Yamaha XS750 User manual

SPEC I F I CAT IONS
A. GENERAL SPECIFICATIONS
Basic color
Dimensions:
Overall length
Overa
l I width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Caster (steering head angle)
TraiI
Weight:
Net
Engine:
Type
Bore x stroke x cylinders
Displacement
Compressionratio
Compression pressure (warm engine)
Lubr i cation :
Lubrication system
Delivery pump type
Carburetion:
Manufacture
Type, I.D. No., Quantity
Rated venturi size
Air filter
Ignition:
Type
Spark plug
Charging
Type
Manufacture, I.D. No.
Maximum output
Battery type
Battery dimensions
Regulator
Rectifier
Starting
Primary drive
Type
Teeth, ratio
Clutch
Crystal Silver
2180mm (85.8 in.)
835mm (32.9 in.)
1150mm (45.3 in.)
810mm (31.9 in.)
1465mm (57.7 in.)
145mm (5.7 in.)
27°
110mm (4.3 in.)
229 kg (505 Ibs.)
________~~
D.O.H.C.,air-cooled,triple
68mm x 68.6mm x3
747cc
8.5:1
142 Ibs in!(±14 Ibs in!)
Pressure lubricated, wet sump
Trocoid
Mikuni
BS34, constant velocity, 1J701, 3 pcs.
34mm
Dry foam rubber
Battery/coi
I
NGK BP-7ES, ChampionN - 7Y
Three - phase, regulated alternator
Hitachi LD120-02
14.5 Vo lt/l8 amp
12 volt 14 amp - hour
134 x 166 x 89mm
Hitachi TL1Z-80
Stanley DE - 4404, Silicon, full wave
Transmission coupled kick
Mitsuba Electric SM - 224C
Hy-Vo silent chain
45/27 1.666
Wet, multiple disc.

Transmission:
Teeth, ratio, overall 1st
2nd
3rd
4th
5th
Secondary Drive:
Transmission 0 utput :
Type, teeth, ratio
Middle gear case
Type, teeth, ratio
Final gear case
Type, teeth, ratio
Chassis:
Frame
Suspension:
Front (type, travel)
Rear (type, travel)
Front
Rear
Brakes:
Front
Rear
Fuel tank
Wheels:
Front
Rear
Tires:
Constant mesh,5 - speed, drum shifter
32/13 2.461 13.285
27/17 1.588 8.636
26/20 1.300 7.069
1 1.095 5.955
22/23 0.956 5.201
Shaft drive
Spur gear, 34/32, 1.063
Bevel gear, 19/18, 1.056
Bevel gear, 32/11, 2.909
Tubular steel double cradle
Telescopic fork, 175mm (6.9 in.)
Swing arm, 75mm (3.0 in.)
3.25 H19 Bridgestone
4.00 H 18 Bridgestone
Dual hydraulicdisc
Single hydraulicdisc
US gal.) Regular leaded or unleaded
1.85 x 19 Cast Aluminum
2.15 x 18 Cast Aluminum
B. MAINTENANCE SPECIFICATIONS
1. Engine
Engine Oil Capacity
Oil and filter change
Oil change
R ecommended Iubrican t :
If temperature does not go below
If temperature does not go above
(3.7
(3.4 US qt.)
(3.0 US qt.)
SAE
SE motor oil
SAE SE motor oil

Middle gear case capacity:
Final Gear case capacity
Recommended Iubr i can t
If temperature doesnot go below
5°C (40°F)
If temperature doesnot go above
A II weather
15°C (60°F)
A
Exhaust B
C
375cc ( 13 oz.)
300cc (1 00 oz.)
SAE 90 Hypoid gear oil, G L - 4
SAE 80 Hypoid gear oil, GL - 4
SAE80W90 Hypoid gear oil,GL - 4
8.018mmm -------------
28.285 ±0.05mm 28.13mm
36.303 ± 0.05mm 36.15mm
Cranking pressure (at sea level)
Maximum difference between cylinders
Free length
10 ± 1 kg/cm!(142 ± 14 psi)
1 .0 kg/cm!(14 psi)
INTAKE/EXHAUST
35.6mm
Camshafts
I
Wire diameter
Number of windings
2.8mm
7.75
Valve stem run - out maximum
Valve seat width standard/maximum
.03mm (.0012 in.)
1.3mm (.050 in.) / 2.0mm (.080 in.)
Wear Iim it
Camshaft bearing surface diameter 24.97~24.98mm (0.9830~0.9835 in.)
Camshaft - to - cap clearance :
Standard
Maximum
Camshaft runout limit
.020~.054mm (.0008~.002 in.)
.160mm (.006in.)
0.1 mm (.004 in) I
Valves
I INNER OUTER
INTAKE/EXHAUST
39.9mm
ALLOWABLE T I LT
FROM VERTICAL
OUTER
I
OUTER
Spring rate (kg/mm) K1 1.84
K2 2.36
K1 3.32
K2 4.18
Installed length
(valve closed)
Installed pressure
(valve closed)
34.5mm31.5mm
1 7.5 ± 0.75kg 17.5 ± 1.2kg
Compressed length
(valve open) 23.0mm 26.0mm
3.9mm
6.4
INTAKE EXHAUST
DIRECTION OF WINDINGS
(TOP TO BOTTOM)
Winding O.D. 15+ 0.3mm
0
21.6 0
- 0.3mm
~
I I 1

"B"
"C" seat width
"D" margin thickness
Stem diameter (O.D.)
Guide diameter (I.D.)
C I ea rance
(Cold engine)
" A " head diameter
0.1 6~ 0.20mm
36 + 0.2
1.3 ±0.15mm
1.2 ±0.2mm
7 + .010mm
-.025mm
7 + .019mm
-.010mm
I "B" face width 2.26 ± 0.57mm
" B " face width
"C" seat width
"D" margin thickness
Stem diameter (O.D.)
2.26 ± 0.57mm
1.3 ± 0.15mm
1.2±0.2mm
7 +.025mm
-.040mm
I Stem - to - guide clearance I 0.020~0.041mm I
EXHAUST
CI ea rance
(Cold engine) 0.2 1~0.25mm
" A " head diameter 31
+ 0.2mm
Guide diameter (I.D.)
7 + .019mm
St em -t o -g uid e clea ra nce 0.035~0.059mm
Cylinder and Piston
Cylinder material
Cylinder liner
Standard bore sizehtandard
Cylinder taper limit
Cylinder out - of - round limit
Piston clearancehtandard
maximum
maximum
Piston Rings
Design
End gap (installed)
Side clearance
Aluminum
Pressed in; special cast iron
68.00~68.02mm / (2.677~2.678 in.)
68.10mm (2.681)
0.05mm (.002 in.)
0.01mm (.0004 in.)
0.050~0.055mm / (.0020~.0022 in.)
0.1mm (.004 in.)
Oil
0.04-0.08mm 0.03-0.07mm
-0.4mm -0.4mm 0.2~0.9mm

Crankshaft and Connecting Rods:
Main bearing oil clearance
Rod bearing oil clearance
Main journalrun - out (maximun)
Oil Pump
Housing - to - outer rotor clearance
Outer rotor - to - inner rotor clearance
Clutch
Friction plate thickness standard
minimum
Clutch plate warp maximum
Clutch spring length standard
minimum
Clutch push rod run
- out maximum
Clutch lever freeplay (end of lever)
Transmission shaft run - out maximum
Middle gear case lash
0.022~0.044mm (.0009~.0017 in.)
0.032~0.054mm (.0013~.0021 in.)
0.03mm (.0012 in.)
,090~.015mm (.0035~.0059 in.)
.03 ~.09mm (.0011~.0035 in.)
3.0mm (0.12 in.)
2.8mm (0.11 in.)
0.05mm (.002 in)
42.8mm (1.685 in.)
41.5mm (1.634 in.)
0.4mm (.016in.)
13~26mm (0.5~1.0 in)
.08mm (.001 in.)
0.1 ~0.2mm (.004~.008 in.)
2. Carburetion
I
Manufacturer
Model, I. D. No.
Main jet
Needle jet
Pilot jet
Starter jet
Jet needles
/ Clip position
Mikuni
BS34,1J701
No. 145
Y - 2
No. 17.5
No. 45
4H11/3
Float level
Pilot screw
Air jet, Main
Air jet, Pilot
Throttle valve
Inlet valve size
Engine idle speed
26.5 ±2.5mm (fromgasket surf
2"turns
1 .0mm
1.6mm
No. 140
2.0mm
1050 ~ 1150 r.p.m.

3. Chassis
Ignition timing retarded
ad va nced
advance starts
Wheels and Tires
Rim run - out, vertical
Rim run - out, horizontal
Tire pressure, front, normal riding
High speed or with passenger
Tire pressure, rear,normal riding
High speed or with passenger
Brakes
Recommended fluid
Pad thickness wear limit
Brake disc maximum deflection
Brake disc minimum thickness
Front brake freeplay (end of lever)
Rear brake freeplay (end
of pedal)
Minimum boiling point
10° @ 1100 rpm
38.5° ± 1.5°@ 2,900 rpm
1550 + 200rpm
0
Front forks
Spring (upper) free length
Spring (lower) free length
Spring rate
(0~100 mm travel)
Fork oil capacity (each side)
preload length
preload length
(100~175mm travel)
Rear shock absorbers
Spring free length
Spring preload length
Spring rate (0~45mm travel)
(45~75mm travel)
2.0mm (.080 in.)
l.0mm (.040in.)
1.8 (26 p.s.i.)
2.0 kg/cm2 (28 p.s.i.)
2.0 kg/cm2 (28 p.s.i.)
2.3 kg/cm2 (33 p.s.i.)
DOT No.3
240°C (464°F)
5.5mm (0.18 in.)
0.15mm (.006 in.)
6.5mm (0.26 in.)
5.0~10.0mm (0.2~0.4 in.)
5.0~10.0mm (0.2~0.4 in.)
~~
55.8mm (2.2 in.)
50.8mm (2.0 in.)
448.3mm (17.65 in.)
423.3mm (16.67 in.)
0.5 kg/mm (28 Ibs/in.)
0.6 kg/mm (33.6 Ibs./in.)
170cc (5.75 US fl. oz.)
253mm (9.95 in.)
228 mm (9.0 in.)
1.9 kg/mm (106 Ibs./in.)
2.6 kg/mm (145 Ibs./in.)
Spark plug
Electrode gap
NGK BP - 7ES or ChampionN - 7Y
0.7~ 0.8mm (.028~.032 in)
Spark plug cap resistance I 5.0 K ohms
Contact point gap
Spring tension
0.3~0.4mm (.012 ~.016 in)
750 ± 100 g (26.5 ±3.5 oz)
Condenser capacity
Insulation resistance
0.22µF ± 10%
10 M ohms or more
Ignition coil type
Spark gap6V
12V
Primary resistance (20°C)
Secondary resistance (20°C)
H itach i CM1 1 - 52A
6mm @ 100 rpm
7mm @ 5,000 rpm
4.0 ± 0.4 ohms
11.0 ± 1.1K ohms

Starter motor type
Armature coil resistance (2O°C)
Field coil resistance (2O°C)
Brush length standard
minimum
Brush spring pressure
Armature mica undercut
Battery type
Charging rate
Generator
type
No load voltage
Field (inner) coil resistance(20°C)
Stator (outer) coil resistance (20°C)
Regulator type
Reg ulated vo I t age
Core gap
Yoke gap
Point gap
Starter relay switch
Cut - in voltage
Winding resistance (20°C)
Lighting
Headlight
Ta i IIight/stopIight
License light
FlasherI ig ht
Flasher pilot light
Meter Iights
High beam indicator light
Oil pressure warning light
Neutral light
~~~
Mitsuba SM
- 224C
0.007 ohms
0.01 ohms
12.5mm (0.5 in)
5.5mm (0.22 in)
620 ± 60g (22.0 ± 2.0 oz)
0.5 ~ 0.8mm (0.02 ~ 0.03 in)
Yuasa YB 14L
1.4 amps for 10 hours
Hitachi Ld 120 - 02
14.5 ± 0.5V
0.48 ± 0.05 ohms
4.04 ± 0.4 ohms
Hitachi TLIZ - 80
14.5 ± 0.5V
0.6 ~ 1 .0mm (.024 ~.040 in)
0.9mm (.035 in)
0.3 ~ 0.4mm (.012 ~.016 in)
Hitachi A104 - 70
6.5 V
3.5 ohms
Sealed beam 12V50/40W
12V 8/27W (two bulbs)
12V27W (four bulbs)
12V 3.4W (two bulbs)
12V 3.4W (two bulbs)
1 2 v 3.4w
1 2 v 3.4w
1 2 v 3.4w
1 2 v 8W

C. Torque Specifications
Spark plug
Cam cap nut
Rod cap
Starter clutch bolt
I Engine
1.5 ~ 2.5m - kg (11.0 ~18.0 ft - lbs.)
0.8 ~ 1 .O m - kg (6.0 ~ 7.0 ft - lbs.)
3.8m - kg (27 ft - lbs.)
2.8 ~ 3.2m - kg (20~ 23 ft - lbs.)
Shift cam locating bolt
Detent assembly
1.3 ~ 2.1m - kg (9 ~ 15 ft - lbs.)
4.0 ~ 4.5m - kg (29 ~ 32 ft - lbs.)
Transmission bearing caps
Crankcase bolts 8mm
1.8 ~ 2.2m - kg (13 ~ 16 ft - lbs.)
2.0 rn-kg (14 ft-lbs.)
10mm
Clutch holding nut
Clutch spring screws
3.7m - kg (27 ft - lbs.)
8 m-kg (58 ft-lbs)
0.8 ~ 1 .O m - kg (6.0 ~ 7.0 ft - lbs.)
Middle gear case mounting screws
Rotor holding bolt
2.0 ~ 2.5m - kg (14 ~ 18 ft - lbs.)
3.0 ~ 4.0m - kg (22 ~ 29 ft - lbs.)
Bearing housing bolt
Oil pipe union bolt
12mm I 8.0 ~ 11.0m - kg (58 ~ 80 ft - lbs.)
2.0 ~ 2.4m - kg (14 ~ 17 ft - lbs.)
2.0 ~ 2.2m - kg (14 ~ 16 ft - lbs.)
Oil pump drive gear nut
Crankshaft turning nut
Cylinder head 8mm
8.0 ~ 12.0m - kg (58 ~ 87 ft - lbs.)
1.5 ~ 2.9m - kg (11 ~ 21 ft - lbs.)
2.0m - kg (14 ft - lbs.)
I 1
10mm
Cylinder holding nuts
3.5m - kg (25 ft - lbs.)
2.0m - kg (14 ft - lbs.)
Camshaft capnuts
Engine mounting bolts 10mm
1 .O m - kg (7 ft - lbs.)
5.0 ~ 6.0m - kg (36 ~ 43 ft - lbs.)
Engine oil drain plug
Oil filter mounting bolt
Middle gear drain plug
Front axle nut
Frontaxle holder nuts
Rear axle nut
Rear axle pinch bolt
Chassis
3.9 ~ 4.7m - kg (28 ~ 34 ft - lbs.)
3.0 ~ 3.4m - kg (22 ~ 25 ft - lbs.)
3.9 ~ 4.7m - kg (28 ~ 34 ft - lbs.)
7.0 ~ 10.0m - kg (50 ~ 72 ft - lbs.)
1.3 ~ 2.3m - kg (9 ~ 17 ft - lbs.)
12.0 ~ 18.0m - kg (87 ~ 130 ft - lbs.)
0.45 ~ 0.75m - kg (3.0 ~ 5.0 ft - lbs.)
Brakes
Caliper support bolt
Caliper mounting bolt
Brakehoseunion bolt
Disc mounting bolt
Front fork pinch bolt
Steering stem top bolt
Swing arm pivot lock nut
Rear shock absorber nut
1.5 ~ 2.0 m-kg (11 ~ 15 ft-lbs.)
4.5 ~ 5.0m - kg (28~ 35 ft - lbs.)
2.3 ~ 2.8m - kg (16 ~ 20 ft - lbs.)
1.7 ~ 2.2m - kg (12 ~ 16 ft - lbs.)
1.3 ~ 2.3 m-kg (9 ~ 17 ft-lbs.)
6.6 ~ 10.5m - kg (48~ 76 ft - lbs.)
8.0 ~ 10.0m - kg (58 ~ 72 ft - lbs.)
2.3 ~ 3.7m - kg (20 ~ 27 ft - lbs.)

Components should be room temperature.
500 - 600

SPECIAL TOOLS
Valve guide remover Clutch holding t o ol
Valve guide installer
Valve spring compressor
Valve seat cutter set
Tappet adjusting to ol
Vacuumgauge
Final drive gear holding t o ol
Clutch plate installation tool Middle
and finalgear holding
to ol
Clutch lock nut wrench Damper special tool
Cam chain cutter Rotor puller
Slide hammer
Gear lash measurement to ol
(middlegear)
Rotor holding to ol
Gear lash measurement to ol
(fin al gear)

d. Turn petcocksto " prime " position.
e. Start motorcycle and allow it to warm up for
2-3 minutes. The warm - up is complete when
engine responds normally to threttle opening.
f. Adjust damping valve on each vacuum gauge
until the needle flutters only slightly. The
gauge needles must respond quickly to rapid
opening of the throttle.
a. The engine must be warmed up before setting
idle speed.
b. Set engine idle speed by turning the throttle
stop screw in (to increase engine speed)
or out
(to decrease speed).
Standard Idle RPM
1,050 - 1,1 50rpm
g. Each gauge will indicate the same reading if
the carburetors are synchronized. The left and
right carburetors are to be synchronized to the
center carburetor, which has no synchronizing
screw. Turn the l e ft carburetor synchronizing
screw until the gauge reading is the same as
for the center carburetor. Repeat for the right
carburetor.
B. Air Filter
1. Removal
a. Li ft the seat and remove the air filter case cap
by removing the pan head screws (2).
- _ -
SYNCHRONIZING SCREWS
3. Idle speed adjustment.
NOTE: Carburetors must be synchronized
before setting final idle speed. The idle speed
adjustment is made by turning only one
throttle stop screw.

b. Pull out the element.
C. Engine/Transmission Oil
1. Oil level measurement
a. To check the level, warm the engine up for
several minutes. Stop the engine. With the
engine stopped, screw the dip stick completely
out and then rest the stick in the hole.
2. Cleaning method
a. Tap the element lightly t o remove most of the
dust and dirt; then blow out theremainingdirt
with compressed air through the inner surface
of the element. I f element isdamaged, replace.
b. Reassemble by reversing the removal pro -
cedure. Check whether the element is seated
completely against the case.
c. The air filter element should be cleaned once
a month or every 1,600km (1,000 miles). It
should be cleaned more often i f the machine
is operated in extremely dusty areas.
without the air cleaner element installed. Ex -
cessive oil contamination and engine wear
may result.
NOTE: When checking engine oil level with
the dip stick, let the unscrewed dip stick rest
on the case threads. Be sure the engine is
stopped and the machine is positioned straight
up and on both wheels.
b. The dip stick has a Minimum and a Maximum
mark. The oil level should be between
the two.
If the level is low, add sufficient oil to raise it
to the proper level.
2. Engine/Transmission oil and oil filter replace -
ment
a. Start the engine. Allow it t o warm up for
minutes. Stop the engine.
b. Place an oil pan under the engine and remove
the oil filler cap.
c. Remove the drain plug and drain the oil.

d. Remove the oil filter bolt and filter element.
e. Reinstall the drain plug (make sure it istight). e. Reinstall the drain plug (make sure it istight).
4.0 ~ 4.5m-kg (28.9-32.5ft-lb)
f. Install the oil filter element andcover. Tighten
the oil filter bolt.
NOTE: Make sure the " 0' ring is positioned
properly.
g. Add oil through the dip stick hole.
Oil quantity: Periodic Oil Change
2.8 liter (3 US qt)
With oil filter change:
3.2 liter (3.4 US qt)
Recommended oil: except in cold weather
Yamalube4 - cycle or SAE 20W40 " SE "
(see page 8)
h. After replacement of engine oil, and/or oil
filter, be sure to check the oil pressure and oil
leakage. The oil pressure indicator lightshould
go off after the engine is started.
CAUTION: If the " Oil " indicator light
remains on, immediately stop the engine.
Refer t o lubrication information in Sec. 3-5
D. Middle Gear/Final Gear Oil
1. Oil level measurement
a. Place the machine on a level surface and place
it on the center stand. The engine should be
cool (at atmospheric temperature). Allow 2
minutes for oil to drain to bottom of cases.
b. Remove the oil filler cap. Check the oil
level
with level gauge (from tool kit) as shown.
The correct oil level is between the two marks
on each endof the level gauge. Use endof
gauge marked " REAR " for measuring the
rear (final) gear case. Use the
end marked
measuringthe middlegear
case.
NOTE: Middle gear and final gear oil can be
checked with same level gauge, which is in
the owners tool kit.

d. Fill the gear case(s) up to specified level.
CAUTION: Take care not to allow foreign
material t o enter the middle and/or final
aear case.
2. Gear oil replacement
a. Place an oil pan under the transmission for
the middle gear and under the final gear case.
b. Remove the middle and/or final gear oil filler
cap(s) and the drain plug(s), and drain the oil.
not to allow foreign material to enter the
middle andlor final gear case. Do not allow
the gear oil to contact the tire and wheel.
c. Reinstall the middle and/or final drain plug(s).
Oil Capacity:
Middle gear case:
Final gear case:
Recommended oil: (see page 8)
375cc (12.7 US. fl 02)
300cc (10.0 U.S. fl 02)
e. Reinstall the filler cap(s) securely.
NOTE: After initial 250 mile oil change, it
is normally notnecessary to change middle
and final gear oil more frequently than the
indicated service interval of 6,000 miles.
E. Clutch Adjustment
This model has a clutch cable length adjustor and a
clutch mechanism adjustor. The cable length adjustor5
are used to take up slack from cable stretch andto
provide sufficient free play for proper clutch operation
under various operating conditions. The clutch mech -
anism adjustor is used to provide the correct amount
of clutch " throw " for proper disengagement. Normal -
ly, once the mechanism is properly adjusted, the only
adjustment required is maintenance of free play at
the clutch handle lever.
1. Free play adjustment
Loosen either the handle lever adjustor lock
nut or the cable length adjustor lock nut.
Next, turn the length adjustor either in or out
until proper lever free play is achieved.

1. Remove the breaker cover
2. Remove the cam chain tensioner
cover.
2. Mechanism adjustment
The second adjustment is located behind the
adjusting cover. Removing the cover will
expose the adjusting set screw and lock nut.
Loosen the lock nut and rotate the set screw
in until it lightly seats against a clutch push
rod that works with the set screw to operate
the clutch. Back the set screw out "turn and
tighten the lock nut. This adjustment must be
checked because heat and clutch wear will
affect this free play, possibly enough to
cause improper clutch operation. Recheck
clutch cable adjustment at handlebar after
adjusting.
F. Cam Chain Adjustment
The cam chain becomesstretched with use, resulting in
improper valve timing and engine noise. To prevent this
the cam chain tensioner must be adjusted regularly.
Loosen the tensioner stopper bolt lock
nut
and then loosen the stopper bolt.
4. Slowly rotate the crankshaft counterclockwise
several turns. When the tensionergets deepest
into the tensioner holder, tighten the stopper
bolt and secure it with the lock nut.
S

5. Reinstall the chain tensioner cap and the con -
tact breaker cover.
G. Valve Clearance Adjustment
NOTE: Valve clearance must be measured with
the engine at room temperature.
1. Remove gas tank.
2. Remove air scoop on cylinderhead
3. Remove cylinder head cover and breaker point
cover. Care should be taken to not scratchor
damage gasket sealing surfaces.
4. Turn crankshaft with nut on l e ft end ofcrank-
shaft to turn cams. The proper position of the
cam when measuring valve clearance is with
the cam lobe directly opposite the valve lifter.
5. Insert a feeler gaugebetween the valve lifter
and the cam heel.
Exhaust valve clearance (cold)
Intake valve clearance (cold)
0.21 - 0.25mm (.008 -.010")
0.16 - 0.20mm (.006 - ,008")
Adjustment
Valve clearance is adjusted by replacing the adjusting
pad on the top of the valve lifter. Adjusting pads are
available in 25 thicknesses ranging from No. 200
(2.00mm) to No. 320(3.20mm) in steps of 0.05mm.
The thickness of each pad is marked on the pad face
that contacts the valve lifter (notthe cam).
Adjustment
of valve clearance is accomplished as follows:
1. Determine valve clearance (feeler gauge
measurement.
2. Remove adjusting padand note number.
3. Select properpad from
appropriate chart
(intake or exhaust chart).
Install newpadand check installed clearance.
4.
Procedure
1. Measure valve clearance. I f clearance is in -
correct, record the measured amountof
clearance. This must be measured carefully.
2. There is a slot in the valve lifter. This slot must
be positioned opposite the blade of the tappet
adjusting tool before the tool is installed.
3. Turn the cam until the lobe fully depresses
the valve lifter and opens the valve. Install the
tappet adjusting tool as shown to hold the
lifter in this depressed position.
AD JUST I NG
TOOL,
CYLINDER
PAD REMOVAL
SLOT

NOTE: The tappet adjusting tool is fastened
to the cylinder head using one (1) allen screw
such as one used to install the cylinder head
cover. Make sure that the tool contacts the
lifter only, and not the pad.
CAUTION: If th e cam lobe touches the tappet
adjusting tool, th e stress may fracture the
cylinder head. DO N O T A LLOW THE C AM
T O CONTAC T T H E TAPPET ADJUSTING
TOO L.
4. Carefully rotate the cam so that the pad can
be removed. To avoid cam touching adjusting
tool, turn cams as follows: (view from left
side o f machine)
Intake: Carefully rotate CLOCKWISE.
Exhaust: Carefully rotate COUNTERCLOCK -
WISE.
5. Remove the pad from the lifter. There is a
slot in thelifter. Useasmall screwdriver or
other blade and a magnetic rod to remove the
pad. Note the number on the pad.
6. Proper pad selection is made as follows:
(Useappropriate chart for exhaust o r intake
valves.)
a. F i n d number o f original (installed) pad num -
ber on chart. Read down on chart.
b. Find measured valve clearance (fr om step 1)
on chart. Read across.
c. A t the intersection of installed padnumber
(down) and measured clearance (across) is a
new pad number.
7.
8.
9.
EXAMPL E: Exhaust valve, installed pad:
No. 250 (readdown)
Measured clearance: 0.32mm
(read across)
New pad number: No. 260
(intersection o f down & across)
NOTE: The new pad number is to be used as
a guide only. Verify the correctness o f this
choice in the following steps).
Install the new pad in the lifter. Install the
pad wit h the number down.
Remove tappet adjusting tool.
T u r n crankshaft to rotate cam several rota -
tions. This w il l set the pad in the lifter.
10. Check valve clearance (step 3). I f clearance is
incorrect, repeat preceding steps until proper
clearance is obtained.
11. Inspect head cover gasket. If bent o r torn,
replace gasket.
12. Reinstall removed parts in reverse order.
H. Compression Pressure Measurement
Insufficient compression pressure w i l l result in per -
formance loss and may indicate leaking valves or worn
or damaged rings.
Procedure
1. Make sure valve clearance is correct.
2. Warm up engine 2-3 minutes. Stop engine.
3. Remove spark plugs.
4. Install compression check gauge.

Intake
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. . ... . , . i.. : .
I
,
CLEARANCE
Exhaust
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