Check brake fluid level and condition. If the motorcycle has been sitting for an extended pe- riod, drain the tank and fill with fresh gasoline. Install the inboard outer race Figure 151 onto the crankcase receptacle. Feeler Gauge The feeler or thickness gauge Figure 25 is used for measuring the distance between two surfaces. Throttle Cables Inspection Free play Inspect the throttle cables from the grip to the carburetor. Install the Nice bearing 3, Figure 162 , washer 4 and handle 5.
Install the test har- nesses Figure 44 between the ignition module and the module connectors. With the engine idling at module and the module connec- operating temperature, voltage must tors. Inspect the access door bearings as described in this chapter. The body bushing Figure 99 should be pressed in 0. If the voltage is incorrect, check for an open circuit between the battery, 30-amp circuit breaker, ignition switch, and fuse block.Next
If you are on dial-up please message me first and i will see if the file is small enough to download via dial up connection Tags: pdf Comments. Install the rocker covers as described in this chapter. If damaged, refer re- placement to a dealership. Make sure the shift forks engage the shifter cam after in- stalling the shift fork shaft. Con- nect the positive voltmeter lead to the white and blue ignition coil terminals Figure 33. Use grease to hold small parts in place if they tend to fall out during assembly.Next
Then disconnect and remove the clutch cable from the slot in the coupling. Make sure all loose debris or small parts that could fall into the spark plug holes in the cylinder head are removed. Measure and record the valve tappet outside diameter B, Figure 38. The maximum lateral side-to-side and radial up-and- down runout is listed in Table 1. If the dis- tance is not within specification, replace the cover. Clutch cable Make sure they are not kinked or chafed. Carefully inspect the inside of the rotor for small bolts, washers or other metal debris that may have been picked up by the magnets.Next
Remove the O-ring Figure 12 from the accelerator pump housing cover. Then, the ignition system is operational and the engine can be re- started. The system will pause for two seconds, and then flash the first digit of the next diagnostic trouble code. Assemble the following components on the countershaft in the following order: a. Drain the engine oil tank Chapter Three. Assemble the upper and lower switch housings and slide the throttle grip onto the handlebar.Next
Mechanical damage may also occur. Place the pilot jet Figure 45 into the passage and tighten it with the same screwdriver used during removal. Felt seal late 1991-1999 models 1986-1994 models 13. Connect the probes of an ohmmeter to the cable termi- nals. Remove the pump cover O-ring Figure 29.Next
Remove the seat Chapter Seventeen. To bring the battery to a full charge, give it an initial charge. Remove the outer timing cover, inner timing cover and Control gasket as described in Chapter Twelve Ohmmeter module 2. On 1991-1993 models, remove the inspection cover Figure 16 and refill with the recommended quantity Ta- ble 4 and type Table 5 transmission oil. If the neutral indicator lamp lights, the neutral switch or attached wire lead is faulty.Next
Do not attempt to reuse removed clamps. Press the canister bracket locking tab and slide the canis- ter toward the left side of the motorcycle and off the bracket. On 1986-1990 models, remove the cam gear guide plates 8, Figure 51. A warm chain increases lubricant penetration. A suitable equivalent is the Yamaha belt tension tool B, Figure 44. Refer to Table 1 for original equipment jet sizes.Next