Yamaha XS850G Spécifications

Componentsshould be room temperature.500 - 600

3-3. GEAR OIL REPLACEMENTNOTE:See Chapter 4 regarding the inspection ofdrained oil. page 110A. Place an oil pan under the transmissionfor the middle g

TROUBLESHOOTINGBasicconditions4-1.TROUBLESHOOTINGCONDITIONSPossible damaged areas3.Alocked-upconditionoftheshaft drive mechanism;nopowertransmittedfro

B. Consider the followingInspection Notes:(1) During coasting, accelerating or decelerating, the“rolling rumble” will increase with rearwheel speed, n

D. OilLeakInspectionIfashaftdrivecomponentissuspectedofleakingoil,firstthoroughlycleantheentiremachine.Theapparentlocationofanoilleakonadustymachinema

REMOVAL OF COMPONENTS5-1.RemovalofComponentsItisnormallynotnecessarytoremovetheenginetoremovethe Middle GearCase.A.DriveShaftJoint(1)Pullrubberbootfro

5-2. CheckingGearLashA. Checkfinaldrivegearlashasfollows(1)Removefinaldrivegearcase.(2)Temporarilysecurebearing housing asfollows(Type1andType2):Place

(8) Checkthisengagementat4positions.Rotatetheshaft 90° eachtimeandrepeatthegearlashcheck.0.1-0.2(0.004-0.008in):Measuredvalueand actual gearlashB. Che

MIDDLE GEAR6-1. Disassembly and InspectionA. Purpose of Drive Pinion RemovalIf either the drive pinion or driven piniongears are damaged, both must be

B. Disassembly (Initial)(1) Remove bearing housing cap.(2) Remove drive pinion circlip.(3) Tap on splined end of drive pinionshaft with a soft hammer.

(3) Remove housing with bearing. Removebearing from case.(2) Hold flange in a vise. Remove self-locking nut.(3) Tap driven pinion with a soft hammer.R

SPECIALTOOLSValveguideremoverClutchholdingtoolValve guide installerValvespringcompressorValveseatcuttersetTappetadjustingtoolVacuumgaugeFinal drive ge

6-2. Reassembly and AdjustmentA. Drive Pinion Assembly(1) Install bearing into middle gear case.(2) Install bearing into bearing housing.(3) Install b

(6) Stake the locking collar of the nut tothe slot on the drive pinion shaft.(7) Install a new o-ring on the bearinghousing.(8) Install original shim

To increase gear lash, use a thickershim. Gear lash can also be adjustedby changing the driven pinion bearinghousing shim(s) in the same way.Toolittle

(6) Final assemblya. Install circlip on drive pinion shaft.b. Remove housing cap screws. Cleanthreads and apply thread sealantsuch as“Loctite”,and rei

c. Hold bearing housing and checkpreload. This preload is determinedby turning the shaft with a torquewrench and measuring the resistanceof the bearin

FINAL GEAR7-1. Disassembly and Inspection23.Ringgearshim,0.25.0.3.0.35.0.4.0.45.0.5~A. Purpose of Ring Gear RemovalBy removing the ring gear assemblyo

B. Ring Gear Removal(1) Remove the nuts (10) holding the bearinghousing.(2) Remove the ring gear assembly and thrustNOTE:The following drive pinion di

(3) Large bearing (rear): Use a universal-type bearing puller to remove innerrace of large bearing from the drivepinion.(4) Use a press and the press

Type 1:a. Install the gear coupling, platewasher, and self-locking nut. Donot install spacers yet. Tightennut gradually until proper bearingpreload is

Type2:Followthesameproceduredescribedforthe Middle Geardrivenpinion.Type2Bearing Preload: 4-5cm-kg(3.4-4.3in-lb)Nuttighteningtorque(forreference):10-1

CorrectpatternDrivepinionIncorrect Pattern Drive pinion CorrectionProcedure:a.Reducedrivepinionshim0.05mm.b.Rechecktoothpattern.c.Ifnecessary,repeat s

C.RingGearAssemblyc.Ifthedistance"a"oftheoldand(1)RinggearassemblycomponentswasherBearing outerracenewbearingsindifferent,removeand measure

DRIVE SHAFT8-l. Drive Shaft InspectionA. RemovalSee page 113, Section5-1D for driveshaft removal.B. Inspection(1) Inspect oil seal for damage. If dama

6-1ELECTRICSTARTINGSYSTEMA. StarterMotor1.Circuitdiagram.STARTERRELAYSWITCHrBATTERYSTARTERSWITCHT2.Removal(seeSection3-2,EngineDisas-sembly).3.Inspect

IMinimumbrushlenoth:5.5mm (0.22in.)f.Checkbrush spring pressure. Replace springifitisweak.B. StarterRelaySwitch1.Inspectiona.Disconnectstarterrelaylea

2.Resistancetestoffieldcoilandstatorcoil.Checktheresistancebetween terminals. Ifre-sistanceisoutofspecification,coilisbroken.Checkthe coil connections

.,.WinfWinfinfEinfEUinfinfVEinfEVinfinfWEinfEWinf infc.Chargingvoltageoutputcanbecontrolledattheregulator. Inside thehousingisascrewthatpushesagainsta

Evenifonlyone element isbroken,replaceassembly.InitialchargingcurrentCAUTION:Thesiliconrectifiercanbedamagedifsubjectedtoovercharging.Specialcareshoul

b. Check theoperationofthepointcamontheshaft.Itmustrotatesmoothly.c.Examinepointcamsurface.Ifsurfaceispittedorworn,thegovernorassemblymustbere-placed.

Standardvalues:Primarycoilresistance:4.0 ohms ± 10% at 20°C (68°F) Secondarycoilresistance11.0K ohms ± 20% at 20°C (68°F) Insulationtest.a.Connect ohm

d.Turnpetcocksto"prime"position.e.Startmotorcycleandallowittowarmupfor2-3minutes.The warm-upiscompletewhenenginerespondsnormallytothrettleop

6-2ChargingSystem,forchecksofbatteryandchargingsystem.Alsocheckfusecondition.Re-placeany"open"fuses.Thereareindividualfusesforvariouscircuit

C.Self-CancelingFlasherSystem1.Description:Theself-cancelingflasher system turnsofftheturnsignalafteraperiodoftimeordistanceinvolvedinturningorchangin

IHEADLIGHTDOESNOT FUNCTION 1"HEAD"INDICATORBULBDOESNOTGLOWVoltage on "LG"WiretoReserveINDICATORLIGHTDOESNOTLIGHTWHENLOWBEAMCOMESON

CASEEXCHANGEWhenthe exterior of the middlegearorfinalgearcaseisdamagedandmustbereplaced,payattentiontothenumbers scribed onthereplacementcases.Followa

2.Interchangeability of Parts for Type 1 and Type 2All the parts except the following parts are interchangeable for both Type 1 and Type 2.These items

OIL SCAVENGE (Return)

SUPPLEMENTXS750-2DNote:Thissectiononlycoversthosepoints which aredifferentfromtheXS750 D.Ifthesubjectdoesnotappearinthissection,pleaserefertotheConten

b.Pullouttheelement.C.Engine/TransmissionOil1.Oillevel measurement a.Tocheckthelevel,warmtheengineupforseveralminutes.Stoptheengine.Withtheenginestopp

Airfilter:TypeTypeIgnition:Spark plug Charging:TypeManufacture,I.D. No. MaximumoutputBatterytypeBatterydimensionsRegulatorRectifierStartingPrimary dei

B.MAINTENANCESPECIFICATIONSEngine/TransmissionoilcapacityTotalamountOilandfilterchangeOilchange2.CarburetionManufacturerMikuniModel,I.D.No.BS34.1J701M

Pagenumbersshowninbrackets correspond topagenumbersoftheXS750DServiceManual.(PAGE19-20)A.MaintenanceIntervalsForNewMachines(XS750D,XS750-2D)Initial400

C.LubricationIntervalsForNewMachines(XS750D,XS750-2D)Middle/Final(rear)gearInitial400km(250miles):Replaceengine/transmissionoilReplaceoilfilterReplace

TorqueSpecificationsFrontaxlenutFrontaxle holder nuts RearaxlenutRearaxlepinch bolt Rearshockabsorber(Top)(Bottom)BrakesCalipersupportboltCalipermount

(PAGE24)C.Engine/Transmissionoil(XS750-2D)2.Engine/Transmissionoilandoilfilterreplacement.g.Addoilthrough the dipstickhole.Specifications should becha

NOTE:Seethatthepunchedmarkonthebrakerodisnotabovethetopsurfaceoftheadjustorlocknutinsecuringthebrakerodadjustorlocknut.(PAGE 86~90)5-3.BRAKES(XS750D,X

(PAGE69)G.Clutchand Primary Drive (XS750D,XS750-2D)1. Installclutchspacer,platewasher,andclutchboss.Installthespringwasher,lockwasherandlocknut.Usethe

5.Installthecylinder.Aringcompressorisusuallynotnecessary.3-6.TIMINGPLATE SETTING(XS750D,A.TimingplatesettingXS750-2D)Adjustmentsrequired when the fol

d.Removetheoil filter boltandfilterelement.e.Reinstallthedrain plug (makesureitistight).e.Reinstallthedrain plug (makesureitistight).4.0 ~4.5m-kg(28.9

5.Raisetheseatand unscrew therearfen-derinstallationboltsuntiltheirthreaded8.Whilesupporting the brake caliper,pullouttherearaxle.portioniscompletelyo

11.Toinstalltherear wheel, reversetheremovalprocedure.NOTE:Wheninstallingtherearwheel,besurethesplinesonthewheelhubfitintothefinalgearcase.Makesurethe

5.Turnthemainswitchon.MakesurethatV2islessthan1.8V.connectingGoodelementNOTE:Donotturnonlightsorsignals.ReplaceReplace6.MakesurethatV2graduallyincreas

X:CAUTION:The silicon rectifier can be damaged ifsubject to overcharging. Special care should be taken to avoid a short circuit and/or incor

d.Fillthegearcase(s)uptospecifiedlevel.CAUTION:Takecarenottoallowforeignmaterialtoenterthemiddleand/orfinalaear case. 2.Gearoilreplacementa.Placeanoil

1.Removethebreakercover2.Removethecamchain tensioner cover.2.MechanismadjustmentThesecondadjustmentislocatedbehindtheadjusting cover. Removing thecove

5.Reinstall the chain tensionercapandthecon-tactbreakercover.G.ValveClearanceAdjustmentNOTE:Valveclearancemustbemeasuredwiththeengineatroomtemperature

NOTE:The tappet adjustingtoolisfastenedtothecylinderheadusingone(1)allenscrewsuchasoneusedtoinstallthecylinderheadcover.Makesurethat the tool contacts

SPECIFICAT IONS A.GENERALSPECIFICATIONSBasiccolorDimensions:Overall length OveralI widthOverall height SeatheightWheelbaseMinimumgroundclearanceCaster

Intake... ...,.i..:.I,CLEARANCEExhaust...

5.Turnoverenginewithkickorelectricstarter2.Removethedraincoverandcleanitwith(makesurebatteryisfullycharged)withsolvent.throttlewide open untilpressure

1)Loosenthe adjusting screwlocknut.2)Byturning the adjustingscrewinorout,adjusttheplayofthebrakeleverandthentighten the locknut.Measurefreeplayatendof

c.Becarefulthatwaterorother contamination doesnotenterthemastercylinderwhen re-filling.Waterwillsignificantlylower the boilingpointandmayresultinvapor

b.CheckthetirewearIfatiretreadshowscrosswiselines,itmeansthatthetireisworntoitslimit.Replacethetire.9. Inspect the O-ring on the spring seat.ReplaceO-

3.Ifthereisloosenessinthesteeringhead,loosenthe crown pinchboltandsteeringfittingbolt.4.Use steering nut wrench to loosen top steering fittingnut.Thet

Therearealsothree(3)pairofunmarkedlines.TheyindicatetheFullAdvancefiringrangeforeachcylinder.ConnecttiminglighttoNo.1(left)cylinder.2.Ignitiontimingof

Thesparkplug must beremovedandchecked.Checkelectrodewear,insulatorcolor, and electrode gap.Sparkpluggap:0.6~0.7mm(0.02~0.03in.)Engineheat and combusti

ENGINE OVERHAUL3-1 ENGINEREMOVALNOTE:Itisnotnecessarytoremovetheenginetoremovethecylinderhead,cylinder, or pistons.A.PreparationForRemoval1. Alldirt,m

D.SideCover,AirCleanerCase4. Removeboltsholdingaircleanercasetoframe.Notegroundwireconnectiononleft1.Removeleftandrightside covers. frame bracket. DO

Transmission:Teeth,ratio,overall1st2nd3rd4th5thSecondaryDrive:Transmission0utput:Type,teeth,ratioMiddlegearcaseType, teeth, ratioFinalgearcaseType, te

2.Removesparkplugwiresandtachometercable.3. Removetwo(2)screwsholdingstartermotorcover.Removestartermotorcover.Disconnectelectricstartercable.4. Disc

2. Removepointscover.RotatethecrankshafttoT.D.C.ofthecompressionstrokeontheNO.1(L.H.)cylinder.Tieeachend of the cam chaintopreventitfromfallingintothe

8.Removesparkplugs.9. Removecylinderheadholdingnutsand boltsas follows: a. Looseneachnutandbolt ½ turn,observingthetorquesequence.b.Removethecylinderh

C. Piston Removal 1.Markeachpistontoaidinreassembly.2. Placeacleantowel or ragintothecrankcasetokeepcirclipsand material fromfallingintotheengine.3.

F. Clutch and Primary Driven Gear 1. RemovesmallcirclipandwasherfromR.H.endoftransmission.2.Removelargercirclip.3.Removeclutchdamper.4.Removeprimarydr

7.Removepressureplatescrewsandclutchsprings.Removepressureplate.8.Removeclutchplates,clutchpushrodandballbearing.9. Useclutch holding tool(specialtool

4. Removekickgearholderbolts.UseaslideH.ShiftLever,ShiftShaftRemovalhammertoremovetheholder.1. Removeclipholdingshiftlevertwo(2).Re-movethelever.2. R

2. Removeneutrallightwire.Removebreakerassemblywiringharnessfromclamps on crank-case. Remove three (3)breaker plate holding screwsandremovebreakerasse

6.Remove cam chaindampers.MiddleGearCaseDisassemblyiscoveredintheShaftDrive,Sectionpage102.7.Removetwo(2)startermotorsecuringbolts.L.Transmission Bear

N.Oil Pump Removal and Disassembly 4.Removeoilpumpcoverandrotorassembly.1.Removestrainer cover. O.CrankcaseDisassemblybolt.Thisboltislocatednearthetra

Middlegearcasecapacity:FinalGearcasecapacityRecommended Iu b r icantIftemperaturedoesnotgobelow5°C (40°F)IftemperaturedoesnotgoaboveAI I weather15°C(6

1. Looseneachbolt½turn,startingwiththeunnumberedbolt.Continuebylooseningthehighestnumberedboltsfirst.The numbers oftheboltsarecastinthecases.Numbers 2

6.Removeboltholding middle drivegeartodriveaxle. Remove spacer.7.Loosen transmission bearing capnuts½ turn. Removenutsandcap.8.Removemiddledrivegear.P

1234567891011121314AXLE,main(13T) GEAR,4thpinion(21T) CIRCLIP WASHER,gearhold5 (25.2-30-1.O) GEAR,3rdpinion(20T) GEAR,5thpinion (23T) CIRCLIP (S-25)

1234567891029 CAM,shiftPIN,dowel(4-8)1112SPRING,compressionGASKET,drain plug 2122BAR,shiftforkguide2FORK,shift1PIN,dowel(4-17.8)13SCREW23SHAFT,shiftl

3-3INSPECTIONANDREPAIRA.CylinderHeadCoverPlaceheadcoveronasurfaceplate. There should benowarpage.Correctbyre-surfacingasfollows:Place#400or#600grit we

d.After installing thevalve guide, use7mmreamer(specialtool)toobtainthepropervalveclearance.Afterfittingthevalveguideintothecylinderhead,besuretogrind

seathavebeenre-surfaced and nowrequireafinal light grinding operation forperfectseal-ing.b.Applyasmallamountofcoarselappingcom-poundtovalveface.Insert

2.Valveliftera. Checkeachvalvelifterforscratchesor other damage.Ifthelifterisdamagedinanyway,the cylinder headsurfaceinwhichitridesisprobablyalsodamag

ordisintegrating damping rubberwillcontam-inatetheengineoilandwilllead to excessiveengine noise. 4.CamChainDampersInspectthetopcamchain damper (stoppe

b.Determinepistonclearanceasfollows:IMinimumboremeasurement-MaximumDistonmeasurement=PistonclearanceEXAMPLE:68.02mm-67.97mm=.05mm pistonclearancec.Pis

"B""C"seatwidth"D" marginthicknessStemdiameter(O.D.)Guide diameter (I.D.)CIearance(Coldengine)"A"headdiameter0

IRun-outlimit:.03mm(.001in.)IIfrun-outexceedslimit,replace crank. 2.InspectionOfInsertsCheckthebearinginserts.Iftheinneroroutersurfaceisburned, flaked

NOTE:Thereisaspecialthrustbearingc. Remove connectingrodand cap. Measure(insert)locatedintheNo.3mainbearingwidthofPlastigaugetodetermineoilclearance.h

EXAMPLE:INSERTCOLORCODENo.1BlueNo.2No. 3No. 4No. 5 BlackBrownGreenYellowd.Whenassembling,applyaliberalcoatofmotoroiltoallbearingsurfaces.NOTE: Whenapp

d.DamperReassembly1)Installthinplatewasher,thrustbearingandthickplatewasherinthatorder.2)Installdampersprings.3)Installcollar.4)Usepressandspecialtool

5. Checkshiftcamdowel pins and sideplateforlooseness, damage orwear. Replace asrequired.6. Checktheshiftcamstopperplateandcirclipandstopperforwear.Re

Middle gear case lash: 0.1~0.2mm(.004~.008")b.Mountadialgaugeagainstthelashmeasure-menttoolatthescribedmark(34mmfromthecenteroftheshaft).c. Holdt

2. Installbearingcap,washers,dndnuts.Tightenbearingcap.Bearingcaptorque:1.8~2.2m-kg(13~16ft-lbs)3. Install plate washer,springwasher,andboltholdingdr

NOTE: Whenanewsealisinstalled,greasethelipsofthesealbefore installation. Inspectthesealafter installation. C.CrankshaftandCrankcases1.Install cranksha

1CRANK,kick2COVER,kicklever3BOSS,kickcrank4BOLT5WASHER,plate(15.5-24-1.5)6789101112131415CIRCLIP(E-10)BALL(7/32inch)SPRING,compression01LSEAL(SD-20-30

1234567891011121314DAMPERASS'YCIRCLIPWASHER,plate (76-95-0.8)BEARINGWASHER,plate (69-95-5.4)SPRING,damperCOLLARCIRCLIPCLUTCHASS'YCLUTCHHOUSI

CrankshaftandConnectingRods:MainbearingoilclearanceRod bearing oilclearanceMainjournalrun-out(maximun)OilPumpHousing-to-outerrotorclearanceOuterrotor-

2.Installshiftlever 2. Thedotonshiftlever2must align withthedotontheshaft.3.Shifttransmissionintosecondgear.The line ontheshiftcammust align withtheli

Clutchnuttorque:8m-kg(58ft-lbs)IClutchscrewtorque:0.8~1.0m-kg(6~7ft-lbs)2.Installaclutchfrictionplate,thenasteelclutchplate.Installclutchfrictionplate

8.Carefully install spacerandclutchhousing.Usecaretoavoiddamagingfrictionplates.9. Place drivechainondrivegear.Installdamperassemblyintoprimarydriveng

K. DriveAxleBearingHousing1.Oildriveaxlebearing.2.Installdriveaxle shim on drive axle.3.Oilthe o-ringonthebearinghousing.Installbearinghousing.Attachw

6.Installstartermotor7.Installstartermotoridlergearandkickidlergear.Installtheidlergearshaft.8.Installclutchballbearingandclutchpushrod.9.Install plat

4.Positionpistonringsasshown.OILRINGTOP(LOWERRAIL)OIL RING 2ND(UPPERRAIL)NOTE:Make sure endsofoilringexpandersarenotoverlapped.O.CylinderHeadInstallat

5.NOTE:Manufacturer'smarksornumbersstampedontheringsareonthetopsideoftherings.Coat pistons and ringswellwithoil.Installthecylinder.Aringcompresso

3.Installoilfilter.Removeoilfilterfillerbolt.NOTE:Seesections3-6onpage106-Filloil filter with0.5lit(0.5qt.)engineoil.Timingplatesetting.ADD OILHERCAUT

123456789101112131415161718192021222324252627282930313233343536373839404142434445CARBURETORASS'YCARBURETORASS'Y1CARBURETORASS'Y2CARBURE

CARBURETION4-1CARBURETORA.DescriptionTheXS750Disequippedwiththree"constantvelocity"(CV)carburetorsmountedonrubberintakemanifolds.Air flow th

3.ChassisIgnition timing retardedadvancedadvancestartsWheelsandTiresRimrun-out,verticalRim run-out, horizontal Tirepressure,front,normalridingHighspee

6.Removethe four (4)screwsholdingthefloatbowlcover.Removefloat bowl cover.Themainjetislocated under acoverinthe float bowl.3. Inspectinletneedle valve

TANG2.JetneedleadjustmentThemid-rangeair/fuelsupplyisaffectedbythepositionoftheneedleintheneedlejet.Ifitisnecessarytoalterthemid-rangeair/fuelmixturec

C.FrontWheelInspection1.Checkforcracks,bendsorwarpageofwheels.Ifawheelisdeformedorcracked,itmustbereplaced.2.Checkwheelrun-out.Ifdeflectionexceedstole

D. ReplacingWheelBearingsIfthebearingsallowplayinthewheelhuborifwheeldoesnotturnsmoothly,replacethebearingsasfollows:1.Cleantheoutsideofthe-wheel hub.

21251CASTWHEEL, rear (2.15-18)2TIRE, rear (4.00-18-4PR)3 TUBE, rear (4.00-18)4 SPACER, bearing5 FLANGE, spacer6BEARING(B6204)7 BEARING (B6204RS)8COLLA

1DISK,rearbrake2WASHER,lock3BOLT,hexagon4CALIPERASS’Y,rear5CALIPERPADKIT6BUSHING,boot7SLEEVE8BOLT,support9SCREW,bleedwithcap10CALIPERSEALKIT11NUT,crow

1PEDAL,brake2BOLT,hexagon3WASHER,spring4SPRING,torsion5SHAFT,brakepedal6JOINT7PIN8WASHER,plate9CIRCLIP (E-6)10ROD,brake11NUT,hexagon12SCREW13NUT,adjus

NOTE: Do notdepressthebrakepedalwhenthewheelisoffthemachine so thatthecaliperpistonisnotforcedoutofthecylinder.9.Toinstalltherearwheel,reversetheremov

1234567891011121314MASTERCYLINDERASS'Y,front15CYLINDERKIT,master16CAP,reservoir17SCREW,cap18DIAPHRAGM,reservoir19BUSHING,diaphragm20BRACKET,maste

1234567891011121314DISK,frontbrakeWASHER,lockBOLT,hexagonFRONTCALIPERASS'Y,rightFRONTCALIPERASS'Y,leftCALIPER PAD KITBUSHING,boot(withgrease

Startermotor type Armaturecoilresistance(2O°C)Fieldcoilresistance(2O°C)BrushlengthstandardminimumBrush spring pressureArmaturemicaundercutBatterytypeC

6.Lightlygreasethesurfaceoftheshimthatcontactsthepad.Bendeachtaboftheshimoverthebrakepad.Thearrowontheshimmustbeinthe turning direction ofthewheel.b.R

D.Brake Inspection andRepairRecommendedBrakeComponentReplacementSchedule:Brakepads. ...AsrequiredPistonseal,dustseal...EverytwoyearsBrakeho

b.Installpadspring,shim(witharrow)andre-tainer.Theshimarrowisinthe direction ofwheelrotation.Installdustsealandclip.c.Installpad spring and pads,d.Ins

5-4 WHEELS,TIRES,TUBESA.WheelInspectionNOTE: Makesurethewheelisbalancedeverytimethetireisreplaced.(RefertoFront WheelInspection.)Wheelsshouldbeinspect

1FRONTFORKASS'Y142FORKTUBE,outerleft153FORKTUBE,outerright165OILSEAL184SEAL,spacer176STOPPERRING,oilseal197BOLT,stud208PIECE,oillock219INNERTUBEC

B. Inspection1. Examine fork inner tube for scratches andstraightness. If the tube is scratched severelyor bent, it should be replaced.2.If the lips o

1BEARING2BEARING3COVER, ball race14NUT, fitting5CROWN, handle6WASHER, plate7BOLT, stem8BOLT, pinch9BOLT, pinch10WASHER, plain11NUT, crown12131415BOLT,

6.Supportsteeringstem(underbracket)andre-movebottom fitting nut.7.Removebearings.C.Inspection1.2.3.4.Washbearingsinsolvent.Inspectbearingsforpittingor

1234567910aREARARMCOMP.BEARING,taperedrollerOILSEAL(SD-25-40-5)COLLAR(17-25-7)SHAFT,pivotNUT,pivotshaftPLUGBOOT,rubberSPRING,tensionSPRING,tension1112

2.Theswingarmismountedontaperedbearings.Movetheswingarmupanddownasshown.Theswingarmshould move smoothly,with-outtightness,bindingorroughspotsthatcould

C.TorqueSpecificationsSparkplugCamcapnutRodcapStarterclutchboltIEngine1.5 ~ 2.5m-kg(11.0 ~18.0ft-lbs.)0.8 ~ 1.Om-kg(6.0 ~ 7.0ft-lbs.)3.8m-kg(27ft-lbs.

3. Remove finalgearassemblyanddriveshaft.4.Removeswing arm pivotplugs,pivotshaftsand swing arm.D. InspectionandLubrication1. Remove oilsealsandbearing

CABLESANDFITTINGSA.CableMaintenance5-10FINALDRIVEGEARNOTE:SeeMaintenanceandLubricationintervalscharts. Cable maintenanceisprimarilyconcernedwithpreven

Placedialgaugeand stand tomeasuregearlashf.Usespecialwrenchtogentlyrotategear(movement)asshown.Gearlash pling from engagementtoengagement.Notementfrom

XS750PowerFlowSchematic

THEBASIC MECHANISM 1-1. An Introduction to the MechanismPoweristransmittedfromthecrankshaftthrough the clutchandtwotransmission shafts toathirdshaft,

Themainserviceconcernsofthe Middle (4)Bearing Preload: ThesetloadforcingGearCaseassemblyare:taperedrollerbearingsagainsttheirraces.(1)GearLash:The pla

1-2.LubricationThemaintenanceofproperlubricationisthemostimportantconsiderationthatcanbegiventotheshaftdrivesystembytheownerorservice person. Almostan

SPECIAL TOOLSThefollowingspecialtoolsarenecessaryforcompleteservicingofshaftdrivecomponents.Gear lashmeasurementtool(final gear)P.No.90890-01231Gearla

Thefollowingspecialtoolsarenotavailablebutcanbeconstructedforshaftdrive component disassemblyand assembly: PressToolNo.1Forfinalgearguidecollerremoval

ROUTINE MAINTENANCE AND INSPECTION3-1. GEAR OIL TYPE AND QUANTITYMiddle Gear Oil Capacity:375 cc(13.0 U.S. fluid oz)Final Gear Oil Capacity:300 cc(10.