XV1700PCR XV1700PCRC SUPPLEMENTARY SERVICE MANUAL

Transcription

1 XV700PCR XV700PCRC SUPPLEMENTARY SERVICE MANUAL LIT PX-897-

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3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data f the XV700PCR/XV700PCRC. F complete service infmation procedures it is necessary to use this Supplementary Service Manual together with the following manual. XV700P/XV700PC SERVICE MANUAL: LIT (5PX-897-0) XV700PCR/XV700PCRC SUPPLEMENTARY SERVICE MANUAL 00 by Yamaha Mot Cpation, U.S.A. First Edition, July 00 All rights reserved. Any reproduction unauthized use without the written permission of Yamaha Mot Cpation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT

4 EAS0000 NOTICE This manual was produced by the Yamaha Mot Company, Ltd. primarily f use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefe, anyone who uses this book to perfm maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance wk attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit f use. This model has been designed and manufactured to perfm within certain specifications in regard to perfmance and emissions. Proper service with the crect tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer f any service infmation changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to confm to federal environmental quality objectives. Yamaha Mot Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications procedures will be fwarded to all authized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: _ Designs and specifications are subject to change without notice. EAS0000 IMPORTANT MANUAL INFORMATION Particularly imptant infmation is distinguished in this manual by the following. WARNING CAUTION: NOTE: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury death to the motcycle operat, a bystander a person checking repairing the motcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motcycle. A NOTE provides key infmation to make procedures easier clearer.

5 EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book f the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential der. The manual is divided into chapters. An abbreviation and symbol in the upper right cner of each page indicate the current chapter. Refer to SYMBO. Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter ( PERIODIC CHECKS AND ADJUSTMENTS ), where the sub-section title(s) appears. Sub-section titles appear in smaller print than the section title. To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the der of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated replaced. Refer to SYMBO. 7 A job instruction chart accompanies the exploded diagram, providing the der of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring me infmation (such as special tools and technical data) are described sequentially.

6 A GEN INFO CHK ADJ ENG ELEC + SPEC CHAS B FI TRBL SHTG EAS00009 SYMBO The following symbols are not relevant to every vehicle. Symbols to 8 indicate the subject of each chapter. General infmation Specifications Periodic checks and adjustments Chassis 5 Engine 6 Fuel injection system 7 Electrical system 8 Troubleshooting Symbols 9 to F indicate the following. 9 Serviceable with engine mounted 0 Filling fluid A Lubricant B Special tool C Tightening tque D Wear limit, clearance E Engine speed F Electrical data C D E F G H I E G M J K L B M M N LT New Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points. G Engine oil H Gear oil I Molybdenum-disulfide oil J Wheel-bearing grease K Lithium-soap-based grease L Molybdenum-disulfide grease Symbols M to N in the exploded diagrams indicate the following. M Apply locking agent (LOCTITE ) N Replace the part

7 CONTENTS SPECIFICATIONS... GENERAL SPECIFICATIONS... ENGINE SPECIFICATIONS... CHASSIS SPECIFICATIONS... ELECTRICAL SPECIFICATIONS... TIGHTENING TORQUES... CHASSIS TIGHTENING TORQUES... CABLE ROUTING... PERIODIC CHECKS AND ADJUSTMENTS... INTRODUCTION... PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM... GENERAL MAINTENANCE AND LUBRICATION CHART... CHASSIS... ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY... CHASSIS... 6 FRONT AND REAR BRAKES... 6 REAR BRAKE MASTER CYLINDER... 6 REAR SHOCK ABSORBER AND SWINGARM... 8 ENGINE... ROCKER ARMS, PUSH RODS AND VALVE LIFTERS... GENERATOR AND STARTER CLUTCH... STATOR COIL ASSEMBLY...

8 GENERAL SPECIFICATIONS/ ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS SPEC Model code ENGINE SPECIFICATIONS Item Standard Limit 5PX (USA) 5PX5 (Califnia) 5PX6 (CDN) Item Standard Limit Electronic fuel injection Model (manufacturer) INP-7 (NIPPON INJECTOR) ---- Quantity ---- Crankshaft C C A D Width A.8 ~. mm (5.8 ~ 5. in) ---- Max. runout C mm (0.006 in) Big end side clearance D 0.0 ~ 0.7 mm (0.06 ~ in) ---- Big end radial clearance E 0.07 ~ 0.07 mm (0.005 ~ in) 0.09 mm (0.005 in) Crankshaft journal-to-crankshaftjournal bearing clearance 0.0 ~ 0.06 mm (0.00 ~ 0.00 in) 0. mm (0.009 in) Fuel pump Pump type Electrical ---- Model (manufacturer) 5PX (MITSUBISHI) ---- Max. consumption amperage 5 A ---- Output pressure 9 ~ 588 kpa (.9 ~ 5.88 kg/cm, 55.7 ~ 8.6 psi) ---- CHASSIS SPECIFICATIONS E Item Standard Limit Front tire Tire type Tubeless ---- Size 0/70 ZR 8 M/C (59 W) /70 ZR 8 (59 W) Model (manufacturer) D0F ST G (DUNLOP)/ BT00F G (BRIDGESTONE) ----

9 CHASSIS SPECIFICATIONS/ ELECTRICAL SPECIFICATIONS/TIGHTENING TORQUES SPEC Tire pressure (cold) 0 ~ 90 kg (0 ~ 98 lb) 50 kpa (.5 kgf/cm, 6 psi) kg (98 lb) ~ Maximum load* 50 kpa (.5 kgf/cm, 6 psi) ---- High-speed riding 50 kpa (.5 kgf/cm, 6 psi) ---- * Load is the total weight of the cargo, rider, passenger and accessies. Min. tire tread depth mm (0.0 in) Rear tire Tire type Tubeless ---- Size 00/50 ZR 7 M/C (75 W) /50 ZR 7 (75 W) Model (manufacturer) D0 ST (DUNLOP)/ ---- BT00R (BRIDGESTONE) Tire pressure (cold) 0 ~ 90 kg (0 ~ 98 lb) 50 kpa (.5 kgf/cm, 6 psi) kg (98 lb) ~ Maximum load* 90 kpa (.9 kgf/cm, psi) ---- High-speed riding 50 kpa (.5 kgf/cm, 6 psi) ---- * Load is the total weight of the cargo, rider, passenger and accessies. Min. tire tread depth mm (0.0 in) ELECTRICAL SPECIFICATIONS Item Standard Limit Ignition coils Model (manufacturer) J07 (DENSO) ---- Minimum ignition spark gap 6 mm (0. in) ---- Primary coil resistance. ~.78 Ω ---- Secondary coil resistance ~ 8 kω ---- Charging system System type AC magneto ---- Model (manufacturer) F5PX (YAMAHA) ---- Nominal output V/ A at 5,000 r/min ---- Stat coil resistance/col 0. ~ 0.9 Ω/W W ---- TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Item Standard Limit Item Thread size Tightening tque Nm m kg ft lb Remarks Rider footrest bracket and frame M LT Rear fender and turn signal light bracket (upper) M Rear fender and turn signal light bracket (lower) M Canister and rider footrest bracket (F Califnia only) M

10 CABLE ROUTING SPEC EB06000 CABLE ROUTING Brake hose Clutch cable Rectifier/regulat Rectifier/regulat lead 5 Rear brake light switch lead 6 Hn lead 7 Stat coil assembly lead È Fasten the rectifier/regulat lead, hn lead, and rear brake light switch lead with a plastic locking tie to the frame. É Fasten the stat coil assembly lead and rectifier/regulat lead with a plastic clamp. Ê Fasten the rear brake light switch lead, hn lead, and stat coil assembly lead with a plastic locking tie to the frame. Ë Fasten the stat coil assembly lead, hn lead, and rear brake light switch lead with a plastic locking tie to the frame. Ê 6 7 Ë È 5 É

11 CABLE ROUTING SPEC Tachometer couplers Right handlebar switch coupler and speedometer couplers Main switch coupler Left handlebar switch couplers 5 Left and right turn signal/position light connects È Secure the wire harness in the holder at the white tape on the harness. É Route each lead behind the headlight assembly bracket bolts. A È 5 É É A

12 CABLE ROUTING SPEC Throttle cable and throttle cable Clutch cable Atmospheric pressure sens Spark plug cap (ignition coil -L spark plug lead) 5 Hn lead 6 Crankshaft position sens lead 7 Hn 8 Sidestand switch lead 9 Starter mot lead 0 Spark plug cap (ignition coil -L spark plug lead) A Rear brake light switch È Pass throttle cable and throttle cable through the cable guide, and then fasten them with a plastic holder. É Fasten the engine stop switch lead, hn lead, and oil temperature sens lead with a plastic locking tie. Ê Fasten the sidestand switch lead, starter mot lead, crankshaft position sens lead, decompression solenoid lead, cylinder identification sens lead, speed sens lead, and neutral switch lead with a plastic locking tie. È É Ï 0 A Ñ Î Ð 5 Ê 6 Í 9 Ì 8 7 Ë 5

13 CABLE ROUTING SPEC Ë Fasten the engine stop switch lead, crankshaft position sens lead, and hn lead with a plastic locking tie. Ì Fasten the starter mot lead and side stand switch lead with a plastic locking tie to the frame. Í Fasten the starter mot lead, fuel tank drain hose, and fuel tank/air filter breather hose with a plastic band to the frame. Be sure not to pinch the fuel tank drain hose the fuel tank/air filter breather hose. Î Fasten the starter mot lead with a plastic locking tie. Ï Clamp the clutch cable between the locknut and washer with a plastic clamp. Ð To the engine. Ñ Fasten the rear brake light switch with a plastic locking tie. È É Ï 0 A Ñ Î Ð 5 Ê 6 Í 9 Ì 8 7 Ë 6

14 CABLE ROUTING SPEC Ignition coil Atmospheric pressure sens lead Ignition coil Ignition coil lead 5 Rear brake light switch coupler 6 Rectifier/regulat lead and hn lead 7 Linear control valve lead 8 Ignition coil lead 9 Fuel return hose 0 Fuel inlet hose È To the rectifier/regulat, hn, and rear brake light switch. É 0 ~ 50 degrees Ê 0 ~ 60 degrees B C E D A E D È 5 A É Ê B C 9 D-D 0 E-E 9 7

15 CABLE ROUTING SPEC Oil temperature sens Fuel hose Spark plug cap (ignition coil -R spark plug lead) Inject lead 5 Throttle position sens lead 6 Intake air pressure sens 7 Intake air temperature sens coupler 8 Intake air pressure sens lead 9 Intake air pressure sens 0 Throttle cables A Brake hose B Spark plug cap (ignition coil -R spark plug lead) C Engine temperature sens lead D Stat coil lead E Neutral switch lead F Speed sens lead G Main wire harness H Ignition coil -R spark plug lead I Lean angle cut-off switch lead J Crankshaft position sens lead K Sidestand switch lead L Starter mot lead M Hn lead N Oil temperature sens lead Ù É 5 Ê A B Ì Ë 6 7 Í C A B A C Ñ È Ð Î Ï E F E D D Ö Õ Ô C B D Ó Ò G G G N Ø H A-A B-B C-C D-D H J M I L K E 8

16 CABLE ROUTING SPEC È To the battery box. É Fasten the main wire harness and fuel hose with a plastic locking tie to the frame. Ê Fasten the main wire harness and spark plug lead # with a plastic locking tie to the frame. Ë Fasten the throttle position sens lead, engine temperature sens lead, and inject lead with a plastic locking tie to the fuel delivery pipe. Ì Fasten the main wire harness and spark plug lead # with a plastic locking tie. Í Fasten the main wire harness, intake air pressure sens lead #, ignition coil -R spark plug lead, and intake air temperature sens coupler with a plastic locking tie. Î Fasten the rear brake light switch lead and ignition coil lead # with a plastic band. Ï Fasten the main wire harness and intake vacuum hose with a plastic locking tie. Ù É 5 Ê A B Ì Ë 6 7 Í C A B A C Ñ È Ð Î Ï E F E D D Ö Õ Ô C B D Ó Ò G G G N Ø H A-A B-B C-C D-D H J M I L K E 9

17 CABLE ROUTING SPEC Ð To the inject sub lead. Ñ To the engine temperature sens. Ò 0 ~ 0 mm (0. ~. in) Ó Position the gray mark on the stat coil lead at the center of the bolt, and then fasten it with a plastic locking tie. Ô To the stat coil. Õ To the decompression solenoid and cylinder identification sens. Ö To the neutral switch. To the speed sens. Ø Fasten the crankshaft position sens lead, sidestand switch lead, lean angle cut-off switch lead, starter mot lead, and hn lead with a plastic locking tie. Ù Fasten the oil temperature sens lead with the lead holder. Ù É 5 Ê A B Ì Ë 6 7 Í C A B A C Ñ È Ð Î Ï E F E D D Ö Õ Ô C B D Ó Ò G G G N Ø H A-A B-B C-C D-D H J M I L K E 0

18 EAS0006 CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all infmation necessary to perfm recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure me reliable vehicle operation, a longer service life and reduce the need f costly overhaul wk. This infmation applies to vehicles already in service as well as to new vehicles that are being prepared f sale. All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM No. ITEM ROUTINE * Valve clearance * Spark plugs * Crankcase ventilation system * Fuel line 5 * Exhaust system 6 * 7 * INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM Electronic fuel injection Evapative Emission control system (F Califnia only) Check valve clearance when engine is cold. Adjust if necessary. Check condition. Adjust gap and clean. Replace at 8,000 mi (,000 km) months and thereafter every 8,000 mi (,000 km) months. Check ventilation hose f cracks damage. Replace if necessary. Check fuel hose f cracks damage. Replace if necessary. Check f leakage. Tighten if necessary. Replace gasket(s) if necessary. Check and adjust engine idle speed and synchronization. Adjust cable free play. Check control system f damage. Replace if necessary. INITIAL 600 mi (,000 km) month,000 mi (7,000 km) 6 months ODOMETER READINGS 8,000 mi (,000 km) months,000 mi (9,000 km) 8 months Every 6,000 mi (5,000 km) 6,000 mi (5,000 km) months 0,000 mi (,000 km) 0 months Replace. Replace. * Since these items require special tools, data and technical skills, have a Yamaha dealer perfm the service.

19 GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ No. ITEM ROUTINE TYPE INITIAL 600 mi (,000 km) month,000 mi (7,000 km) 6 months ODOMETER READINGS 8,000 mi (,000 km) months,000 mi (9,000 km) 8 months 6,000 mi (5,000 km) months Engine oil Change. * Engine oil filter cartridge * Air filter elements * Front brake 5 * Rear brake 6 * Clutch 7 * Transfer case oil 8 * Throttle grip housing and cable 9 * Control cables 0 * Rear arm pivot bearing Brake and clutch lever pivot shafts Brake pedal and shift pedal shafts * Sidestand pivot * Sidestand switch 5 * Front fk 6 * Steering bearings Replace. Check condition and f damage. Replace if necessary. Check operation and fluid leakage. Crect if necessary. Check operation and fluid leakage. Crect if necessary. Check operation and free play. Crect if necessary. Check vehicle f leakage. Replace every 6,000 mi (5,000 km) months. Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. Apply chain lube thoughly. Check bearing assembly f looseness. Moderately repack every 6,000 mi (5,000 km) months. Lubricate. Apply grease lightly. Lubricate. Apply grease lightly. Check operation and lubricate. Apply grease lightly. Check and clean replace if necessary. Check operation and f leakage. Check bearing assembly f looseness. Moderately repack every 6,000 mi (5,000 km) months. 0,000 mi (,000 km) 0 months Replace brake fluid. Replace brake fluid. SAE 80 API GL- hypoid gear oil Change. Check. Change. Yamaha Chain and Cable Lube engine oil (API SE) 0W-0 Lithium-soapbased grease Lithium-soapbased grease (allpurpose grease) Lithium-soapbased grease (allpurpose grease) Lithium-soapbased grease (allpurpose grease) Repack. Lithium-soapbased grease (allpurpose grease) Repack.

20 GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ No. ITEM ROUTINE TYPE 7 * Wheel bearings 8 * Rear suspension link pivots 9 * Drive belt Check bearings f smooth rotation. Lubricate. Apply grease lightly. Check belt tension. Adjust if necessary. Lithium-soapbased grease INITIAL 600 mi (,000 km) month,000 mi (7,000 km) 6 months ODOMETER READINGS 8,000 mi (,000 km) months,000 mi (9,000 km) 8 months 6,000 mi (5,000 km) months Every,500 mi (,000 km) * Since these items require special tools, data and technical skills, have a Yamaha dealer perfm the service. NOTE: From,000 mi (7,000 km) 6 months, repeat the maintenance intervals starting from,000 mi (7,000 km) 6 months. NOTE: _ Air filters This model s air filters are equipped with disposable oil-coated paper elements, which must not be cleaned with compressed air to avoid damaging them. The air filter elements need to be replaced me frequently when riding in unusually wet dusty areas. Hydraulic brake service After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked damaged. 0,000 mi (,000 km) 0 months

21 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHASSIS CHK ADJ EAS0056 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING _ Securely suppt the motcycle so that there is no danger of it falling over. Spring preload CAUTION: _ Never go beyond the maximum minimum adjustment positions.. Adjust: spring preload NOTE: Adjust the spring preload with the special wrench. a. Loosen the locknut. b. Turn the spring preload adjusting nut in direction a b. Direction a Direction b Spring preload is increased (suspension is harder). Spring preload is decreased (suspension is softer). Adjusting positions a Minimum: 5 mm (.05 in) Standard: 5 mm (. in) Maximum: 6 mm (.8 in) CAUTION: _ Never turn the spring preload adjusting nut beyond the maximum minimum setting.

22 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Rebound damping CHK ADJ CAUTION: Never go beyond the maximum minimum adjustment positions.. Adjust: rebound damping a. Turn the adjusting knob in direction a b. Direction a Direction b Rebound damping is increased (suspension is harder). Rebound damping is decreased (suspension is softer). Adjusting positions Minimum: 0 clicks out* Standard: 0 clicks out* Maximum: clicks out* * from the fully turned-in position 5

23 FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER FRONT AND REAR BRAKES CHASSIS 6 CHAS 7 8 LT Nm (. m kg, 7 ft Ib) 5 8 Nm (.8 m kg, 5 ft Ib) Nm (.0 m kg, ft Ib) New 6 Nm (.6 m kg, ft Ib) Nm (. m kg, 7 ft Ib) Order Job/Part Q ty Remarks Removing the rear brake master Remove the parts in the der listed. cylinder Brake master cylinder cover Refer to REMOVING THE Union bolt REAR BRAKE MASTER Copper washer CYLINDER and ASSEM- Brake hose Disconnect. BLING AND INSTALLING THE REAR BRAKE MAS- TER CYLINDER in chapter. (Manual No.: 5PX ) 5 Brake master cylinder bracket 6 Rear brake light switch 7 Hn connect Disconnect. 8 Rider footrest assembly (right) 6

24 FRONT AND REAR BRAKES CHAS LT Nm (. m kg, 7 ft Ib) 5 8 Nm (.8 m kg, 5 ft Ib) Nm (.0 m kg, ft Ib) New 6 Nm (.6 m kg, ft Ib) Nm (. m kg, 7 ft Ib) Order Job/Part Q ty Remarks 9 Cotter pin 0 Pin Brake rod Locknut Brake master cylinder F installation, reverse the removal procedure. 7

25 REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, ft Ib) 0 Nm (.0 m kg, 7. ft Ib) 8 6 Nm (.6 m kg, ft Ib) Nm (0.7 m kg, 5. ft Ib) Nm (.5 m kg, 90 ft lb) 0 Order Job/Part Q ty Remarks Removing the rear shock absber Remove the parts in the der listed. and swingarm Rear brake master cylinder bracket Refer to FRONT AND REAR BRAKES in chapter. (Manual No.: 5PX-897-0) Rear exhaust pipe Refer to ENGINE in chapter 5. (Manual No.: 5PX-897-0) Rear wheel Refer to REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY in chapter. (Manual No.: 5PX-897-0) Adjusting bolt Locknut Lower drive belt cover plate Spacer 5 Lower drive belt cover 6 Hn coupler Disconnect. 7 Hn 8

26 REAR SHOCK ABSORBER AND SWINGARM CHAS 59 Nm (5.9 m kg, ft Ib) 0 Nm (.0 m kg, 7. ft Ib) 8 6 Nm (.6 m kg, ft Ib) Nm (0.7 m kg, 5. ft Ib) Nm (.5 m kg, 90 ft lb) 0 Order Job/Part Q ty Remarks 8 Brake hose holder Refer to REMOVING THE REAR 9 Self-locking nut SHOCK ABSORBER AND SWINGARM 0 Bolt (shock absber-connecting armframe) in chapter (Manual No.: 5PX-897-0) Cover (left and right) and INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM in chapter Pivot shaft nut/washer /. (Manual No.: 5PX-897-0) Pivot shaft Rear shock absber and swingarm assembly F installation, reverse the removal procedure. 9

27 REAR SHOCK ABSORBER AND SWINGARM CHAS 59 Nm (5.9 m kg, ft Ib) Nm (.0 m kg, 9 ft Ib) Nm (5.9 m kg, ft Ib) Order Job/Part Q ty Remarks Removing the rear shock absber and swingarm Remove the parts in the der listed. Self-locking nut/washer/bolt // Bolt = 00 mm (.9 in) Self-locking nut/washer/bolt // Bolt = mm (.88 in) Connecting arm O-ring 5 Rear shock absber 6 Spacer/O-ring / 7 Self-locking nut/washer/bolt // Bolt = 77 mm (.0 in) 8 Relay arm Refer to INSTALLING THE REAR 9 Spacer/oil seal/bearing // SHOCK ABSORBER AND SWINGARM 0 Spacer/bearing / in chapter. (Manual No.: 5PX-897-0) Spacer/bearing / 0

28 REAR SHOCK ABSORBER AND SWINGARM CHAS 59 Nm (5.9 m kg, ft Ib) Nm (.0 m kg, 9 ft Ib) Nm (5.9 m kg, ft Ib) Order Job/Part Q ty Remarks Swingarm Dust cover Spacer 5 Bearing F installation, reverse the removal procedure.

29 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENGINE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 0 Nm (.0 m kg, 7. ft Ib) 8 Nm (.8 m kg, ft Ib) 0 Nm (. m kg, 8.7 ft Ib) 0 Nm (.0 m kg, 7. ft Ib) (5) 5 New () 5 LT 9 Nm (0.9 m kg, 6.5 ft Ib) 8 Nm (.8 m kg, 5 ft Ib) Order Job/Part Q ty Remarks Removing the engine left side cover Remove the parts in the der listed. and camshaft sprocket cover Seat/fuel tank/silencer air filter case Refer to SEAT AND SIDE COVERS, FUEL TANK and SILENCER AIR FIL- TER CASE in chapter. (Manual No.: 5PX-897-0) Muffler/exhaust pipes Refer to ENGINE in chapter 5. (Manual No.: 5PX-897-0) Engine oil Drain. Refer to CHANGING THE ENGINE OIL in chapter (Manual No.: 5PX-897-0). Spark plug cap / Disconnect. Refer to INSTALLING THE Spark plug CAMSHAFT SPROCKET Shift rod COVER AND ENGINE Rider footrest assembly (left) LEFT SIDE COVER in 5 Canister F califnia only. chapter 5. (Manual No.: 5PX-897-0)

30 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 0 Nm (.0 m kg, 7. ft Ib) 8 Nm (.8 m kg, ft Ib) 0 Nm (. m kg, 8.7 ft Ib) 0 Nm (.0 m kg, 7. ft Ib) (5) 5 New () 5 LT 9 Nm (0.9 m kg, 6.5 ft Ib) 8 Nm (.8 m kg, 5 ft Ib) Order Job/Part Q ty Remarks 6 Engine left side cover 7 Rubber damper 8 Timing mark accessing screw 9 Crankshaft end cover Refer to INSTALLING THE CAMSHAFT 0 Decompression solenoid cover SPROCKET COVER AND ENGINE Camshaft sprocket cover LEFT SIDE COVER in chapter 5. Dowel pin (Manual No.: 5PX-897-0) Cylinder identification sens Camshaft sprocket cover 5 Camshaft sprocket cover gasket F installation, reverse the removal procedure

31 GENERATOR AND STARTER CLUTCH ENG EAS00 GENERATOR AND STARTER CLUTCH STATOR COIL ASSEMBLY 7 Nm (0.7 m kg, 5. ft Ib) 0 Nm (.0 m kg, 7. ft Ib) 0 Nm (.0 m kg, 7. ft Ib) (9) 8 9 New LT 0 Nm (.0 m kg, 7. ft Ib) 5 8 Nm (.8 m kg, 5 ft Ib) Order Job/Part Q ty Remarks Removing the stat coil assembly Remove the parts in the der listed. Muffler/exhaust pipes Refer to ENGINE in chapter 5. (Manual No.: 5PX-897-0) Engine oil Drain. Refer to CHANGING THE ENGINE OIL in chapter. (Manual No.: 5PX-897-0) Plastic locking tie Plastic band Rear brake light switch coupler Disconnect. Hn connects 5 Rider footrest assembly (right) 6 Stat coil assembly coupler Disconnect. 7 Oil delivery pipe

32 GENERATOR AND STARTER CLUTCH ENG 7 Nm (0.7 m kg, 5. ft Ib) 0 Nm (.0 m kg, 7. ft Ib) 0 Nm (.0 m kg, 7. ft Ib) (9) 8 9 New LT 0 Nm (.0 m kg, 7. ft Ib) 5 8 Nm (.8 m kg, 5 ft Ib) Order Job/Part Q ty Remarks 8 Generat cover 9 Generat cover gasket 0 Dowel pin Stat coil assembly lead holder Stat coil assembly F installation, reverse the removal procedure. 5

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