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.

6 3

8 5 4

EB003000

ILLUSTRATED SYMBOLS
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

CHK ADJ
5 6

10

Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text.
10 11 12 13 14 15 16 17

11

12

Can be serviced with engine mounted Filling fluid Lubricant Special tool Torque Wear limit, clearance Engine speed , V, A

13

14

15

16

17

18

19

20

Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18 19 20 21 22 23

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

24

25

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 (LOCTITER) 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

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard

Model code: Basic weight: With oil and a full fuel tank Tire: Type Size Manufacturer Type

XVS1100: 5PB2 275 kg With tube 110/90-18 61S 170/80-15M/C 77S DUNLOP DUNLOP K555F K555 200 kg

front rear front rear front rear

Maximum load-except motorcycle:

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS
ENGINE Item Camshaft: Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam dimensions Standard Chain drive (left & right) 25.000 X 25.021 mm 24.96 X 24.98 mm 0.020 X 0.061 mm SSS SSS SSS SSS Limit

Intake

Exhaust

A B C A B C

Camshaft runout limit

39.112 X 39.212 mm 32.093 X 32.193 mm 7.162 mm 39.112 X 39.212 mm 32.127 X 32.227 mm 7.162 mm SSS

39.012 mm 31.993 mm 7.012 mm 39.012 mm 32.027 mm 7.012 mm 0.03 mm

MAINTENANCE SPECIFICATIONS
CHASSIS Item Front suspension: Front fork travel Fork spring free length Fitting length Collar length Spring rate Stroke Optional spring Oil capacity Oil level Oil grade Rear suspension: Shock absorber travel Spring free length Fitting length Spring rate Stroke Optional spring Tightening torques g Part to be tightened Brake caliper and bracket Thread size Nm M10 27 Tightening torque mSkg 2.7 Standard 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 X 77.5 mm 77.5 X 140 mm No 0.464 L 108 mm Fork oil 10W or equivalent 50 mm 179.5 mm 163 mm 117.7 N/mm (12 kg/mm) 0 X 50 mm No

SPEC

Limit SSS 350 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

(K1) (K2) (K1) (K2)

(K1) (K1)

Remarks ftSlb 20

MAINTENANCE SPECIFICATIONS
ELECTRICAL Item Ignition coil: Model/manufacturer Primary winding resistance Secondary winding resistance Charging system: Type Model/manufacturer Nominal output Stator coil resistance/color 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 Standard F6T541 /MITSUBISHI 3.57 X 4.83 at 20_C 10.7 X 14.5 k at 20_C

SPEC

Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 5 mm SSS 27 mm SSS SSS SSS

A.C. magneto F4T654 /MITSUBISHI 14 V 305 W at 5,000 r/min 0.36 X 0.44 at 20_C/White White Constant mesh type SM-13/MITSUBA 0.6 kW 0.026 X 0.034 at 20_C 10 mm 7.65 X 10.01 N (780 X 1021 g) 28 mm 0.7 mm MS5F-421 /JIDECO 180 A

CABLE ROUTING
EB206000

SPEC

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

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

SPEC

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.

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)

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.

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

SPEC

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

22 23 24 25 26 27 28 29 30 31 32

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

SPEC

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.

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_ X 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 boxs 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

SPEC

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)

23 24 25 26 27 28 29 30 31 32 33 34 35 36

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

12

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.

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.

13

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.

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.

14

CABLE ROUTING
1 2 3 4 5 6 7

SPEC

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

INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS

EB300000

CHK ADJ

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: S The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. S From 50,000 km, repeat the maintenance intervals starting from 10,000 km. S Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
ODOMETER READING ( NO. NO 1 2 * * ITEM Fuel line Fuel filter CHECK OR MAINTENANCE JOB S Check fuel hoses for cracks or damage. S Check condition. S Check condition. S Clean and regap. S Replace. 4 * Valves S Check valve clearance. S Adjust S Clean. S Replace. S Check operation. S Adjust. S Check operation, fluid level and vehicle for fluid leakage. (See NOTE) S Replace brake pads. 8 * Rear brake S Check operation, fluid level and vehicle for fluid leakage. (See NOTE) S Replace brake pads. 9 * Brake hose Wheels S Check for cracks or damage. S Replace. (See NOTE) S Check runout, spoke tightness and for damage. S Tighten spokes if necessary. S S S S Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 1 10 20 1,000 km) 30 40

ANNUAL CHECK

Spark plugs

5 6

Air filter element Clutch

Front brake

Whenever worn to the limit

Whenever worn to the limit

Every 4 years

10 *

11

Tires

12 * 13 * 14 * 15 16 *

Wheel bearings Steering bearings Chassis fasteners Sidestand Sidestand switch

S Check bearing for looseness or damage. S Check bearing play and steering for roughness. S Lubricate with lithium-soap-based grease. S Make sure that all nuts, bolts and screws are properly tightened. S Check operation. S Lubricate. S Check operation.

Every 20,000 km

16

INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS

ODOMETER READING ( NO NO. 17 * ITEM Front fork Rear shock absorber assembly CHECK OR MAINTENANCE JOB S Check operation and for oil leakage. S Check operation and shock absorber for oil leakage. S Lubricate the pivoting points with molybdenum disulfide grease. S Check starter (choke) operation. S Adjust engine idling speed and synchronization. S Change. S Replace. S Check oil level and vehicle for oil leakage. S Change. S Lubricate. S Check operation. S Adjust headlight beam. 1 10 20

CHK ADJ
1,000 km) 30 40
EAU03541

ANNUAL CHECK

18 *

19 * 20 21 22 23 24 *

Carburetors Engine oil Engine oil filter element Final gear oil Moving parts and cables Lights, signals and switches

NOTE: S The air filter needs more frequent service if you are riding in unusually wet or dusty areas. S 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: S connector 1 2. Remove S headlight bulb cover 2

3. Remove: S headlight bulb holder 1 4. Remove: S 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: S 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: S headlight bulb holder 7. Install: S headlight bulb cover 8. Connect: S leads

18

ADJUSTING THE HEADLIGHT BEAM

EAS00184

CHK ADJ

ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S 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: S 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

CARB

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

AIR INDUCTION SYSTEM

CARB

Order 1 2 3 4 5 6 7 8 9

Job name/Part name 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

Qty 1 1 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed.

For installation, reverse the removal procedure.

21

AIR INDUCTION SYSTEM

EAS00510

CARB

CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace.

2. Check: S reed valve 1 S reed valve stopper S reed valve seat Cracks/damage ! Replace the reed valve.

3. Measure: S reed valve bending a Out of specification ! Replace the reed valve. Maximum reed valve bending 0.4 mm
1 Surface plate

4. Check: S air cutoff valve Cracks/damage ! Replace.

5. Check: S 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 mSkg)

30 Nm (3.0 mSkg)

27 Nm (2.7 mSkg)

Order

Job name/Part name Removing the front brake calipers Brake fluid Brake hose holder Union bolt Copper washers Brake hose Retaining bolt Brake caliper assembly

Qty

Remarks Remove the parts in the order listed. Drain

1 2 3 4 5 6

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 mSkg) 18 Nm (1.8 mSkg)

110 Nm (11.0 mSkg)

7 Nm (0.7 mSkg)

Order

Job name/Part name Removing the lower bracket

Qty

Remarks Remove the parts in the order listed. Stand the motorcycle on a level surface.

WARNING
Securely support the motorcycle so that there is no danger of it falling over. 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 Refer to FRONT FORK. Refer to HANDLEBAR. Disconnect

1 2 3 4 5 6 7 8

24

STEERING HEAD

CHAS

1st 2nd

52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg)

110 Nm (11.0 mSkg)

7 Nm (0.7 mSkg)

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)

Qty 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