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...
spec
SPECIFICATIONS GENERAL SPECIFICATIONS 3LD-000101 3SC-000101 E 3TD-000101 CH 3LD-000101 3SC-000101 E 3TD-000101 CH Overall Width Overall Height Seat Height Wheelbase 2,285 mm 90.0 in B F GB NL E I 2,355 mm 92.7 in D S DK SF N CH 815 mm 32.1 in 1,355 mm 53.3 in 865 mm 34.1 in 1,505 mm 59.3 in 240 mm 9.5 in Engine Engine Type Cylinder Arrangement Displacement Bore x Stroke Compression Ratio Compression Pressure Starting System Liquid cooled 4-stroke, DOHC Forward inclined parallel 2-cylinder 749...
Note Sow
Engine idling speed and carburetor synchronization should be adjusted properly before adjusting the throttle cable free play. Throttle cable free play a Out of specification- Adjust. 2. Remove Side cowling Side covers Seat Refer to SEAT, FUEL TANK AND COVER section.
gen info 1
10. Plastigage set Green P N YU-33210 This gauge is needed to measure the clearance for the connecting rod bearing and the crankshaft bearing. 11. YAMAHA bond No. 1215 P N 90890-85505 This sealant bond is used for crankcase mating surfaces, etc. 12. Piston ring compressor P N 90890-04121 This tool is used to compress piston rings when installing the cylinder. P N 90890-01325 P N 90890-01352 This tester is used for checking the cooling system.
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
r Lines indicate straightedge measurement. Cylinder Bore Size Measureing Point 87.000 - 87.005 mm 3.4252-3.4254 in 40 mm 1.6 in Camshaft Outside Diameter Shaft-to-cap Clearance Cam Dimensions Intake 24.967-24.980 mm 0.9830-0.9835 in 0.020-0.054 mm 0.0008-0.0021 in 35.7-35.8 mm 1.4055-1.4094 in 35.6 mm 1.4 in Timing Chain Chain Type No. of Links Chain Adjustment Method
Engine 1
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...
gen info
This tool is used to hold the rotor. P N 90890-01362 P N 90890-01382 2 These tools are used to remove the rotor. P N 90890-04019 P N 90890-04114 2 These tools are used to remove and install the valve assemblies. 8. Valve guide remover and installer set 5.5 mm P N 90890-04016 These tools are used to remove, install and re-bore the valve guide. This tool is used to adjust the valve clearance.
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 Apj
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...
General Torque Specifications
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. A Distance across flats B Outside thread...
Engine Oil Level Inspection Engine Oil Replacement
Do not add any chemical additives. 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
1. 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...
Lubrication Point And Grade Of Lubricant
Matching surface Cylinder head and cylinder head cover
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...
Note
1. 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
1. 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.
Preparation For Removal
1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to SPECIAL TOOL. 3. When disassembling the machine, keep mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been mated through normal wear. Mated parts must be reused as an assembly or replaced. 4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up...
spec 1
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...