter element 2 . Check the O-ring, if cracked or damaged, replace them with a new one. Install the oil filter element and oil filter cover. Drain bolt oil strainer case Drain plug oil pan Drain bolt oil strainer case 30 Nm 3.0 m-kg, 22 ft-lb Drain plug oil...
For Engine Service
Hexagon wrench 6 mm P N 90890-01395 This tool is used to loosen or tighten the cylinder head securing nut. 2. Piston pin puller P N 90890-01304 This tool is used to remove the piston pin. 3. Universal clutch holder P N 90890-04086 This tool is used to hold the clutch when removing or installing the clutch boss locknut. 4. Torx wrench T30 P N 90890-05245 This tool is used to loosen or tighten the main axle bearing retainer bolt.
Cable Routing
Main switch lead Front brake switch lead Handlebar switch lead right Throttle cable Band Handlebar switch lead left Clutch switch lead Clutch cable Guide fj Front flasher light lead left Front flasher light lead right Flasher relay the front flasher light leads. LB J To the auxiliary light. 0 After clamping the front flasher light leads, pass them into the hole of the front flasher stay. D Pass the speedometer cable through the guide. 5 Clutch switch lead 3 Starter cable Starting circuit...
Motorcycle Identification
The frame serial number 1 is stamped into the right side of the steering head. Starting serial number 3LD-000101 3SC-000101 E 3TD-000101 CH The engine serial number T is stamped into the right side of the engine. Starting serial number 3LD-000101 3SC-000101 E 3TD-000101 CH The first three digits of these numbers are for model identifications the remaining digits are the unit production number. Designs and specifications are subject to change without notice.
Xtz Valve Adjustment
Valve, Valve Seat, Valve Guide Valve Clearance Cold 0.20 mm 0.006-0.008 in 0.30 mm 0.010-0.012 in 25.9-26.1 mm 1.020-1.028 in 27.9-28.1 mm 1.098-1.106 in 2.06-2.46 mm 0.081 -0.097 in 2.06-2.46 mm 0.081 -0.097 in 0.9-1.1 mm 0.035-0.043 in 0.9-1.1 mm 0.035-0.043 in 0.8-1.2 mm 0.032-0.047 in 0.8-1.2 mm 0.032-0.047 in 5.475-5.490 mm 0.2156-0.2161 in 5.460-5.475 mm 0.2150 - 0.2156 in 5.45 mm 0.214 in 5.43 mm 0.214 in 5.50-5.51 mm 0.216-0.217 in 5.50-5.51 mm 0.216-0.217 in 5.55 mm 0.219 in 5.55 mm...
Hitachi Ms5d-191
First, tighten the ring nut approximately 38 Nm 3.8 m kg, 27 ft lb by using the torque wrench, then loosen the ring nut one turn. 2. Retighten the ring nut to specification. Ignition System Ignition Timing B.T.D.C. Advanced Timing B.T.D.C. Advancer Type 10 at 1,150 r min 43 at 6,000 r min Electrical type T.C.I. Pickup Coil Resistance Color 184 27612 at 20 C 68 F Blue Yellow-Green White TNDFO6 NIPPON DENSO Ignition Coil Model Manufacturer Minimum Spark Gap Primary Winding Resistance Secondary...
For Tune Up
Inductive tachometer P N 90890-03113 This tool is needed for detecting engine rpm. 2. Inductive timing light P N 90890-03109 This tool is necessary for checking ignition timing. 3. Compression gauge P N 90890-03081 This gauge is used to measure the engine compression. This gauge is used to measure the fuel level in the float chamber.
Spec
Engine Oil Capacity Periodic Oil Change With Oil Filter Replacement Total Amount 4.1 L 3.6 Imp qt, 4.3 US qt 4.4 L 3.9 Imp qt, 4.7 US qt Coolant Total Amount Including All Routes Carburetor Type x Quantity Manufacturer DPR8EA-9 X24EPRU-9 NGK NIPPON DENSO 0.8-0.9 mm 0.031 -0.035 in Transmission Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type Operation Chassis Frame Type Caster Angle Trail With tube 90 90-21 54 H BRIDGESTONE...
