FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XVS1100 (N). For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XVS1100 (L) SERVICE MANUAL: 5EL1-AE1
EB000000
XVS1100 (N) SUPPLEMENTARY SERVICE MANUAL 2000 by Yamaha Motor Co.,Ltd. First edition, September 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
EB001000
NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. 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 motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. Yamaha Motor Company, Ltd.is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
CAUTION: NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.
EB002000
HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 :
This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper right corner of the page. 3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs. 2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6 . The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.
2
1
6 3
8 5 4
7
EB003000
1
ILLUSTRATED SYMBOLS
2
3
Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 Troubleshooting
4
CHK ADJ 5
6
7
8
9
10
11
12
13
14
Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text. 10 11 12 13 14 15 16 17
15
16
17
18
19
20
21
24
22
23
25
Can be serviced with engine mounted Filling fluid Lubricant Special tool Torque Wear limit, clearance Engine speed Ω, V, A
Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points. 18 19 20 21 22 23
Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium-soap base grease Apply molybdenum disulfide grease
Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply locking agent 24 and when to install new parts 25 . 24 Apply locking agent (LOCTITE) 25 Replace
CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 2 3 4
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 16 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 REPLACING THE HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . 18 ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 19
CARBURETION AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . 20 CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . 22
CHASSIS FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERAL SPECIFICATIONS
SPECIFICATIONS GENERAL SPECIFICATIONS Item
Standard
Model code:
XVS1100: 5PB2
Basic weight: With oil and a full fuel tank
275 kg
Tire: Type Size Manufacturer Type
front rear front rear front rear
Maximum load-except motorcycle:
With tube 110/90-18 61S 170/80-15M/C 77S DUNLOP DUNLOP K555F K555 200 kg
–1–
SPEC
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS ENGINE Item
Standard
Camshaft: Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam dimensions
Intake
Exhaust
Camshaft runout limit
“A” “B” “C” “A” “B” “C”
Limit
Chain drive (left & right) 25.000 25.021 mm 24.96 24.98 mm 0.020 0.061 mm
39.112 39.212 mm 32.093 32.193 mm 7.162 mm 39.112 39.212 mm 32.127 32.227 mm 7.162 mm
39.012 mm 31.993 mm 7.012 mm 39.012 mm 32.027 mm 7.012 mm 0.03 mm
–2–
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS Item Front suspension: Front fork travel Fork spring free length Fitting length Collar length Spring rate Stroke
Standard
(K1) (K2) (K1) (K2)
Optional spring Oil capacity Oil level Oil grade Rear suspension: Shock absorber travel Spring free length Fitting length Spring rate Stroke Optional spring
(K1) (K1)
Limit
140 mm 356.9 mm 319.4 mm 183 mm 4.41 N/mm (0.9 kg/mm) 6.37 N/mm (1.3 kg/mm) 0 77.5 mm 77.5 140 mm No 0.464 L 108 mm Fork oil 10W or equivalent
350 mm
50 mm 179.5 mm 163 mm 117.7 N/mm (12 kg/mm) 0 50 mm No
Tightening torques g Part to be tightened Brake caliper and bracket
Tightening torque
Thread size M10
–3–
Remarks
Nm
mkg
ftlb
27
2.7
20
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL Item
Standard
Limit
Ignition coil: Model/manufacturer Primary winding resistance Secondary winding resistance
F6T541 /MITSUBISHI 3.57 4.83 Ω at 20_C 10.7 14.5 kΩ at 20_C
SSS SSS SSS
Charging system: Type Model/manufacturer Nominal output Stator coil resistance/color
A.C. magneto F4T654 /MITSUBISHI 14 V 305 W at 5,000 r/min 0.36 0.44 Ω at 20_C/White – White
SSS SSS SSS SSS
Constant mesh type
SSS
SM-13/MITSUBA 0.6 kW 0.026 0.034 Ω at 20_C 10 mm 7.65 10.01 N (780 1021 g) 28 mm 0.7 mm
SSS SSS SSS 5 mm SSS 27 mm SSS
MS5F-421 /JIDECO 180 A
SSS SSS
Electric starter system: Type Starter motor: Model/manufacturer Output Armature coil resistance Brush overall length Brush spring pressure Commutator diameter Mica undercut Starter relay: Model/manufacturer Amperage rating
–4–
CABLE ROUTING
SPEC
EB206000
CABLE ROUTING Clutch cable Starter cable Handlebar switch lead (left) Handlebar switch lead (right) High tension code Throttle cable Fuel hose (fuel cock-filter) Fuel breather hose (fuel tank-roll over valve) (for CAL) 9 Fuse box 10 Alarm connector 11 Fuel pump lead 1 2 3 4 5 6 7 8
Speed sensor lead Sidestand switch lead Neutral switch lead Pickup coil lead To engine A.C. magneto lead Ventilation hose Sensing hose (AIS-carburetor joint) 20 Fuel hose (carburetor-fuel pump) 21 Clip 22 Brake hose 12 13 14 15 16 17 18 19
–5–
23 24 25 26 27 28 29 30 31
Heat protector Speed meter lead Wireharness Purge hose (carburetor-solenoid valve) (for CAL) Fitting plate Fuel hose (inlet) (fuel filter-fuel pump) Fuel hose (outlet) (carburetorfuel pump) Alarm connector lead Wireharness
CABLE ROUTING 27
A Fasten the handlebar switch lead (left and rihgt) to the handlebar with plastic locking tie and cut the end of tie. B Fasten the mainharness with a plastic clamp at the back of the cable guide. C Clamp the wireharness with the hook of frame side.
SPEC
D When installing the pipe of G When connecting the sensing throttle cable press it inside. hose (carburetor joint-AIS) with E Clamp the fuel hoses to the a nozzle. frame with the clamp. H Push the sensing hose inside of F Change the fuel hose (fuel cock the LID and not bend the sensing side) and fuel hose (carburetor hose. side) between guide of frame I Push the wireharness inside of and clamp. (carburetor side is the side cover. upper)
–6–
CABLE ROUTING J Position the all connectors inside O Route the clutch cable through of the connector cover. the cable guide. K Through the wireharness of so- P Position the throtlle cable and lenoid valve between AIS duct starter cable as shown and and fuel hose (for CAL). clamp them with holder. L Fasten the alarm lead with a Q Fasten the handlebar switch plastic band on the LID. leads (left and right) under the M Fasten the sidestand switch lead handle crown with a plastic to the bracket of LID with plastic band. Set the band at four locking tie. notches and install it no slacking. N Fasten the lead with locking tie R Route the each hoses through the near the side cover. frame guide and do not pinch it.
–7–
SPEC
S When installing the fitting plate, do not pinch the each hoses and wireharness. T Wher install the AIS push the wireharness to space of rearside.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11
Battery Battery positive (+) lead Starter motor positive lead Speedmeter lead Fuel hose (carburetor-fuel pump) High tension code Main switch lead Throttle cable Brake hose Handlebar switch lead (right) Headlight lead
12 Ignition coil 13 Breather hose 14 Purge hose (carburetor-solenoid 15 16 17 18 19 20 21
valve) (for CAL) Rear brake switch Reserve hose Air filter drain hose Delay relay Battery negative (–) lead Starter motor positive (+) lead Oil level switch lead
–8–
22 23 24 25 26 27 28 29 30 31 32
SPEC
Rear brake switch lead Carburetor heater connecter Light reduce relay Rectifier/ regulator Stay. 1 Down tube frame Stay. 2 Battery box Carburetor heater lead Light reduce lelay lead
CABLE ROUTING 33 34 35 36 37 38 39 40 41
Flasher relay Handlebar switch lead (left) Silencer Throttle position sensor lead Carburetor heater lead Thermo switch lead Starting circuit cut-off relay Horn Rectifire/ regulator and light (reduce relay) lead
A Clamp the battery positive (+) lead to the battery with battery band. B Connect the battery negative (–) lead and push it in to the space between battery box and battery. C Push the wireharness into the space between frame and starter motor relay.
–9–
SPEC
D Route the rectifire / regulator lead, wireharness and starter motor positive (+) lead through the out of frame bracket and fasten them to the frame with a plastic locking tie. The place to fix must be between 0 mm and 10 mm from the top of the diverging point of the lead on the harness side whitch connected the battery negative (–) lead.
CABLE ROUTING E Connect the purge hose (carburetor side-solenoid valve side) with joint, knob is out side of frame. F Route the front turn signal / position light lead and headlight lead through the rear of headlight body hole. G Connect the ignition coil lead at red tape to the right side. H Knob of clip is rearside of body.
SPEC
I Fasten the rear brake switch M Fasten the rear brake switch lead lead to the rear brake switch and master cylinder reservoir bracket with a plastic locking tie hose to the down tube with a plasand cut of the end, inside of frame. tic locking tie, and cut the end of J Fasten the wireharness, starter locking tie and position is inside of motor positive (+) lead and batframe. tery negative (–) lead to the N About 20 mm from bead end. frame with a plastic locking tie. O Locate the band to forward of K From the engine. down tube. L About 70 mm P Route the rectifire/regulator lead and carburetor heater lead through inside of battery box hole to outside it and connect them.
–10–
CABLE ROUTING Q To rear brake. R Fasten the rear brake switch lead with a band to down tube. (four point) S Cutting part at the edge of the band. T About 30_ 45_
SPEC
U Fasten the oil level sensor lead V Clamp the handlebar switch lead with a locking tie to battery box. (right) to the frame with a holder. Fix to the battery box with the The part to open and shut is outband. To fix, algin the band to the side of the body. bottom of the box’s hole while fix- W Arrange the throttle position sening the lead to the back of the box sor connector, carburetor heater (inside the body). The cutting part connector and thermo switch at the edge of the band comes to connector between the starting the front side of the body. circuit cut off relay and high tension code. X Put the light reduce relay lead, carburetor heater lead into the bottom of the groove.
–11–
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11
Brake hose Throttle cable Master cylinder reservoir hose High tension code Purge hose (carburetor-solenoid valve) (for CAL) Rear brake switch lead Fuel hose (carburetor-fuel pump) Delay relay Battery negative (–) lead Battery negative (–) lead connector Battery
12 13 14 15 16 17 18 19 20 21 22
Battery positive (+) lead Taillight lead Starter relay Starter motor positive (+) lead Fuel tank breather hose (fuel tank-roll over valve) (for CAL) Outlet Inlet Ventilation hose Starter cable Sensing hose (AIS-carburetor joint) Fuel hose (fuel cock-fuel filter)
–12–
23 24 25 26 27 28 29 30 31 32 33 34 35 36
SPEC
Throttle position sensor lead Carburetor heater lead Tappet cover Clutch cable Thermo switch lead Wireharness Frame Igniter unit LID. 2 Mud guard Fuel filter LID. Ignitor unit lead Speed meter lead connecter
CABLE ROUTING A Clamp the throttle cables with E Position the steel band end to the holder. Position the end of right side. clip downword. F Route the battery positive (+) B Route the rear brake switch lead lead through the slit of the batunder the master cylinder resertery box. vor hose. G Clamp the igniter unit lead to the C Position the band end of right frame with a holder. side bracket. H To the rear fender. D Position the steel band end to forward.
–13–
SPEC
I Connect the wireharness to the ignitar unit through the hole of LID. 2. J Route the fuel tank breather hose under the fuel filter and connect it (fuel tank sideroll over valve side) with a joint. Position the end of clip outside.
CABLE ROUTING K Position the mark on the steel O Clamp the clutch cable and startband to forward. er cable with a holder. L Fasten the wireharness with a Position the end of holder down band on the tool box plate. side. M Fasten the wireharness to the P Route the igniter lead through frame with a plastic locking tie. the igniter plate hole to the wirePosition the locking tie front of harness. the holder. Q To the wireharness. N Route the wireharness outside R Clamp the taillight lead with mud of the guide on the frame. guard clamp.
–14–
SPEC
S Clamp the taillight lead with a holder on the mud guard. T Position the locking tie upward. U The front direction of the level body.
CABLE ROUTING 1 2 3 4 5 6 7
Throttle cable Starter cable Clutch cable Handlebar switch lead (left) Headlight lead Brake hose Handlebar switch lead (right)
A Route the handlebar switch lead (right) rear side of the throttle cable.
–15–
SPEC
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS
CHK ADJ
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS NOTE: The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING ( 1,000 km) NO NO.
ITEM
CHECK OR MAINTENANCE JOB
1
*
Fuel line
Check fuel hoses for cracks or damage.
2
*
Fuel filter
Check condition.
Spark plugs
Check condition. Clean and regap.
3
1
10
20
30
40
ANNUAL CHECK
√
√
√
√
√
√ √
*
Valves
5
Air filter element
6
Clutch
7
*
Front brake
Check valve clearance. Adjust
√
Clean.
√
*
Rear brake
*
Brake hose
√
√
√ √
Check operation. Adjust.
√
√
√
√
√
Check operation, fluid level and vehicle for fluid leakage. (See NOTE)
√
√
√
√
√
Check operation, fluid level and vehicle for fluid leakage. (See NOTE)
√
√
√
√
√
√
Check for cracks or damage. Replace. (See NOTE)
√
√
√
√
√
√
√
Tires
√
√
√
√
12 *
Wheel bearings
Check bearing for looseness or damage.
√
√
√
√
13 *
Steering bearings
√
√
√
√
*
√
Every 4 years
Check runout, spoke tightness and for damage. Tighten spokes if necessary.
11
√
Whenever worn to the limit
Wheels
10 *
√
Whenever worn to the limit
Replace brake pads. 9
√
√
√
Replace.
Replace brake pads. 8
√ √
Replace. 4
√
Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.
Check bearing play and steering for roughness.
√
Lubricate with lithium-soap-based grease.
14 *
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.
15
Sidestand
Check operation. Lubricate.
16 *
Sidestand switch
Check operation.
Every 20,000 km
√
–16–
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS
CHK ADJ
ODOMETER READING ( 1,000 km) NO NO.
ITEM
17 *
Front fork
18 *
Rear shock absorber assembly
CHECK OR MAINTENANCE JOB
1
10
20
30
40
Check operation and for oil leakage.
√
√
√
√
Check operation and shock absorber for oil leakage.
√
√
√
√
Lubricate the pivoting points with molybdenum disulfide grease.
√
ANNUAL CHECK
√
19 *
Carburetors
Check starter (choke) operation. Adjust engine idling speed and synchronization.
√
√
√
√
√
√
20
Engine oil
Change.
√
√
√
√
√
√
21
Engine oil filter element
Replace.
√
22
Final gear oil
Check oil level and vehicle for oil leakage.
√
Change.
√
23
Moving parts and cables
Lubricate.
24 *
Lights, signals and switches
Check operation. Adjust headlight beam.
√
√ √
√ √
√
√
√
√
√
√
√
√
√
√
√
√ EAU03541
NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service – Regularly check and, if necessary, correct the brake fluid level. – Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. – Replace the brake hoses every four years and if cracked or damaged.
–17–
REPLACING THE HEADLIGHT BULB
CHK ADJ
ELECTRICAL SYSTEM EAS00182
REPLACING THE HEADLIGHT BULB 1. Disconnect: connector 1 2. Remove headlight bulb cover 2
3. Remove: headlight bulb holder 1 4. Remove: headlight bulb 2
WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: headlight bulb (New) Secure the new headlight bulb with the headlight bulb holder.
CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Install: headlight bulb holder 7. Install: headlight bulb cover 8. Connect: leads
–18–
ADJUSTING THE HEADLIGHT BEAM
CHK ADJ
EAS00184
ADJUSTING THE HEADLIGHT BEAM 1. Adjust: headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b. Direction a Headlight beam is raised. Direction b Headlight beam is lowered. 2. Adjust: headlight beam (horizontally) a. Turn the adjusting knob 2 in direction a or b. Direction a Headlight beam moves to the right. Direction b Headlight beam moves to the left.
–19–
AIR INDUCTION SYSTEM
CARBURETION AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM DIAGRAMS
1 2 3 4 A B C D E
Reed valve Air filter Orifice Carburetor joint (near cylinder) To the front cylinder head To the rear cylinder head To the orifice To the carburetor joint (rear cylinder) To the air cut-off valve
NOTE: The orifice 3 should be installed with the arrow mark facing the air cut-off valve side.
–20–
CARB
AIR INDUCTION SYSTEM
Order 1 2 3 4 5 6 7 8 9
Job name/Part name
Q’ty
Removeing the air induction system Side cover Air filter Air filter to air cut valve hose Air cut valve Vacuume hose 2 Orifice Vacuum hose 1 Reed valve case to rear cylinder head pipe Reed valve case to rear cylinder head pipe
CARB
Remarks Remove the parts in the order listed.
1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
–21–
AIR INDUCTION SYSTEM
CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM 1. Check: hoses Loose connection Connect properly. Cracks/damage Replace. pipes Cracks/damage Replace.
2. Check: reed valve 1 reed valve stopper reed valve seat Cracks/damage Replace the reed valve.
3. Measure: reed valve bending a Out of specification Replace the reed valve. Maximum reed valve bending 0.4 mm 1 Surface plate
4. Check: air cutoff valve Cracks/damage Replace.
5. Check: air cleaner Cracks/damage Replace. Clogged Clean.
–22–
FRONT AND REAR BRAKES
CHAS
CHASSIS FRONT AND REAR BRAKES FRONT BRAKE CALIPERS
6 Nm (0.6 mkg)
30 Nm (3.0 mkg)
27 Nm (2.7 mkg)
Order
1 2 3 4 5 6
Job name/Part name
Q’ty
Removing the front brake calipers Brake fluid Brake hose holder Union bolt Copper washers Brake hose Retaining bolt Brake caliper assembly
Remarks Remove the parts in the order listed. Drain
1 1 2 1 2 1
Refer to “REMOVING/INSTALLING THE FRONT BRAKE CALIPERS”.
For installation, reverse the removal procedure.
–23–
STEERING HEAD
CHAS
STEERING HEAD
1st 2nd
52 Nm (5.2 mkg) 18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
Order
Job name/Part name
Q’ty
Remarks Remove the parts in the order listed. Stand the motorcycle on a level surface.
Removing the lower bracket
WARNING Securely support the motorcycle so that there is no danger of it falling over.
1 2 3 4 5 6 7 8
Front fork legs Handlebar 1 Headlight lens unit – Leads (in the headlight body) Front turn signal/position light (left/right) 1/1 1 Headlight body 1/1 Brake hose joint/holder 1 Upper bracket 1 Lock washer 1 Upper ring nut
–24–
Refer to “FRONT FORK”. Refer to “HANDLEBAR”. Disconnect
STEERING HEAD
1st 2nd
CHAS
52 Nm (5.2 mkg) 18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
Order 9 10 11 12 13 14 15
Job name/Part name Rubber washer Lower ring nut Bearing cover Lower bracket Bearing (upper) Rubber seal Bearing (lower)
Q’ty 1 1 1 1 1 1 1
Remarks Refer to “REMOVING THE LOWER BRACKET/INSTALLING THE STEERING HEAD”.
For installaiton, reverse the removal procedure.
–25–
