Yamaha SR125 Service Manual 3MW AE1 1997 English repair how to mechanical failure carburateur...
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Transcript of Yamaha SR125 Service Manual 3MW AE1 1997 English repair how to mechanical failure carburateur...
EB000000
SR125SERVICE MANUAL
1996 by Yamaha Motor Co., Ltd.1st Edition, September 1996
All rights reserved. Any reprinting orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.
is expressly prohibited .
NOTE:
WARNING
CAUTION:
EB001000
NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir 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 mo-torcycle 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 andunfit for use.
Yamaha Motor Company, Ltd., is continually striving to improve all its models. Modifications and signif-icant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future aditions of this manual where applicable.
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATIONParticularly 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 ordeath to the motorcycle operator, a bystander or a person inspecting orrepairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoiddamage to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
12
6
7
6
4 3
8
YP002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATIONThis 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 on 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 eachsection. It is located in the upper left corner of the page.
3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-nied by corresponding illustrations.
EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at start of each removaland disassembly section.1. An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs.2. Numbers 5 are given in the order of 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.
21
1
3
5
7
9
2
4
8
6
23 24
2220
18 1917
15
1413
11 12
10
GENINFO SPEC
ENG
CARB
ELEC
CHAS
INSPADJ
TRBLSHTG
16
EB003000
ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are designed asthumb tabs to indicate the chapter’s numberand content.
1 General information
2 Specifications
3 Periodic inspection and adjustment
4 Engine
5 Carburation
6 Chassis
7 Electrical
8 Troubleshooting
Illustrated symbols 9 to 16 are used to identifythe specifications appearing in the text.
9 Possible to maintain with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
13 Tightening
14 Wear limit, clearance
15 Engine speed
16 Ω , V, A
Illustrated symbols 17 to 22 in the exploded dia-grams indicate the types of lubricants and lu-brication points.17 Apply engine oil
18 Apply gear oil
19 Apply molybodenum disulfide oil
20 Apply wheel bearing grease
21 Apply lightweight lithium-soap baes grease
22 Apply molybdenum disulfide grease
Illustrated symbols 23 to 24 in the exploded dia-grams indicate the where to apply locking agent23 and when to install new parts 24 .
23 Apply locking agent (LOCTITE )
24 Use new one
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION ANDADJUSTMENT
ENGINE OVERHAUL
CARBURATION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
GENINFO 1SPEC 2
3ENG 4
CARB 5CHAS 6ELEC 7TRBLSHTG 8
INSPADJ
INDEX
CHAPTER 1.GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL PROCEDURES 1-2. . . . . . . . . . . . . . . REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO USE THE CONVERSION TABLE 1-5. . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
MOTORCYCLE IDENTIFICATIONGENINFO
NOTE:
YP100000
GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONSR100020
FRAME SERIAL NUMBERThe frame serial number 1 is stamped into theright side of the frame.
EB100030
ENGINE SERIAL NUMBERThe engine serial number 1 is stamped into thecrankcase.
Designs and specifications are subject tochange without notice.
MODEL LABELThe model label 1 is affixed under the seat.This information will be needed to order spareparts.
1-2
IMPORTANT INFORMATIONGENINFO
EB101000
IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCE-DURES1. Remove all dirt, mud, dust and foreign mate-
rial before removal and disassembly.2. Use proper tools and cleaning equipment.3. Refer to the “SPECIAL TOOLS” section.4. When disassembling the machine, always
keep mated parts together. This includesgears, cylinders, pistons and other parts thathave been “mated” through normal wear.Mated parts must always be reused or re-placed as an assembly.
5. During machine disassembly, clean all partsand place them in trays in the order of disas-sembly. This will speed up assembly and al-low for the correct installation of all parts.
6. Keep all parts away from any source of fire.
NB101010
REPLACEMENT PARTS1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-mended by Yamaha for all lubrication jobs.Other brands may be similar in function andappearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearingsduring reassembly. Apply grease to the oilseal lips.
1-3
OR
IMPORTANT INFORMATIONGENINFO
CAUTION:
EB101030
LOCK WASHERS/PLATES AND COTTERPINS1. Replace all lock washers/plates and cotter
pins after removal. Bend lock tabs along thebolt or nut flats after the bolt or nut has beentightened to specification.
EB101040
BEARINGS AND OIL SEALSInstall bearings and oil seals so that themanufacturer’s marks or numbers are visible.When installing oil seals, apply a light coating oflightweight lithium base grease to the seal lips.Oil bearings liberally when installing, if ap-propriate.
1 Oil seal
Do not use compressed air to spin the bear-ings dry. This will damage the bearing sur-faces.
1 Bearing
EB101050
CIRCLIPS1. Check all circlips carefully before reassemb-
ly. Always replace piston pin clips after oneuse. Replace distorted circlips. When instal-ling a circlp 1 , make sure that the sharp-edged corner 2 is positioned opposite thethrust 3 it receives. See sectional view.
4 Shaft
1-4
CHECKING OF CONNECTIONSGENINFO
NOTE:
NOTE:
EB801000
CHECKING OF CONNECTIONSDealing with stains, rust, moisture, etc. on theconnector.1. Disconnect:Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector twoor three.
4. Pull the lead to check that it will not come off.5. If the terminal comes off, bend up the pin 1
and reinsert the terminal into the connector.
6. Connect:Connector
The two connectors “click” together.
7. Check for continuity with a tester.
If there is no continuity, clean the terminals.Be sure to perform the steps 1 to 7 listed abovewhen checking the wireharness.
For a field remedy, use a contact revitalizeravailable on the market.
Use the tester on the connector as shown.
1-5
HOW TO USE THE CONVERSION TABLEGENINFO
EB201000
HOW TO USE THE CONVERSION TABLEAll specification data in this manual are listed in Sl and METRIC UNITS.Use this table to convert METRIC unit data to IMPERIAL unit data.Ex.METRIC MULTIPLIER IMP
** mm 0.03937 = ** in 2 mm 0.03937 = 0.08 in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
Torque
mkgmkgcmkgcmkg
7.23386.7940.07230.8679
ftlbinlbftlbinlb
Weight kgg
2.2050.03527
lboz
Distance
km/hrkmmmcmmm
0.62140.62143.2811.0940.39370.03937
mphmiftydinin
Volume/Capacity
cc (cm3)cc (cm3)lit (liter)lit (liter)
0.035270.061020.87990.2199
oz (IMP liq.)cuinqt (IMP liq.)gal (IMP liq.)
Miscellaneouskg/mmkg/cm2
Centigrade
55.99714.22349/5 (C) + 32
lb/ inpsi (lb/ in2)Fahrenheit (F)
1-6
SPECIAL TOOLSGENINFO
EB102000
SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appropriate special tools; this will help prevent damage caused by the use of inappropriate tools orimprovised techniques.When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Usage Illustration
90890-0108090890-04052
Rotor pullerAttachment
This tool is used when removing or installingthe meter gear bush.
90890-0108390890-01084
Rocker arm shaft puller boltWeight
These tools are used when removing orinstalling the rocker arm shafts.
90890-01268 Ringnut wrench
This tool is used to loosen and tighten theexhaust and steering ringnut.
90890-01311 Valve adjusting tool
This tool is necessary for adjusting valveclearance.
90890-01312 Fuel level gauge
This gauge is used to measure the fuel levelin the float chamber.
90890-0136790890-01400
Fork seal driver weightFork seal driver attachment (ø30 mm)
This tool is used when installing the fork seal.
90890-01403 Ring nut wrench
This tool is used to loosen and tighten thesteering ring nut.
90890-01701 Sheave holder
This tool is used for holding the secondarysheave.
90890-01996 Cylinder cup installer set
This tool is used for installing the cylindercup to the master cylinder piston.
1-7
SPECIAL TOOLSGENINFO
Tool No. Tool name/Usage Illustration
90890-03079 Thickness gauge
This tool is used to measure the valveclearance.
90890-0308190890-04082
Compression gaugeAdaptor
These tools are used to measure the enginecompression.
90890-03112 Pocket tester
These instruments are invaluable forchecking the electrical system.
90890-03113 Engine tachometer
This tool is needed for detecting engine rpm.
90890-03141 Timing light
This tool is necessary for checking ignitiontiming.
90890-0401990890-04108
Valve spring compressorAttachment
These tools are used when removing orinstalling the valve and the valve spring.
90890-04064 Valve guide remover 6 mm
This tool is used to remove the valve guide.
90890-04065 Valve guide reamer 6 mm
This tool is used to rebore the valve guide.
90890-04066 Valve guide installer 6 mm
This tool is needed to install the valve guidesproperly.
90890-04086 Clutch holding tool
This tool is used for holding the Clutch Boss.
1-8
SPECIAL TOOLSGENINFO
Tool No. Tool name/Usage Illustration
90890-04101 Valve lapper
This tool is used for removing and installingthe lifter and for lapping the valve.
90890-06754 Ignition checker
This instrument is necessary for checking theignition system components.
90890-85505 Yamaha bond No.1215
This sealant (bond) is used for crankcasemating surface, etc.
CHAPTER 2.SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TORQUE SPECIFICATIONS 2-15. . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINT AND GRADE OF LUBRICANT 2-16. . . . . . . . . . . . . ENGINE 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION DIAGRAM 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model SR125
Model code: 3MW6
Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius
1,915 mm775 mm1,080 mm745 mm1,280 mm155 mm2,100 mm
Basic weight:With oil and full fuel tank 113 kg
Engine:Engine typeCylinder arrangementDisplacementBore strokeCompression ratioCompression pressure (STD)Starting systemLubrication system:
Air-cooled 4-stroke, SOHCForward-inclined single cylinder0.124 L (124 cm3)57.0 48.8 mm10.0 : 11,200 kPa (12.0 kg/cm2, 12.0 bar) at 1,000 r/minElectric starterWet sump
Oil type or grade:Engine oil API “SE” or higher grade
Periodic oil changeWith oil filter replacementTotal amount
1.0 L1.1 L1.3 L
Air filter: Wet type element
Fuel:TypeFuel tank capacityFuel reserve capacity
Regular unleaded gasoline10.0 L1.6 L
2-2
GENERAL SPECIFICATIONS SPEC
Model SR125
Carburetor:Type/quantityManufacturer
Y24P/1TEIKEI
Spark plug:TypeManufacturerSpark plug gap
DR8EANGK0.6 0.7 mm
Clutch type: Wet, multiple-disc
Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationGear ratio 1st
2nd3rd4th5th
Spur gear73/22 (3.318)Chain drive49/14 (3.500)Constant mesh 5 speedLeft foot operation36/16 (2.250)31/21 (1.476)27/24 (1.125)25/27 (0.926)23/29 (0.793)
Chassis:Frame typeCaster angleTrail
Diamond26.7590 mm
Tire:TypeSize front
rearManufacture front
rearType front
rear
Tube type3.00-17 45P3.50-16 52PINOUEINOUE8F8RA
Tire pressure (cold tire):Maximum load-except motorcycleLoading condition A *
frontrear
Loading condition B *frontrear
164 kg0 90 kg175 kPa (1.75 kg/cm2, 1.75 bar)200 kPa (2.0 kg/cm2, 2.0 bar)90 205 kg175 kPa (1.75 kg/cm2, 1.75 bar)225 kPa (2.25 kg/cm2, 2.25 bar)
*Load is the total weight of cargo, rider, passenger, and accessories.
2-3
GENERAL SPECIFICATIONS SPEC
Model SR125
Brake:Front brake type
operationRear brake type
operation
Single disc brakeRight hand operationDrum brakeRight foot operation
Suspension:Front suspensionRear suspension
Telescopic forkSwingarm
Shock absorber:Front shock absorberRear shock absorber
Coil spring/Oil damperCoil spring/Oil damper
Wheel travel:Front wheel travelRear wheel travel
120 mm78 mm
Electrical:Ignition systemGenerator systemBattery typeBattery capacity
C.D.I.C.D.I. magneto12N 7-3B12 V 7 AH
Headlight type: Bulb type
Bulb wattage quantity:HeadlightAuxiliary lightTail /brake lightFlasher lightMeter lightHigh beam indicatorNeutral indicatorTURN indicator
12 V 36 W/36 W 112 V 4 W 112 V 5 W/21 W 112 V 21 W 412 V 3.4 W 112 V 3.4 W 112 V 3.4 W 112 V 3.4 W 2
2-4
MAINTENANCE SPECIFICATIONS SPEC
Head Dia. Face Width Seat Width Margin Thickness
MAINTENANCE SPECIFICATIONSENGINE
Item Standard Limit
Cylinder head:Warp limit 0.03 mm
Cylinder:Bore sizeTaper limitOut of round limit
57.00 57.02 mm
57.1 mm0.05 mm0.01 mm
Camshaft:Cam dimensionsIntake “A”
“B”“C”
Exhaust “A”“B”“C”
Camshaft runout limit
36.537 36.637 mm30.131 30.231 mm6.59 mm36.577 36.677 mm30.214 30.314 mm6.63 mm
36.45 mm30.05 mm
36.49 mm30.13 mm
0.03 mm
Cam chain:Cam chain type/No. of linksCam chain adjustment
DID 25SH/104 ENDLESSManual
Rocker arm/rocker armshaft:Rocker arm inside diameterRocker shaft outside diameterRocker arm-to-rocker armshaftclearance
12.000 12.018 mm11.985 11.991 mm
0.009 0.033 mm
12.036 mm11.950 mm
Valve, valve seat, valve guide:Valve clearance (cold) IN
EX0.05 0.09 mm0.11 0.15 mm
Valve dimensions
“A” head diameter INEX
“B” face width INEX
“C” seat width INEX
“D” margin thickness INEX
Stem outside diameter INEX
28.9 29.1 mm23.9 24.1 mm2.4 2.8 mm2.4 2.8 mm0.9 1.1 mm0.9 1.1 mm0.8 1.2 mm0.8 1.2 mm5.975 5.990 mm5.960 5.975 mm
5.955 mm5.940 mm
2-5
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Guide inside diameter INEX
Stem-to-guide clearance INEX
Stem runout limitValve seat width IN
EX
6.000 6.012 mm6.000 6.012 mm0.010 0.037 mm0.025 0.052 mm
0.9 1.1 mm0.9 1.1 mm
6.042 mm6.042 mm0.08 mm0.10 mm0.03 mm1.6 mm1.6 mm
Valve spring:Free length (inner) IN/EX
(outer) IN/EXSet length (valve closed)
(inner) IN/EX(outer) IN/EX
Compressed pressure(inner) IN/EX(outer) IN/EX
Tilt limit (inner) IN/EXTilt limit (outer) IN/EXDirection of winding (inner) IN/EXDirection of winding (outer) IN/EX
35.5 mm37.2 mm
22.5 mm24.0 mm
26.7 30.7 kg52.4 40.2 kg
ClockwiseCounterclockwise
33.5 mm35.2 mm
2.5/1.5 mm2.5/1.5 mm
Piston:Piston to cylinderclearancePiston size “D”Piston over size (1st)Piston over size (2nd)Measuring point “H”Piston off-setPiston off-set directionPiston pin boreinside diameterPiston pin outside diameter
0.025 0.045 mm
56.960 56.975 mm57.25 mm57.50 mm7.0 mm0.5 mmIN side15.002 15.013 mm
14.978 14.992 mm
15.045 mm
14.975 mm
Piston rings:Top ring:TypeDimensions (B T)End gap (installed)Side clearance (installed)
2nd ring:TypeDimensions (B T)End gap (installed)Side clearance
Oil ring:Dimensions (B T)End gap (installed)
Plane2.3 2.5 mm0.15 0.35 mm0.03 0.07 mm
Plane2.3 2.5 mm0.15 0.35 mm0.02 0.06 mm
2.5 2.8 mm0.3 0.9 mm
0.60 mm0.15 mm
0.60 mm0.15 mm
2-6
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Crankshaft:
Crank width “A”Runout limit “C”Big end side clearance “D”Big end radial clearanceSmall end free play “F”
55.95 56.00 mm
0.35 0.65 mm0.010 0.025 mm0.8 1.0 mm
0.03 mm1.0 mm
Clutch:Friction plate thicknessQuantity
Clutch plate thicknessQuantity
Clutch spring free lengthQuantity
Push rod bending limit
2.9 3.1 mm4 pcs.1.6 mm3 pcs.34.9 mm4 pcs.
2.7 mm
0.05 mm
32.9 mm
0.2 mm
Transmission:Main axle runout limitDrive axle runout limit
0.08 mm0.08 mm
Carburetor:TypeI.D. markMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)Needle jet (N.J)Cut away (C.A)Pilot outlet (P.O)Pilot jet (P.J)Bypass 1 (B.P.1)Pilot screw (P.S)Valve seat size (V.S)Starter jet 1 (G.S.1)Starter jet 2 (G.S.2)Float height (F.H)Engine idle speedIntake vacuumCOOil temperature
Y24P4WP-10#102ø1.34C9A-3/52.6002.250.8#381.02ø2.0#60#6428.5 mm1,250 1,350 r/min180 200 mmHg4.5 5.5%60 70C
Oil pump;TypeTip clearanceSide clearanceBypass valve setting pressure
Trochoid type0.03 0.09 mm0.10 0.15 mm80 120 kPa(0.8 1.2 kg/cm2, 0.8 1.2 bar)
0.14 mm0.35 mm
2-7
MAINTENANCE SPECIFICATIONS SPEC
TIGHTENING TORQUESENGINE
Th dTightening
Part to be tightened Part name Threadsize
Q’tyg gtorque Remarksg
sizey
Nm mkg
Cylinder head blind plugCylinder head and cylinderCylinder head(Timing chain side)Cam sprocket coverValve coverPlateSpark plugCylinderBuffer bossC.D.I. magnetoValve adjuster locknutCam sprocketTiming chain tensioner(Body)(Cap)Timing chain guide (intake)Oil pumpOil pump and crankcaseDrain plugOil filter coverDrain bolt (oil filter)Carburetor joint and carburetorCarburetor joint and cylinderCarburetor joint and air filterAir filter caseAir filter case and frameMuffler and frameExhaust pipe and cylinderCrankcase (left and right)Crankcase cover (left)Crankcase cover (left)Crankcase cover (right)Drive sprocket coverStarter clutchKick crankPrimary drive gearClutch springClutch bossPush lever axlePush lever adjuster
ScrewBoltBolt
ScrewBoltBolt—
BoltNutBoltNutBolt
NutNutBolt
ScrewScrewBolt
ScrewBolt
ScrewScrewScrewScrewScrew
BoltBolt
ScrewScrewScrewScrewScrewBoltBoltNut
ScrewNut
ScrewNut
M6M8M8
M6M6M6
M12M6
M14M10M6
M10
M14M14M6M6M6
M35M6M6M6M5M5M5M6M8M6M6M6M4M6M6M8
M32M14M5
M14M8M6
242
252121121
1121312121122221391923114111
72220
7108
181050501460
305877
437
10122447201277277
30
506
70128
0.72.22.0
0.71.00.81.81.05.05.01.46.0
3.00.50.80.70.74.30.71.01.20.20.40.40.72.01.20.70.70.20.70.73.0
5.00.67.01.20.8
Stake
2-8
MAINTENANCE SPECIFICATIONS SPEC
Part to be tightened Part nameThread
size Q’tyTightening
torque Remarksg size yNm mkg
Drive sprocketShift cam (Segment)Shift pedalPick up coilNeutral switchStator coilStarter motor
BoltScrewBolt
ScrewScrewScrewScrew
M6M6M6M6
M10M4M6
2114161
101287
2037
1.01.20.80.72.00.30.7
2-9
MAINTENANCE SPECIFICATIONS SPEC
Tightening sequenceCylinder head
Crankcase
Item Standard Limit
2-10
MAINTENANCE SPECIFICATIONS SPEC
CHASSIS
Item Standard Limit
Steering system:Steering bearing typeNo./size of steel balls (upper)
(lower)
Ball bearing22 pcs. 0.1875 in19 pcs. 0.251 in
Front suspension:Front fork travelFork spring free lengthFitting lengthSpring rate (K1)
(K2)Stroke (K1)
(K2) Oil capacity Oil level Oil grade Inner tube vend limit
120 mm326.1 mm311.1 mm3.6 N /mm (0.36 kg/mm)5.1 N/mm (0.51 kg/mm)0 85 mm85 120 mm0.177 L (177 cm3)135 mmFork oil 15 WT or equivalent
321 mm
0.2 mm
Rear suspension:Shock absorber strokeSpring free lengthFitting lengthSpring rate (K1)
(K2)Stroke (K1)
(K2)
65 mm178.5 mm198 mm18.3 N/mm (1.83 kg/mm)21.6 N/mm (2.16 kg/mm)0 30 mm30 65 mm
173 mm
Front wheel:TypeRim sizeRim materialRim runout limit radial
lateral
Spoke wheel17 1.60Steel
2 mm2 mm
Rear wheel:TypeRim sizeRim materialRim runout limit radial
lateral
Spoke wheel16 1.85Steel
2 mm2 mm
Drive chain:Type/manufacturerNo. of linksChain free play
428HG/DAIDO12025 35 mm
2-11
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Front brake:TypeDisc outside diameterDisc thicknessPad thickness (inner)
(outer)Master cylinder inside diameterCaliper cylinder 1 inside diameterCaliper cylinder 2 inside diameterBrake fluid type
Single disc267 mm4 mm6.2 mm6.2 mm12.7 mm30.16 mm25.4 mmDOT#4 or DOT#3
3.5 mm0.8 mm0.8 mm
Rear brake:TypeDrum inside diameterShoe thicknessShoe spring free length
Leading, trailing110 mm4 mm50.5 mm
111 mm2 mm
Brake lever:Brake lever free play (at lever end) 2 5 mm
Brake pedal:Brake pedal free playBrake pedal position
20 30 mm0 mm
Clutch lever:Clutch lever free play (at lever end) 10 15 mm
Throttle cable free play 3 5 mm
2-12
MAINTENANCE SPECIFICATIONS SPEC
NOTE:
TIGHTENING TORQUESCHASSIS
Part to be tightened Thread sizeTightening
torque RemarksgNm mkg
Handle crown and front forkHandle crown and steering shaftHandlebar holder (under and upper)Steering ring nutMaster cylinder and cap (front brake)Handlebar under holder and nutMaster cylinder (front brake)Brake hose union bolt (front brake)Front flasher and staySteering shaft and front forkEngine and front engine stayFront engine stay and frameEngine and top engine stayTop engine stay and frameEngine and engine bracket (frame)Swingarm pivot shaftRear shock absorber and frameRear shock absorber and swingarmSwingarm and tension barTension bar and rear brake shoe plateGrab bar and frameFuel tank an fuel cockRear flasher and staySidestand (bolt)Sidestand (nut)Rear footrest (left)Front wheel axleRear wheel axle and nutBrake caliper and front forkBrake disc and front wheelDriven sprocket and clutch hubBrake caliper bleed screwMeter gear and meter cableBrake cam leverFront wheel axle pinch bolt
M10M10M8
M25M4
M10M6
M10M12M10M8M8M8M8M8
M12M10M10M8M8M8M6
M12M8M8
M10M14M14M10M8
M10M7
M12M6M8
45402072
409
304
30333333333345403020201674
1916455965402340639
20
4.54.02.00.70.24.00.93.00.43.03.33.33.33.33.34.54.03.02.02.01.60.70.41.91.61.55.96.54.02.34.00.60.30.92.0
Refer to NOTE
1. When tighten the ring nut, should be steady the ball bearings and the steering shaft moving smooth-ly.
2. First, tighten the ring nut approximately 38 Nm (3.8 mkg) by using the torque wrench, then loosenthe ring nut one turn and retighten the ring nut to specification.
2-13
MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL
Item Standard Limit
Ignition timing:Ignition timing (B.T.D.C.)Advanced timingAdvanced type
9 at 1,300 r/min29 at 5,500 r/minElectrical type
C.D.I.:Pickup coil resistance/color
Source coil resistance/color
C.D.I. unit model/manufacturer
656 984 Ω at 20C/Red – White624 936 Ω at 20C/Brown – Green4WP/YAMAHA
Ignition coil:Model/ manufacturerMinimum spark gapPrimary winding resistanceSecondary winding resistance
2JN/YAMAHA6 mm0.32 0.48 Ω at 20C5.68 8.52 kΩ at 20C
Spark plug cap:TypeResistance
Resin type10 kΩ
Charging system:TypeModel/manufacturerStandard outputStator coil resistance/color
C.D.I. magneto4WP/YAMAHA14 V 9 A/5,000 r/min0.48 0.72 Ω at 20C/White – White
Rectifier/regulator:Model/manufacturerType (regulator)No load regulated voltageCapacity (rectifier)Withstand voltage
SH553D/SHINDENGENSemi conductor-short circuit type14.5 V25 A200 V
Battery:Specific gravity 1.280
Electric starter system:TypeStarter motor:Model/ manufacturerOutputArmature coil resistanceBrush overall lengthBrash spring pressureCommutator diameterMica undercut (depth)
Constant mesh type
SM-14/MITUBA0.6 kW0.0207 0.0253 Ω at 20C10 mm5.30 6.47 N28 mm0.7 mm
3.5 mm
27 mm
2-14
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Starter relay:Model/manufacturerAmperage ratingCoil winding resistance
MS5D-191/JIDECO100 A3.9 4.7 Ω at 20C
Horn:Model/manufacturerMaximum amperage
YF-12/NIKKO2.5 A
Flasher relay:TypeModel/manufacturerFlasher frequency
Condenser typeFR2204/MITUBA85 cycle/min
Circuit breaker:TypeMainReserve
Fuse20 A 1 pcs.20 A 1 pcs.
2-15
GENERAL TORQUE SPECIFICATIONS SPEC
GENERAL TORQUE SPECIFICATIONSThis chart specifies torque for standard fasten-ers with standard I.S.O. pitch threads. Torquespecifications for special components or as-semblies are included in the applicable sectionsof this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, inprogressive stages, until full torque is reached.Unless otherwise specified, torque specifica-tions call for clean, dry threads. Componentsshould be at room temperature.
A: Distance across flats
B: Outside thread diameter
A(Nut)
B(Bolt)
General torquespecifications
(Nut) (Bolt)Nm mkg
10 mm 6 mm 6 0.6
12 mm 8 mm 15 1.5
14 mm 10 mm 30 3.0
17 mm 12 mm 55 5.5
19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0
2-16
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC
LUBRICATION POINT AND GRADE OF LUBRICANTENGINE
Lubrication Point Symbol
Oil seal lips (all)
Bearing retainer (all)
Bolt (cylinder head)
Crank pin
Connecting rod (big end)
Piston pin
Piston/piston ring
Buffer boss
Valve stem/valve guide (IN, EX)
Valve stem end (IN, EX)
Rocker arm shaft
Cam and bearing (camshaft)
Rocker arm inner surface
Crankcase mating surfaces Yamaha bond No.1215
O-ring (all)
Starter idle gear thrust surfaces
Starter clutch (outer/roller)
Starter wheel gear inner surface
Push rod
Primary driven gear inner surface
Push lever axle
Transmission gear inner surface
Shift fork/guide bar
2-17
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC
CHASSIS
Lubrication Point Symbol
Steering head pipe bearing (upper/ lower)
Front wheel oil seal lips (left /right)
Rear wheel oil seal lips (left /right)
Rear wheel hub
Rear brake shoe plate, camshaft and pivoting pin
Pivoting points (brake pedal shaft and frame)
Sidestand sliding surface/mounting bolt
Pivoting point (centerstand)
Tube guide (throttle grip) inner surface
Brake lever bolt /master cylinder sliding surface
Clutch lever bolt /cable sliding surface
Steering lock sliding surface
Gear unit (speedometer)
Chain guard inner surface/swigarm insert surface
2-18
1 Rocker arm (IN)2 Rocker shaft3 Rocker arm (EX)4 Camshaft5 Oil pump6 Push lever
LUBRICATION DIAGRAM SPEC
LUBRICATION DIAGRAM
2-19
1 Oil pump2 Oil filter3 Crankshaft4 Main axle5 Drive axle6 Oil strainer
LUBRICATION DIAGRAM SPEC
2-20
A Clamp the handlebar switchlead, (left and right), front brakeswitch lead, clutch switch lead tothe handlebar.
B Do not contact the horn and wire-harness.
12 Clutch switch coupler13 Handlebar switch lead (left)14 Front flasher lead (left)15 Horn lead16 Flasher relay17 Handlebar switch lead (right)18 Front brake switch lead19 Front flasher (right)20 Meter lead21 Front flasher lead (right)22 Wireharness
1 Front brake switch lead2 Brake hose3 Handlebar switch lead (right)4 Throttle cable5 Clutch cable6 Clutch switch lead7 Handlebar switch lead (left)8 Speedometer cable9 Clamp10 Main switch coupler11 Front flasher (left)
CABLE ROUTING SPEC
CABLE ROUTING
2-21
A Align the clamp to the white tapeon the wireharness
B Pass the clutch cable throughthe outside of the throttle cable.
C Pass the brake hose and throttlecable through the slit of theheadlight body. And pass themthe right inside of the front fork.
D Pass the brake hose to the holder.E Clamp the clutch cable to the
down tube of the frame.
CABLE ROUTING SPEC
1 Clamp2 Wireharness3 High tension cord4 Collar5 Ignition coil6 Ground lead7 Ignition coil lead8 Brake hose9 Clutch cable10 Rear brake switch11 Starting circuit cut-off relay12 Battery breather hose
2-22
A Clamp the speedometer cable tothe steering bracket and passthe cable to the cable holder.
B Pass the brake hose through thebrake hose holder.
14 Rectifier /Regulator15 Thermostatic switch16 Throttle cable17 Clutch cable18 Wireharness19 Speedometer cable20 Cable holder21 Brake hose holder22 Cable holder23 Brake hose24 Starter motor lead25 Sidestand switch26 Rectifier /Regulator lead
CABLE ROUTING SPEC
1 Neutral switch lead2 Pickup coil lead3 C.D.I. unit4 Rear flasher lead (right)5 Rear flasher lead (left)6 Tail /Brake light lead7 C.D.I. magneto lead8 Thermostatic switch lead9 Clamp10 Sidestand switch lead11 Starter relay lead12 Fuse13 Starter relay
2-23
CABLE ROUTING SPEC
1 Air filter case2 Battery3 Swingarm4 Battery breather pipe5 Lid6 Air filter case drain pipeA Pass the air filter case drain pipe
inside the swingarm.
SPEC
CHAPTER 3.PERIODIC INSPECTIONS
AND ADJUSTMENTS
INTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1. . . . . . . . . . .
SIDE COVER, SEAT AND FUEL TANK 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE ADJUSTMENT 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . IDLING SPEED ADJUSTMENT 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THROTTLE CABLE ADJUSTMENT 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG INSPECTION 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION TIMING CHECK 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION PRESSURE MEASUREMENT 3-9. . . . . . . . . . . . . . . . ENGINE OIL LEVEL INSPECTION 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIMING CHINE TENSIONER ADJUSTMENT 3-13. . . . . . . . . . . . . . . . . . . CLUTCH ADJUSTMENT 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CLEANING 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM INSPECTION 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE ADJUSTMENT 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE ADJUSTMENT 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE FLUID LEVEL INSPECTION 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD INSPECTION 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SHOE INSPECTION 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE LIGHT SWITCH ADJUSTMENT 3-20. . . . . . . . . . . . . . . . . . . . . . . AIR BLEEDING 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CHAIN SLACK ADJUSTMENT 3-22. . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD INSPECTION 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSPECTION 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER ADJUSTMENT 3-25. . . . . . . . . . . . . . . . . . . . TIRE INSPECTION 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPOKE INSPECTION AND TIGHTENING 3-28. . . . . . . . . . . . . . . . . . . . . WHEEL INSPECTION 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY INSPECTION 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE INSPECTION 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BEAM ADJUSTMENT 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INSPADJ
10
11
12
13
14
15
16
17
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALSEVERY
NO. ITEM ROUTINEBRAKE-IN1,000 KM
6,000 kmor
6 months
12,000 kmor
12 months
1 * Valve(s) Check valve clearance. Adjust if necessary.
2 * Cam chain Check chain tension. Adjust if necessary.
3 Spark plugCheck condition.Clean or replace if necessary.
4 Air filter Clean. Replace if necessary.
5 * CarburetorCheck idle speed/starter operation.Adjust if necessary.
6 * Fuel lineCheck fuel hose for cracks or damage.Replace if necessary.
7 Engine oil Replace (Warm engine before draining.)
8 * Engine oil filter Replace
9 * Front brakeCheck operation/ fluid leakage. /see NOTE.Correct if necessary.
Rear brake Check operation. Adjust if necessary.
Clutch Check operation. Adjust if necessary.
* Rear arm pivotCheck rear arm assembly for looseness.Correct if necessary. Moderately repackevery 24,000 km or 24 months.***
* WheelsCheck balance/damage/runout /spoke tightness.Replace if necessary.
* Wheel bearingsCheck bearing assembly for looseness/damage.Replace if damaged.
*Steeringbearing
Check bearing assembly for looseness.Correct if necessary.Moderately repack every 24,000 km or24 months.**
* Front forksCheck operation/oil leakage.Repair if necessary.
*Rear shockabsorber
Check operation/oil leakage.Repair if necessary.
*: It is recommended that these items be serviced by a Yamaha dealer.**: Medium weight wheel bearing grease. (bearing type)***: Lithium soap base grease. (bush type)
3-2
PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJ
18
19
20
21
NOTE:
EVERY
NO. ITEM ROUTINEBRAKE-IN1,000 KM
6,000 kmor
6 months
12,000 kmor
12 months
Drive chainCheck chain slack/alignment. Adjust if necessary.Clean and lube.
EVERY 500 km
* Chassis fastenersCheck all chassis fittings and fasteners.Correct if necessary.
* SidestandCheck operation.Repair if necessary.
* BatteryCheck specific gravity.Check breather pipe for proper operation.Correct if necessary.
*: It is recommended that these items be serviced by a Yamaha dealer.**: Medium weight wheel bearing grease. (bearing type)***: Lithium soap base grease. (bush type)
Brake fluid replacement:1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid.
Normally check the brake fluid level and fill the fluid as required.2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.3. Replace the brake hoses every four years, or if cracked or damaged.
3-3
Order Job name/Part name Q’ty Remarks
1234
5
Side cover, seat and fuel tankremovalSide cover (left)Side cover (right)SeatFuel pipe
Fuel tank
1111
1
Remove the parts in order.
Reverse the removal procedure for instal-lation.
Disconnect the fuel pipe, set the fuel cocklever “OFF” position.
NOTE:
SIDE COVER, SEAT AND FUEL TANKINSPADJ
SIDE COVER, SEAT AND FUEL TANK
3-4
VALVE CLEARANCE ADJUSTMENTINSPADJ
NOTE:
***************************************
***************************************
SR03004
ENGINEVALVE CLEARANCE ADJUSTMENT
Valve clearance adjustment should be madewith the engine cool, at room temperature.When the valve clearance is to be measured oradjusted, the piston must be at Top Dead Cen-ter (T.D.C.) on the compression stroke.
1. Remove:SeatSide cover (left and right)Fuel tankRefer to “SIDE COVER, SEAT AND FUELTANK” section.
2. Remove:Spark plug cap 1Spark plugValve cover (intake side) 2Valve cover (exhaust side) 3
3. Remove:Timing check plug (with O-ring) 1Center plug (with O-ring) 2
4. Measure:Valve clearanceOut of specification Adjust.
Valve clearance (cold):Intake valve 0.05 0.09 mmExhaust valve 0.11 0.15 mm
Measurement steps:Rotate the crankshaft counterclockwise toalign the slit a on the rotor with the station-ary pointer b on the crankcase cover (left)when the piston is Top Dead Center (TDC).
Measure the valve clearance by using a feel-er gauge.Out of specification Adjust clearance.
3-5
A B
VALVE CLEARANCE ADJUSTMENT/IDLING SPEED ADJUSTMENT
INSPADJ
***************************************
14 Nm (1.4 mkg)
***************************************
10 Nm (1.0 mkg)
New
10 Nm (1.0 mkg)
New
18 Nm (1.8 mkg)
5. Adjust:Valve clearance
Adjustment steps:Loosen the locknut 1 .Turn the adjuster 3 in or out with the valve ad-justing tool 2 until specified clearance is ob-tained.
Turning in Valve clearance is decreased.
Turning out Valve clearance is increased.
Valve adjusting tool:90890-01311
Hold the adjuster to prevent it from moving andtighten the locknut.
Measure the valve clearance. If the clearance is incorrect, repeat abovesteps until specified clearance is obtained.
6. Install:Valve cover (intake side) 1
O-ring 2 Valve cover (exhaust side) 3
O-ring 4 A Intake side
B Exhaust side
7. Install:Spark plugTiming check window screw 1(with O-ring)
Center plug 2(with O-ring)
YP303022
IDLING SPEED ADJUSTMENT1. Start the engine and let it warm up for several
minutes.2. Attach: Inductive tachometer to the spark plug lead.
Inductive tachometer:90890-03113
3-6
IDLING SPEED ADJUSTMENT/THROTTLE CABLE ADJUSTMENT
INSPADJ
***************************************
***************************************
NOTE:
***************************************
NOTE:
3. Check:Engine idling speedOut of specification Adjust.
Engine idling speed:1,250 1,350 r/min
4. Adjust:Engine idle speed
Adjustment steps:Turn the pilot screw 1 until it is lightly seated.Turn the pilot screw out by the specified num-ber of turns.
Pilot screw:2 turns out
Turn the throttle stop screw 2 in or out until thespecified idling speed is obtained.
Turning in Idling speed is increased.
Turning out Idling speed is decreased.
5. Adjust:Throttle cable free playRefer to “THROTTLE CABLE ADJUST-MENT” section.
YP303032
THROTTLE CABLE ADJUSTMENT
Prior to adjusting the throttle cable free play, theengine idling speed should be adjusted.
1. Check:Throttle cable free play aOut of specification Adjust.
Free play (throttle cable):3 5 mm at throttle grip flange
2. Adjust:Throttle cable free play
Adjustment steps:
Never accelerate the throttle when stopping theengine.
3-7
THROTTLE CABLE ADJUSTMENT/SPARK PLUG INSPECTION
INSPADJ
WARNING
***************************************
CAUTION:
Loosen the locknut 1 on the throttle cable.Turn the adjuster 2 in or out until specifiedfree play is obtained.
Turning in Free play is increased.
Turning out Free play is decreased.
Tighten the locknut.
After adjusting, turn the handlebar to theright and to the left to ensure that this doesnot cause the engine idling speed tochange.
EB303040
SPARK PLUG INSPECTION1. Remove:Spark plug capSpark plug
Before removing the spark plug, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinder.
1. Check:Spark plug typeIncorrect Replace.
Standard spark plug:DR8EA (NGK)
2. Inspect:Electrode 1Wear/damage Replace.
Insulator 2Abnormal color Replace.Normal color is a medium-to-light tan color.
3. Clean:Spark plug(with spark plug cleaner or wire brush)
4. Measure:Spark plug gap a(with a wire gauge)Out of specification Adjust gap.
Spark plug gap:0.6 0.7 mm
3-8
SPARK PLUG INSPECTION/IGNITION TIMING CHECK
INSPADJ
18 Nm (1.8 mkg)
NOTE:
NOTE:
***************************************
***************************************NOTE:
5. Install:Spark plug
Before installing a spark plug, clean the gasketsurface and plug surface.
YP303052
IGNITION TIMING CHECK
Prior to checking the ignition timing, check allelectrical connections related to the ignitionsystem. Make sure all connections are tight andfree of corrosion and that all ground connec-tions are tight.
1. Remove:Timing check plug
2. Attach:Timing light 1Engine tachometer 2(to the spark plug lead)
Timing light:90890-03141
Engine tachometer:90890-03113
3. Check: Ignition timing
Checking steps:Start the engine and let it warm up for severalminutes. Let the engine run at the specifiedspeed.
Engine idling speed:1,250 1,350 r/min
Visually check the stationary pointer a toverify it is within the required firing range b in-dicated on the flywheel.Incorrect firing range Check the ignitionsystem.
Ignition timing is not adjustable.
3. Install:Timing check plug
3-9
COMPRESSION PRESSURE MEASUREMENTINSPADJ
NOTE:
CAUTION:
SR303060
COMPRESSION PRESSURE MEASUREMENT
Insufficient compression pressure will result inperformance loss.
1. Check:Valve clearanceOut of specification Adjust.Refer to “VALVE CLEARANCE ADJUST-MENT” section.
2. Start the engine and let it warm up for severalminutes.
3. Turn off the engine.4. Remove:Spark plug
Before removing the spark plug, use com-pressed air to blow away any dirt accumu-lated in the spark plug well to prevent it fromfalling into the cylinder.
5. Attach:Compression gauge 1
Compression gauge:90890-03081
Adaptor:90890-04082
6. Measure:Compression pressureIf it exceeds the maximum pressure allowed Inspect the cylinder head, valve surfacesand piston crown for carbon deposits.If it is below the minimum pressure Squirta few drops of oil into the affected cylinderand measure again.Follow the table below.
Compression pressurep p(With oil applied into cylinder)
Reading Diagnosis
Higher thanwithout oil
Worn or damaged pistons
Same aswithout oil
Possible defective ring(s),valves, cylinder head gas-ket or piston Repair.
3-10
COMPRESSION PRESSURE MEASUREMENT/ENGINE OIL LEVEL INSPECTION
INSPADJ
***************************************
WARNING
18 Nm (1.8 mkg)
NOTE:
Compression pressure (at sea lev-el):Standard:
1,200 kPa (12.0 Kg/cm 2, 12 bar)Minimum:
1,100 kPa (11.0 Kg/cm 2, 11 bar)
Measurement steps:Crank the engine with the throttle wideopenuntil the reading on the compression gaugestabilizes.
Before cranking the engine, ground allspark plug leads to prevent sparking.
7. Install:Spark plug
YP303070
ENGINE OIL LEVEL INSPECTION1. Stand the motorcycle on a level surface.
Make sure the motorcycle is upright when in-specting the oil level.
2. Start the engine and let it warm up for a fewminutes.
3. Turn off the engine.4. Inspect:Engine oil levelOil level should be between maximum 1and minimum 2 marks.Oil level is below the minimum mark Add oil up to the proper level.
RECOMMENDED ENGINE OILRefer to the chart for selection of the oils suitedto the atomosperic temperature.
Recommended oil:Refer to the following chart forselection of oils which are suitedto the atmospheric temperatures.
Recommended engine oil classifica-tion:
API STANDARD:API “SE” or higher grade
3-11
ENGINE OIL LEVEL INSPECTION/ENGINE OIL REPLACEMENT
INSPADJ
CAUTION:
NOTE:
***************************************
***************************************
Do not put in any chemicals additives oruse oils with a grade of CD a or higher.
Be sure not to use oils labeled “ENERGYCONSERVING II” b or higher. Engine oilalso lubricates the clutch and additivescould cause clutch slippage.
Be sure no foreign material enters thecrankcase.
5. Start the engine and let it warm up for a fewminutes.
6. Turn off the engine and inspect the oil levelonce again.
Wait a few minutes until the oil settles before in-specting the oil level.
SR303082
ENGINE OIL REPLACEMENT1. Start the engine and let it warm up for several
minutes.2. Turn off the engine and place a container un-
der the engine.3. Remove:Oil filler plug 1Drain plug 2Drain the crankcase of its oil.
4. Loosen:Bolt 1 (oil filter cover-lower)
5. Drain the crankcase of its oil.If the oil filter is to be replaced during this pro-cedure, remove the following parts and rein-stall them afterwards.
Replacement steps:Remove the oil filter cover 1 and oil filter ele-ment 2 .
Check the O-ring 3 . If it is cracked or dam-aged, replace it.
Install the oil filter element and oil filter cover.
Screw:7 Nm (0.7 mkg)
Bolt:10 Nm (1.0 mkg)
3-12
ENGINE OIL REPLACEMENTINSPADJ
43 Nm (4.3 mkg)
NOTE:
CAUTION:
***************************************
***************************************
6. Install:Drain plug
Inspect the O-ring. If it is damaged, replace itwith a new one.
Before reinstalling the drain plug, do not for-get to fit the O-ring, compression spring andoil strainer. Be sure you fit each item in thecorrect position and order.
7. Fill:Crankcase
Oil quantity:With oil filter change 1.1 LWithout oil filter change 1.0 L
Refer to “ENGINE OIL LEVEL INSPECTION”section.
8. Inspect:Oil flow
Inspection steps:Slightly loosen the oil check bolt 1 .Start the engine and keep it idling until the oilbegins to seep from the oil check bolt.If no oil comes out after one minute, turn theengine off so it will not seize.
Check oil passages and oil pump for damageor leakage.
Start the engine after solving the problem(s),and recheck the oil pressure.
Tighten the oil check bolt to specification.
Oil check bolt:7 Nm (0.7 mkg)
3-13
TIMING CHAINE TENSIONER ADJUSTMENT/CLUTCH ADJUSTMENT
INSPADJ
***************************************
***************************************5 Nm (0.5 mkg)
SR*******
TIMING CHAINE TENSIONER ADJUSTMENT1. Remove:Cap 1
2. Check:RodCheck the rod end 1 is flush with the adjust-er end 2 .Not flush Adjust.
3. Adjust:Timing chine tension
Adjustment steps:Loosen the locknut 1 .Turn the adjuster 2 in or out until the rod end
3 is flush with the adjuster end.Tighten the locknut 1 .
Locknut:30 Nm (3.0 mkg)
4. Install:Cap
EB303093
CLUTCH ADJUSTMENT1. Check:Clutch cable free play aOut of specification Adjust.
Free play (clutch lever):10 15 mm at clutch lever end
3-14
CLUTCH ADJUSTMENT/AIR FILTER CLEANING
INSPADJ
***************************************
NOTE:
***************************************
CAUTION:
2. Adjust:Clutch cable free play
Adjustment steps:Crankcase sideMake sure that the adjuster 1 and locknut 2are fully tightened.
Loosen the locknut 2 .Turn the adjuster 1 in or out until the specifiedfree play is obtained.
Turning in Free play is decreased.
Turning out Free play is increased.
Tighten the locknut 2 .
If the amount of free play is still incorrect, adjustthe clutch cable free play with the other adjuster(on the clutch lever holder).
Lever sideLoosen the locknut 3 .Turn the adjuster 4 in or out until the specifiedfree play is obtained.
Turning in Free play is increased.
Turning out Free play is decreased.
Tighten the locknut 3 .
SR303123
AIR FILTER CLEANING1. Remove:Side cover (right)Air filter element holderAir filter element 1Plate 2
Never operate the engine without the air fil-ter element installed. Unfiltered air willcause rapid wear of engine parts and maydamage the engine. Operating the enginewithout the filter element will also affect thecarburetor tuning, leading to poor engineperformance and possible overheating.
3-15
AIR FILTER CLEANING/EXHAUST SYSTEM INSPECTION
INSPADJ
NOTE:
CAUTION:
WARNING
2. Inspect:Air filter element 1Damage Replace.
3. Clean:Air filter elementUse solvent to clean the element.
After cleaning, remove the remaining solvent bysqueezing the element.
Do not twist the filter element when squeez-ing it.
Never use low flash point solvents such asgasoline to clean the air filter element. Suchsolvents may cause a fire or an explosion.
4. Apply the recommended oil to the entire sur-face of the filter and squeeze out the excessoil. The element should be wet but not drip-ping.
Recommended oil:Engine oil
5. Install:Plate 1Air filter element 2Air filter element holderSide cover (right)
T******
EXHAUST SYSTEM INSPECTION1. Inspect:Exhaust pipe 1Muffler 2Crack/Damage Replace.
Gasket 3Exhaust gas leaks Replace.
3-16
EXHAUST SYSTEM INSPECTIONINSPADJ
1
2
2. Check:Tightening torque
Bolt :12 Nm (1.2 mkg)
Nut :20 Nm (2.0 mkg)
3-17
FRONT BRAKE ADJUST MENT/REAR BRAKE ADJUSTMENT
INSPADJ
***************************************
CAUTION:
WARNING
***************************************
EB304002
CHASSISFRONT BRAKE ADJUSTMENT1. Check:Brake lever free play aOut of specification Adjust.
Free play (Brake lever):2 5 mm at brake lever end
2. Adjust:Brake lever free play
Adjustment steps:Loosen the locknut 1 .Turn the adjuster 2 in or out until the specifiedfree play is obtained.
Turning in Free play is decreased.
Turning out Free play is increased.
Tighten the locknut.
Make sure that there is no brake drag afteradjusting the front brake lever free play.
A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. This air must be removed by bleed-ing the brake system before the motorcycleis operated. Air in the brake system will con-siderably reduce braking performance andcould result in loss of control and possiblyan accident. Inspect and bleed the brakesystem if necessary.
NB304012
REAR BRAKE ADJUSTMENT1. Check:Brake pedal height aOut of specification Adjust.
Brake pedal height:0 mmbelow the top of the footrest
3-18
REAR BRAKE ADJUSTMENTINSPADJ
***************************************
***************************************
***************************************
CAUTION:
***************************************
2. Adjust:Brake pedal height
Adjustment steps:Loosen the locknut 1 .Turn the adjuster 2 in or out until the specifiedpedal height is obtained.
Turning in Pedal height is decreased.
Turning out Pedal height is increased.
Tighten the locknut.
3. Check:Brake pedal free play aOut of specification Adjust
Free play (Brake pedal):20 30 mm at brake lever end
4. Adjust:Brake pedal free play
Adjustment steps:Turn the adjuster 1 in or out until the specifiedfree play is obtained.
Turning in Free play is decreased.
Turning out Free play is increased.
Make sure that there is no brake drag afteradjusting the brake pedal height and thefree play.
5. Adjust:Brake light switchRefer to “BRAKE LIGHT SWITCH ADJUST-MENT”.
3-19
BRAKE FLUID LEVEL INSPECTIONINSPADJ
NOTE:
NOTE:
CAUTION:
WARNING
EB304020
BRAKE FLUID LEVEL INSPECTION1. Stand the motorcycle on a level surface.
Make sure the motorcycle is upright when in-specting the brake fluid level.
Stand the motorcycle on its centerstand if ithas one. If not, place a suitable stand underthe motorcycle.
2. Inspect:Brake fluid levelBrae fluid level is below the “LOWER” levelline a Fill to proper level.
Recommended brake fluid:DOT #4 or DOT #3
For a correct reading of the brake fluid level,make sure the top of the handlebar brake fluidreservoir is horizontal.
Brake fluid may corrode painted surfaces orplastic parts. Always clean up any spilt fluidimmediately.
Use only the designated brake fluid. Otherfluids may deteriorate the rubber seals,causing leakage and poor brake perfor-mance.
Refill with the same type of fluid. Mixingfluids may result in a harmful chemicalreaction leading to poor brake perfor-mance.
Be careful that water does not enter thebrake fluid reservoir during refilling. Waterwill significantly lower the boiling point ofthe fluid and may cause vapour lock.
3-20
BRAKE PAD INSPECTION/BRAKE SHOE INSPECTION/BRAKE LIGHT SWITCH ADJUSTMENT
INSPADJ
NOTE:
***************************************
***************************************
EB304030
BRAKE PAD INSPECTION1. Operate the brake lever.2. Inspect:Brake pad (front)Wear indicators 1 almost touch the brakedisc Replace the brake pads as a set.Refer to “FRONT BRAKE” in CHAPTER 6.
EB304040
BRAKE SHOE INSPECTION1. Operate the brake pedal.2. Inspect:Brake shoesWear indicator 1 reaches the wear limit line2 Replace the brake shoes as a set.Refer to “REAR WHEEL” in CHAPTER 6.
EB304050
BRAKE LIGHT SWITCH ADJUSTMENT
The brake light switch is operated by move-ment of the brake pedal.
Adjustment is correct when the brake lightcomes on just before the braking effect actual-ly starts.
1. Check:Brake light operation timing Incorrect Adjust.
2. Adjust:Brake light operating timing
Adjustment steps:Hold the main body 1 of the switch with yourhand so that it does not rotate, and turn the ad-juster 2 in or out until the proper operationtiming is obtained.
Turning in Brake light comes on fast.
Turning out Brake light comes on slows.
3-21
AIR BLEEDINGINSPADJ
WARNING
***************************************
NOTE:
EB304070
AIR BLEEDING(HYDRAULIC BRAKE SYSTEM)
Bleed the brake system whenever:The system is disassembled.A brake hose is loosened or removed.The brake fluid level is very low.Brake operation is faulty.Loss of braking performance may occur ifthe brake system is not properly bled.
1. Bleed:Brake system
Air bleeding steps:a. Fill the reservoir with the proper brake fluid.b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.c. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2 .d. Place the other end of the hose into a con-
tainer.e. Slowly apply the brake lever several times.f. Pull the lever in. Hold the lever in position.g. Loosen the bleed screw and allow the lever
to travel towards its limit.h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.i. Repeat steps (e) to (h) until all air bubbles
have disappeared from the brake fluid.
When bleeding the brake system, make surethat there is always enough brake fluid in thebrake fluid reservoir before applying the brakelever. Ignoring this precaution could allow air toenter the brake system, considerably lengthen-ing the bleeding procedure.
3-22
AIR BLEEDING/DRIVE CHAIN SLACK ADJUSTMENT
INSPADJ
NOTE:
WARNING
***************************************
NOTE:
CAUTION:
WARNING
j. Tighten the bleed screw.
Bleed screw:6 Nm (0.6 mkg)
If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours.Repeat the bleeding procedure when the tinybubbles in the brake system have disappeared.
k. Fill the brake fluid reservoir to the proper lev-el.Refer to “BRAKE FLUID LEVEL INSPEC-TION”.
Check brake operation after bleeding thebrake system.
SR304093
DRIVE CHAIN SLACK ADJUSTMENT
Before checking and adjusting, rotate the rearwheel several revolutions and check the slackat several points to find the tightest point. Checkand if necessary adjust the drive chain slackwith the rear wheel in this “tightest” position.
Too little chain slack will overload the en-gine and other vital parts; keep the slackwithin the specified limits.
Securely support the motorcycle so thatthere is no danger of it falling over.
Stand the motorcycle on its centerstand.
3-23
A B
DRIVE CHAIN SLACK ADJUSTMENTINSPADJ
***************************************
NOTE:
***************************************
CAUTION:
1. Check:Drive chain slackOut of specification Adjust.
Drive chain slack:25 35 mm
a Check window
b Adjustable limit
c Usable limit
d Usable range2. Adjust:Drive chain slack
A Standard
B Useful limit
Adjustment steps:Loosen the axle nut 1 .Turn the chain adjusters 2 clockwise or coun-terclockwise until the specified drive chainslack is obtained.
Clockwise Chain slack is decreased.
Counter-clockwise
Chain slack is increased.
Turn each chain adjuster exactly the sameamount to maintain correct axle alignment.(There are marks e on each chain adjuster.Use them when adjusting the slack for properalignment.)
Before tightening the axle nut to specification,make sure that there is no clearance at the ad-juster (or the swingarm end) on both sides bypushing the wheel forward.
Rear wheel axle:65 Nm (6.5 mkg)
Do not adjust the drive chain slack abovethe usable range b of check window a .
3-24
STEERING HEAD INSPECTIONINSPADJ
WARNING
NOTE:
***************************************
NOTE:
***************************************
SR304130
STEERING HEAD INSPECTION
Securely support the motorcycle so thatthere is no danger of it falling over.
1. Stand the motorcycle on a level surface.
Stand the motorcycle on its centerstand.
2. Elevate the front wheel by placing a suitablestand under the engine.
3. Check:Steering assembly bearingsGrasp the bottom of the lower front fork tubesand gently rock the fork assembly.Looseness Adjust the steering head.
4. Adjust:Steering head
Adjustment steps:Tighten the ring nut 1 using the ring nutwrench 2 .
Loosen the ring nut completely, then tighten it.
When tighten the ring nut, should be steady theball bearings and steering shaft movingsmoothly.
Ring nut wrench:90890-01403
Steering ring nut:1st step: 38 Nm (3.8 mkg)2nd step: 7 Nm (0.7 mkg)
Check the steering head for looseness or bind-ing by turning it all the way in both directions.
3-25
FRONT FORK INSPECTION/REAR SHOCK ABSORBER ADJUSTMENT
INSPADJ
WARNING
WARNING
***************************************
a
b
EB304140
FRONT FORK INSPECTION
Securely support the motorcycle so thatthere is no danger of it falling over.
1. Stand the motorcycle on a level surface.2. Check: Inner tubeScratches/damage Replace.
Oil sealExcessive oil leakage Replace.Hold the motorcycle upright and apply thefront brake.
3. Check:OperationPush down hard on the handlebars severaltimes.Unsmooth operation Repair.Refer to “FRONT FORK” in CHAPTER 6.
YP304160
REAR SHOCK ABSORBER ADJUSTMENT
Always adjust each rear shock absorberpreload to the same setting. Uneven ad-justment can cause poor handling and lossof stability.
Securely support the scooter so there is nodanger of it falling over.
1. Adjust:Spring preloadTurn the adjuster ring 1 to direction a or b .
Adjustment steps:Turn the adjuster ring in or out.
Turning toward Spring preload isincreased.
Turning toward Spring preload isdecreased.
3-26
REAR SHOCK ABSORBER ADJUSTMENT/TIRE INSPECTION
INSPADJ
CAUTION:
***************************************
WARNING
Adjustment numbers:
Standard 1
Minimum 1
Maximum 5
Never turn the adjuster beyond the maxi-mum or minimum setting.
Always adjust each shock absorber to thesame setting.
EB304171
TIRE INSPECTION1. Measure:Tire inflation pressureOut of specification Adjust.
Tire inflation pressure should only bechecked and adjusted when the tire tem-perature equals the ambient air tempera-ture. Tire inflation pressure and suspen-sion must be adjusted according to thetotal weight of the cargo, rider, passengerand accessories (fairing, saddlebags, etc.if approved for this model), and accordingto whether the motorcycle will be operatedat high speed or not.NEVER OVERLOAD THE MOTORCYCLE.
Operation of an overloaded motorcyclecould cause tire damage, accident or inju-ry.
Basic weight:With oil andfull fuel tank
113 kg
Maximum load* 164 kg
Cold tire pres-sure
Front Rear
Up to 90 kgload*
175 kPa(1.75 kg/cm 2,
1.75 bar)
200 kPa(2.0 kg/cm 2,
2.0 bar)
90 kg maximum. load*
175 kPa(1.75 kg/cm 2,
1.75 bar)
25 kPa(2.25 kg/cm 2,
2.25 bar)
* Load is the total weight of the cargo, rider, pas-senger and accessories.
3-27
TIRE INSPECTIONINSPADJ
WARNING
WARNING
2. Inspect:Tire surfacesWear/damage Replace.
Minimum tire tread depth(front and rear): 1.6 mm
1 Tread depth2 Side wall3 Wear indicator
It is dangerous to ride with a worn-out tire.When the tire tread begins to show signs ofwear, replace the tire immediately.
Patching a punctured tube is not recom-mended. If it is absolutely necessary to doso, use great care and replace the tube assoon as possible with a good quality re-placement tube.
Do not use tubeless tires on a wheel de-signed for tube type tires only. Tire failureand personal injury may result from sud-den deflation.
Tube type wheel Tube type tire only
T beless type wheel
Tube type orTubeless type wheel
yptubeless tire.
Be sure to install the correct tube when us-ing tube type tires.
After extensive tests, the tires listed belowhave been approved by Yamaha Motor Co.,Ltd. for this model. No guarantee concern-ing handling characteristics can be given ifa tire combination other than one ap-proved by Yamaha is used on this motor-cycle. The front and rear tires should al-ways be by the same manufacturer and ofthe same design.
After mounting a tire, ride conservatively fora while to give the tire time to seat itselfproperly in the rim. Failure to do so couldlead to an accident with possible injury tothe rider or damage to the motorcycle.
2. After a tire repair or replacement, be sure totighten the valve stem locknut 1 to specifi-cation.
Locknut:1.5 Nm (0.15 mkg)
3-28
SPOKE INSPECTION AND TIGHTENING/WHEEL INSPECTION
INSPADJ
NOTE:
NOTE:
WARNING
EB304190
SPOKE INSPECTION AND TIGHTENING1. Inspect:Spokes 1Bending/damage Replace.Loose spoke Retighten.
2. Tighten:Spokes
Be sure to tighten the spokes before and afterbreak-in.
Nipple:2 Nm (0.2 mkg)
EB304180
WHEEL INSPECTION1. Inspect:WheelsDamage/Bends Replace.
Always balance the wheel when a tire or wheelhas been changed or replaced.
Never attempt to make any repairs to thewheel.
3-29
BATTERY INSPECTIONINSPADJ
CAUTION:
NOTE:
CAUTION:
EB305001
ELECTRICALBATTERY INSPECTION1. Remove:Side covers (left and right)Refer to “SIDE COVER, SEAT AND FUELTANK” section.
2. Inspect:Electrolyte levelElectrolyte level should be between the up-per 1 and lower 2 level marks.Electrolyte level is too low Add electrolyteto proper level.
Refill with distilled water only. Tap watercontains minerals which are harmful to abattery.
3. Inspect:Battery terminalsDirt Clean with a wire brush.Poor connection Correct.
After cleaning the terminals, apply a light coat ofgrease to the terminals.
4. Inspect:Breather hoseObstruction Remove.Damage Replace.
When inspecting the battery, make sure thatthe breather hose is routed correctly. If thebreather hose is positioned in such a way asto allow battery electrolyte or gas to comeinto contact with the frame, this could dam-age the motorcycle and ruin its finish.
5. Connect:Breather hose 1Make sure that the hose is properly attachedand routed.
6. Check:Specific gravityLess than 1.280 Recharge the battery.
Charging Current:0.7 amps/10 hrs
Specific Gravity:1.280 at 20C
3-30
BATTERY INSPECTIONINSPADJ
***************************************
***************************************CAUTION:
WARNING
Replace the battery if:Battery voltage will not rise to a specific valueor bubbles fail to rise during charging.
Sulphation of one or more cells occurs, (as in-dicated by the plates turning white, or materialaccumulating in the bottom of the cell).
Specific gravity readings after a long, slowcharge indicate that one cell is charged lowerthan the rest.
Warpage or buckling of plates or insulators isevident.
Always charge a new battery before using itto ensure maximum performance.
Battery electrolyte is dangerous. It containssulfuric acid which is poisonous and highlycaustic.Always follow these preventive measures:Avoid bodily contact with electrolyte as itcan cause severe burns and permanenteye injury.
Wear protective eye gear when handling orworking near batteries.
Antidote (EXTERNAL):SKIN – Flush with water.EYES – Flush with water for 15 minutes andget immediate medical attention.
Antidote (INTERNAL):Drink large quantities of water or milk fol-lowed with milk of magnesia, beaten egg orvegetable oil. Get immediate medicalattention.
Batteries generate explosive hydrogengas.
Always follow these preventive measures:Charge batteries in a well – ventilated area.Keep batteries away from fire, sparks oropen flames (e.g., welding equipment,lighted cigarettes, etc.)
DO NOT SMOKE when charging or han-dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUTOF REACH OF CHILDREN.
3-31
BATTERY INSPECTION/FUSE INSPECTIONINSPADJ
CAUTION:
CAUTION:
***************************************
NOTE:
***************************************
7. Install:Battery
8. Connect:Battery leads
Connect the positive lead 1 first and thenconnect the negative lead 2 .
9. Connect:Breather hoseBe sure the hose is properly attached androuted.Refer to “CABLE ROUTING” section.
10. Install:Side covers (left and right)Refer to “SIDE COVER, SEAT AND FUELTANK” section.
T305010
FUSE INSPECTION
Always turn off the main switch whenchecking or replacing the fuse. Otherwise, ashort circuit may occur.
1. Remove:Side covers (left and right)Refer to “SIDE COVER, SEAT AND FUELTANK” section.
Fuse holder 12. Inspect:Fuse
Inspection steps:Connect the pocket tester to the fuse andcheck it for continuity.
Set the tester selector to “Ω 1” position.
Pocket tester:90890-03112
If the tester is indicated at ∞. Replace thefuse.
3-32
FUSE INSPECTION/HEADLIGHT BEAM ADJUSTMENT
INSPADJ
***************************************
WARNING
***************************************
3. Replace:Blown fuse
Replacement steps:Turn off the main switch. Install a new fuse with the proper current rat-ing.
Turn on switches to verify operation of relatedelectrical devices.
If the fuse blows again immediately, check theelectrical circuit.
Never use a fuse with a rating other than thatspecified. Never use other materials in placeof a fuse. An improper fuse may cause ex-tensive damage to the electrical system,malfunction of lighting and ignition systemsand could possibly cause a fire.
4. Install:Fuse holderSide cover (left and right)Refer to “SIDE COVER, SEAT AND FUELTANK” section.
EB305022
HEADLIGHT BEAM ADJUSTMENT1. Adjust:Headlight beam (vertical)Loosen the bolt 1 and adjust the headlightunit.
CHAPTER 4.ENGINE OVERHAUL
ENGINE REMOVAL 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST PIPE, STARTING MOTOR AND WIRE READ 4-1. . . . . . . . . CARBURETOR, CLUTCH CABLE AND DRIVE CHAIN 4-2. . . . . . . . . . ENGINE 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLILNDER HEAD 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAM SPROCKET COVER 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD REMOVAL 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD INSPECTION 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD INSTALLATION 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAM SHAFT AND ROCKER ARMS 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARM AND ROCKER ARM SHAFT REMOVAL 4-11. . . . . . . . . CAMSHAFT INSPECTION 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 4-12. . . . CAMSHAFT AND ROCKER ARM INSTALLATION 4-12. . . . . . . . . . . . . .
VALVES AND VALVE SPRINGS 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVES AND VALVE SPRINGS REMOVAL 4-15. . . . . . . . . . . . . . . . . . . . VALVES AND VALVE GUIDES 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE SEATS INSPECTION 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVES AND VALVE SPRINGS INSTALLATION 4-18. . . . . . . . . . . . . . . .
CYLINDER AND PISTON 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON AND PISTON RINGS REMOVAL 4-21. . . . . . . . . . . . . . . . . . . . . . CYLINDER AND PISTON INSPECTION 4-21. . . . . . . . . . . . . . . . . . . . . . . PISTON RING INSPECTION 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON PIN INSPECTION 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON RINGS, PISTON AND CYLINDER INSTALLATION 4-24. . . . . .
CLUTCH 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE COVER (RIGHT) 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH REMOVAL 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH INSPECTION 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUSH ROD INSPECTION 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH INSTALLATION 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY DRIVE GEAR REMOVAL 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP INSPECTION 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL DELIVERY PASSAGE INSPECTION
(CRANK CASE COVER (right)) 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP INSTALLATION 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY DRIVE GEAER INSTALLATION 4-36. . . . . . . . . . . . . . . . . . . . .
BALANCER GEAR 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BALANCER DRIVEN GEAR REMOVAL 4-38. . . . . . . . . . . . . . . . . . . . . . . DRIVE GEAR INSPECTION 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BALANCER DRIVE GEAR ASSEMBLY 4-38. . . . . . . . . . . . . . . . . . . . . . . . BALANCER GEAR INSTALLATION 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT AND SEGMENT 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT REMOVAL 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT INSPECTION 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEGMENT INSTALLATION 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIFT SHAFT INSTALLATION 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CDI MAGNETO AND STARTER CLUTCH 4-44. . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE COVER (LEFT) 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PICKUP COIL AND STATOR COIL 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI MAGNETO AND STARTER CLUTCH 4-46. . . . . . . . . . . . . . . . . . . . . . CDI MAGNETO REMOVAL 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER CLUTCH INSPECTION 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER CLUTCH INSTALLATION 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . CDI MAGNETO INSTALLATION 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANK CASE AND CRANKSHAFT 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND BALANCER WEIGHT 4-52. . . . . . . . . . . . . . . . . . . . . CRANKCASE SEPARATION 4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLUNGER SEAL REMOVAL 4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT INSPECTION 4-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLUNGER SEAL INSTALLATION 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BALANCER WEIGHT INSTALLATION 4-55. . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE INSTALLATION 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT CAM AND SHIFT FORK 4-56. . . . . . . . . . . . . . . . . DRIVE AXLE AND MAIN AXLE 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL 4-58. . . . SHIFT FORK SHIFT CAM INSPECTION 4-58. . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION, SHIFT CAM AND SHIFT FORK INSTALLATION 4-59
4-1
Order Job name/Part name Q’ty Remarks
1234567
Exhaust pipe, starting motor andwire read removalSide cover, seat and fuel tank
Rear foot rest (right)Exhaust pipe Ass’yExhaust pipe gasketGround leadStarting motor readCDI magneto readPlug cap
1111111
Refer to “SIDE COVER, SEAT AND FUEL TANK” section in CHAPTER 3.
Remove the parts in order.
Reverse the removal procedure forinstallation.
12 Nm (1.2 mkg)
20 Nm (2.0 mkg)
ENGINE REMOVAL ENG
EB400000
ENGINE OVERHAULENGINE RE MOVALEXHAUST PIPE, STARTING MOTOR AND WIRE READ
4-2
ENGINE REMOVAL ENG
Order Job name/Part name Q’ty Remarks
12345
67
Carburetor, clutch cable and drivechain removalCarburetor
Clutch cableCrankcase breather hoseShift pedalDrive sprocket coverRear wheel axle nut
Sprocket holderDrive sprocket/drive chain
11111
11/1
Remove the parts in order.
Loosen the axle nut and slacken the drive chain.
NOTE:
Refer to “CARBURETOR” section in CHAPTER 5.
Reverse the removal procedure forinstallation.
10 Nm (1.0 mkg)
65 Nm (6.5 mkg)
8 Nm (0.8 mkg)
7 Nm (0.7 mkg)
CARBURETOR, CLUTCH CABLE AND DRIVE CHAIN
4-3
ENGINE REMOVAL ENG
Order Job name/Part name Q’ty Remarks
12345
Engine removal
Engine stay (top)Front engine stayEngine mount bolt (rear upper)Engine mount bolt (rear under)Engine
11111
Remove the parts in order.Securely support the motorcycle so there is no danger of it falling over.
Reverse the removal procedure forinstallation.
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
ENGINE
4-4
CYLINDER HEAD ENG
Order Job name/Part name Q’ty Remarks
1234567
Cam sprocket cover removalSide cover, seat and fuel tank
Exhaust pipe assembly
Carburetor assembly
Engine stay (top)
Spark plugCam sprocket cover/O-ringValve cover (intake side)/O-ringValve cover (exhaust side)/O-ringCarburetor joint/O-ringTiming mark cap/O-ringCenter cap/O-ring
11/11/11/11/11/11/1
Remove the parts in order.
Refer to “SIDE COVER SEAT AND FUEL TANK REMOVAL” section in CHAPTER 3.Refer to “ENGINE REMOVAL” section inCHAPTER 4.Refer to “CARBURETOR” section in CHAPTER 5.Refer to “ENGINE REMOVAL” section inCHAPTER 4.
Reverse the removal procedure forinstallation.
10 Nm (1.0 mkg)
2 Nm (0.2 mkg)
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)
18 Nm (1.8 mkg)
CYLINDER HEADCAM SPROCKET COVER
4-5
CYLINDER HEAD ENG
Order Job name/Part name Q’ty Remarks
12345678
Cylinder head removalTiming chain tensioner cap/O-ringTiming chain tensioner assemblyCam sprocket/Timing chainIgnition coilCylinder headDowel pinsGasketCylinder head gasket
1/11
1/111311
Remove the parts in order.
Refer to “CYLINDER HEAD REMOVAL/INSTALLATION” section.
Refer to “CYLINDER HEAD INSTALLATION” section.
Reverse the removal procedure forinstallation.
22 Nm (2.2 mkg)
20 Nm (2.0 mkg)
5 Nm (0.5 mkg)
60 Nm (6.0 mkg)
30 Nm (3.0 mkg)
CYLINDER HEAD
4-6
CYLINDER HEAD ENG
NOTE:
NOTE:
T401030
CYLINDER HEAD REMOVAL1. Align:Slit a on the magneto(with stationary pointer b on the crank casecover)
Turn the crank shaft counterclockwise with a wrench and align the “I” mark c with the cylinder head match mark d when the piston isat TDC on the compression stroke.
2. Loosen:Cam sprocket bolt 1
3. Remove:Timing chain tensioner assembly 1
4. Remove:Cam sprocket boltCam sprocket 1Timing chain 2
Fasten a safety wire to the timing chain to prevent it from falling into the crankcase.
4-7
CYLINDER HEAD ENG
NOTE:
NOTE:
***************************************
NOTE:
***************************************
5. Remove:Cylinder head
Loosen the nuts in their proper loosening sequence.
Start by loosening each nut 1/2 turn until all are loose.
YP402000
CYLINDER HEAD INSPECTION1. Eliminate:Carbon deposits(from combustion chambers)Use a rounded scraper.
Do not use a sharp instrument to avoid damaging or scratching:Spark plug threadsValve seats
2. Inspect:Cylinder headScratches/damage Replace.
3. Measure:Cylinder head warpageOut of specification Resurface.
Cylinder head warpage:Less than 0.03 mm
Warpage measurement and resurfacementsteps:Place a straightedge and a feeler gaugeacross the cylinder head.
Measure the warpage.If the warpage is out of specification, resurfacethe cylinder head.
Place a 400 600 grit wet abrasive paper onthe surface plate, and resurface the head us-ing a figure-eight sanding pattern.
Rotate the cylinder head several times for aneven resurfacement.
4-8
CYLINDER HEAD ENG
New
New
22 Nm (2.2 mkg)M8 (1 4)
20 Nm (2.2 mkg)M8 (5 6
NOTE:
***************************************
NOTE:
CAUTION:
***************************************
SR********
CYLINDER HEAD INSTALLATION1. Install:Dowel pins 1 Gasket 2Gasket (cylinder head) 3
2. Install:Cylinder head
apply engine oil onto the nut threads.Tighten the bolts starting with the lowest numbered one.
3. Install:Calm sprocketTiming chain
Installing steps:Turn the crank shaft counterclockwise until theslit 1 matches the stationary pointer 2 .
Align the dowel pin 3 on the camshaft with thestationary pointer 4 on the cylinder head.
Align the “I” mark 5 on the cam sprocket withthe stationary pointer 6 on the cylinder head.
Fit the timing chain 7 onto cam sprocket 8and install the cam sprocket on the camshaft.
When installing the cam sprocket, keep the tim-ing chain as tight as possible on the exhaustside.
Do not turn the crankshaft during installa-tion of the camshaft. Damage or impropervalve timing will result.
Remove the safety wire from the timing chain.
4-9
CYLINDER HEAD ENG
60 Nm (6.0 mkg)
NOTE:
4. Install:Plate washerBolt (timing chain)Timing chain tensioner assembly
5. Tighten:Bolt (timing chain)
Install the bolt while holding the magnetomounting bolt with a wrench.
6. Check:Magneto rotor slitAlign the stationary pointer with the crank-case cover (left).
Cam sprocket “I” markAlign the stationary pointer with the cylinderhead.Out of alignment Adjust.
7. Check:Timing chain tensionRefer to “TIMING CHAIN ADJUSTMENT”section in CHAPTER 3.
Valve clearanceRefer to “VALVE CLEARANCE ADJUST-MENT” section in CHAPTER 3.
4-10
CAM SHAFT AND ROCKER ARMS ENG
Order Job name/Part name Q’ty Remarks
123456789
Cam shaft and rocker arm removalCylinder headLock washerPlateCollarCam shaftRocker arm shaft (intake side)Rocker arm shaft (exhaust side)Rocker armO-ringNut/Adjuster
11111121
2/2
Remove the parts in order.Refer to the “CYLINDER HEAD” section.
Refer to the “ROCKER ARM AND ROCKER ARM SHAFT REMOVAL/CAMSHAFT AND ROCKER ARM INSTALLATION” section.
Refer to the “CAMSHAFT AND ROCKERARM INSTALLATION” section.
Reverse the removal procedure forinstallation.
14 Nm (1.4 mkg)
14 Nm (1.4 mkg)
8 Nm (0.8 mkg)
CAM SHAFT AND ROCKER ARMS
4-11
CAM SHAFT AND ROCKER ARMS ENG
NOTE:
NOTE:
SR******
ROCKER ARM AND ROCKER ARM SHAFTREMOVAL1. Remove:Camshaft 1Collar (camshaft) 2
Use 10 mm bolt 3 to remove the camshaft.
2. Remove:Rocker arm shaft (intake)Rocker arm shaft (exhaust)
Attach a rocker arm shaft puller bolt 1 andweight 2 to the rocker arm shaft and slide outthe shaft.
Rocker arm shaft puller bolt:90890-01083
Weight:90890-01084
YP402052
CAMSHAFT INSPECTION1. Inspect:Cam lobesPitting/Scratches/Blue discoloration Replace.
2. Measure:Cam lobes length A and B .Out of specification Replace.
Cam lobes length:Intake:
A 36.537 36.637 mm<Limit: 36.45 mm>B 30.13 30.231 mm<Limit: 30.05 mm>
Exhaust:A 36.577 36.677 mm<Limit: 36.49 mm>B 30.214 30.314 mm<Limit: 30.13 mm>
3. Inspect:Camshaft oil passageStuffed Blow out oil passage with com-pressed the air.
4-12
CAM SHAFT AND ROCKER ARMS ENG
***************************************
***************************************
YP402060
ROCKER ARMS AND ROCKER ARMSHAFTS INSPECTION1. Inspect:Rocker arm shaftsRocker armsWear/Pitting/Scratches/Blue discoloration Replace.
Inspection steps: Inspect the two contact areas on the rockerarms for signs of unusual wear.
Rocker arm shaft hole.Cam-lobe contact surface.Excessive wear Replace.
Inspect the surface condition of the rocker armshafts.Pitting/scratches/blue discoloration Re-place or check lubrication.
Measure the inside diameter a of the rockerarm holes.Out of specification Replace.
Inside diameter (rocker arm):12.000 12.018 mm<Limit: 12.036 mm>
Measure the outside diameter of the rockerarm shafts.Out of specification Replace.
Outside diameter (rocker arm shaft):
11.985 11.991 mm<Limit: 11.950 mm>
SR******
CAMSHAFT AND ROCKER ARMINSTALLATION1. Lubricate:Camshaft
Camshaft:Molybdenum disulfide oil
Camshaft bearing:Engine oil
4-13
ENGCAM SHAFT AND ROCKER ARMS
NOTE:
CAUTION:
NOTE:
New8 Nm (0.8 mkg)
NOTE:
2. Apply:Molybdenum disulfide oil(onto the rocker arm and rocker arm shaft)
Molybdenum disulfide oil
3. Install:Rocker armRocker arm shaft 1
Apply engine oil onto the outside of the rockerarm shaft and apply molybdenum disulfide oilonto the inside of the rocker arm.
Install the rocker arm shaft (intake), mach thecut away a and bolt hole b .
Make sure that the rocker shaft installdirection.
Install the rocker arm shaft into the threadside for the out.
4. Install:Camshaft 1Collar 2
Apply engine oil onto the cam profile face andjournal face.
Install the camshaft, mach the dowel pin aand cylinder head mark b .
5. Install:Plate 1Lock washer 2 Bolt 3
After tighten the bolt, bend the end of the rockwasher.
4-14
Order Job name/Part name Q’ty Remarks
1
2345678
Valves and valve springs removalCylinder headRocker arm, Camshaft
Valve cotters
Spring retainerValve spring (inner)Valve spring (outer)Valve (intake)Valve (exhaust)Valve guide (stem seal)Spring seat
4
2221122
Remove the parts in order.Refer to “CYLINDER HEAD” section.Refer to “CAMSHAFT AND ROCKERARMS” section.
Refer to “VALVES AND VALVESPRINGS REMOVAL/INSTALLATION”section.
Refer to “VALVES AND VALVE SPRINGS INSTALLATION” section.
Reverse the removal procedure forinstallation.
VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS
4-15
VALVES AND VALVE SPRINGS ENG
NOTE:
CAUTION:
ab
***************************************
NOTE:
YP401150
VALVES AND VALVE SPRINGS REMOVAL1. Remove:Valve cotters 1
Attach a valve spring compressor and attach-ment 2 between the valve spring retainer andcylinder head to remove the valve cotters.
Do not compress so much as to avoid dam-age to the valve spring.
Valve spring compressor:90890-01253
Valve spring compressor attachment:
90890-04108
NB402010
VALVES AND VALVE GUIDES1. Measure:Stem-to-guide clearance
Stem-to-guide clearance =valve guide inside diameter –valve stem diameter
Out of specification Replace the valveguide.
Clearance (stem to guide):Intake:
0.010 0.037 mm<Limit: 0.08 mm>Exhaust:
0.025 0.052 mm<Limit: 0.10 mm>
2. Replace:Valve guide
Replacement steps:
Heat the cylinder head in an oven to 100C toease guide removal and installation and tomaintain correct fit.
Remove the valve guide using a valve guideremover 1 .
4-16
VALVES AND VALVE SPRINGS ENG
NOTE:
***************************************
NOTE:
Install the new valve guide using a valve guideinstaller 2 and valve guide remover 1 .
After installing the valve guide, bore the valveguide using a valve guide reamer 3 to obtainproper stem-to-guide clearance.
Valve guide remover (6 mm):90890-04064
Valve guide installer (6 mm):90890-04065
Valve guide reamer (6 mm):90890-04066
Reface the valve seat after replacing the valveguide.
3. Eliminate:Carbon deposits (from the valve face)
4. Inspect:Valvel facePitting/wear Grind the face.
Valve stem endMushroom shape or diameter larger than thebody of the stem Replace.
5. Measure:Margin thickness aOut of specification Replace.
Margin thickness:Intake 0.8 1.2 mmExhaust 0.8 1.2 mm
6. Measure:Runout (valve stem)Out of specification Replace.
Runout:Less than 0.03 mm
Always replace the guide when installing anew valve.
Always replace the oil seal if the valve is re-moved or replaced.
4-17
VALVES AND VALVE SPRINGS ENG
***************************************
***************************************
***************************************
NOTE:
CAUTION:
EB402020
VALVE SEATS INSPECTION1. Eliminate:Carbon deposits(from the valve face and valve seat)
2. Inspect:Valve seatsPitting/wear Reface the valve seat.
3. Measure:Valve seat width aOut of specification Reface the valve seat.
Valve seat width:Intake:
0.9 1.1 mm<Limit: 1.6 mm>
Exhaust:0.9 1.1 mm<Limit: 1.6 mm>
Measurement steps:Apply Mechanic’s blueing dye (Dykem) 1 tothe valve face.
Install the valve into the cylinder head.Press the valve through the valve guide andonto the valve seat to make a clear pattern.
Measure the valve seat width. Where the valveseat and valve face made contact, blueing willhave been removed.
If the valve seat is too wide, too narrow, or theseat is not centered, the valve seat must be re-placed.
EB402020
4. Lap:Valve faceValve seat
After replacing the valve seat, valve and valveguide, the valve seat and valve face should belapped.
Lapping steps:Apply a coarse lapping compound a to thevalve face.
Do not let compound enter the gap betweenthe valve stem and the guide.
4-18
VALVES AND VALVE SPRINGS ENG
NOTE:
NOTE:
***************************************
Apply molybdenum disulfide oil to the valvestem.
Install the valve into the cylinder head.
Turn the valve until the valve face and valveseat are evenly polished, then clean off allcompound.
Valve lapper:90890-04101
For best lapping results, lightly tap the valveseat while rotating the valve back and forth be-tween your hand.
Apply a fine lapping compound to the valveface and repeat the above steps.
Make sure to clean off all compound from thevalve face and valve seat after every lappingoperation.
Apply Mechanic’s blueing dye (Dykem) b tothe valve face.
Install the valve into the cylinder head.Press the valve through the valve guide andonto the valve seat to make a clear pattern.
Measure the valve seat width c again.
EB404032
VALVES AND VALVE SPRINGSINSTALLATION1. Deburr:Valve stem endUse an oil stone to smooth the stem end.
4-19
VALVES AND VALVE SPRINGS ENG
Molybdenum disulfide oil
New
NOTE:
NOTE:
CAUTION:
2. Apply:Molybdenum disulfide oil(onto the valve stem 3 and oil seal 2 )
3. Install:Valve spring seat 1Valve stem seat 2 Valve 3(into the cylinder head)
Valve spring 4Spring retainer 5
Install the valve spring with the larger pitch afacing upwards.
b Smaller pitch
4. Install:Valve cotters 1
Install the valve cotters while compressing thevalve spring with a valve spring compressor andattachment 2 .
Valve spring compressor:90890-01253
Valve spring compressorattachment:
90890-04108
5. Secure the valve cotters onto the valve stemby tapping lightly with a piece of wood.
Do not hit so much as to damage the valve.
4-20
CYLINDER AND PISTON ENG
Order Job name/Part name Q’ty Remarks
123456789
Cylinder and piston removalCylinder headTiming chain guide (exhaust side)Cylinder/O-ringO-ringDowel pinCylinder gasketPiston pin circlipPiston pinPistonPiston ring set
11/11212111
Remove the parts in order.Refer to “CYLINDER HEAD” section.
Refer to “PISTON AND PISTON RINGSREMOVAL” section.Refer to “PISTON RINGS, PISTON ANDCYLINDER INSTALLATION” section.
Refer to “PISTON RINGS, PISTON ANDCYLINDER INSTALLATION” section.
Reverse the removal procedure forinstallation.
CYLINDER AND PISTON
4-21
CYLINDER AND PISTON ENG
NOTE:
NOTE:
***************************************
NOTE:
YP******
PISTON AND PISTON RINGS REMOVAL1. Remove:Piston pin circlip 1Piston pin 2Piston 3
Before removing the piston pin circlip, cover thecrankcase opening with a clean towel or rag toprevent the circlip from falling into the crankcase cavity.
2. Remove:Top ring2nd ringOil ring
When removing the piston ring, open the endgap of the ring by fingers, and push up the otherside of the ring.
EB402100
CYLINDER AND PISTON INSPECTION1. Inspect:Cylinder and piston wallsVertical scratches Rebore or replace thecylinder and the piston.
2. Measure:Piston-to-cylinder clearance
Measurement steps:1st step:Measure the cylinder bore “C” with a cylinderbore gauge.
Measure the cylinder bore “C” in parallel to andat right angles to the crankshaft. Then, find theaverage of the measurements.
4-22
CYLINDER AND PISTON ENG
***************************************
Cylinder bore “C” 57.00 57.02 mm
Taper limit “T” 0.05mm
Out of round “R” 0.01mm
“C” = Maximum D
“T” = (Maximum D 1 or D2) – (Maximum D 5 or D6)
“R” = (Maximum D 1, D3 or D5)– (Minimum D 2, D4 or D6)
If out of specification, rebore or replace the cyl-inder, and replace the piston and piston ringsas a set.
2nd step:Measure the piston skirt diameter “P” with amicrometer.
a 5.5 mm from from the piston bottom edge.
Piston size P
Standard 56.960 56.975 mm
Oversize 1 0.25 mm
Oversize 2 0.50 mm
If out of specification, replace the piston andthe piston rings as a set.
3rd step:Calculate the piston-to-cylinder clearance us-ing the following formula:
Piston-to-cylinder clearance =Cylinder bore “C” –Piston skirt diameter “P”
Piston-to-cylinder clearance:0.025 0.045 mm
If out of specification, rebore or replace the cyl-inder, and replace the piston and piston ringsas a set.
4-23
CYLINDER AND PISTON ENG
NOTE:
NOTE:
NOTE:
EB402110
PISTON RING INSPECTION1. Measure:Side clearanceOut of specification Replace the pistonand the piston rings as a set.
Eliminate the carbon deposits from the pistonring grooves and rings before measuring theside clearance.
Side clearance:Top ring: <Limit>
0.03 0.07 mm <0.15 mm>2nd ring: <Limit>
0.02 0.06 mm <0.15 mm>
2. Position:Piston ring(into the cylinder)
Push the ring with the piston crown so that thering will be at a right angle to the cylinder bore.
a 5 mm
3. Measure:End gapOut of specification Replace.
You cannot measure the end gap on the expan-der spacer of the oil ring. If the oil ring rails showexcessive gap, replace all three rings.
End gap:Top ring: <Limit>
0.15 0.35 mm <0.60 mm>2nd ring: <Limit>
0.15 0.35 mm <0.60 mm>Oil ring: 0.3 0.9 mm
4-24
CYLINDER AND PISTON ENG
***************************************
ba
***************************************
NOTE:
EB402120
PISTON PIN INSPECTION1. Inspect:Piston pinBlue discoloration/grooves Replace, theninspect the lubrication system.
2. Measure:Piston pin-to-piston clearance
Measurement steps:Measure the piston pin outside diameter a .If out of specification, replace the piston pin.
Outside diameter (piston pin):14.978 14.992 mm<Limit> 14.975 mm
Measure the piston inside diameter b .Calculate the piston pin-to-piston clearanceusing the following formula:
Piston pin-to-piston clearance =Bore size (piston pin) –Outside diameter (piston pin)
If out of specification, replace the piston.
Clearance (piston pin-to-piston):0.010 0.035 mm
EB404184
PISTON RINGS, PISTON AND CYLINDERINSTALLATION1. Install:Top ring 12nd ring 2Side rails (oil ring) 3Expander spacer (oil ring) 4
Make sure to install the piston rings so that themanufacturer’s marks or numbers are locatedon the upper side of the rings.
Lubricate the pistons and piston rings liberallywith engine oil.
4-25
CYLINDER AND PISTON ENG
New
NOTE:
New
NOTE:
Engine oil
New
NOTE:
2. Install:Piston 1Piston pin 2Piston pin clip 3
Apply engine oil onto the piston pins.The “” mark a on the piston must face theexhaust side of the cylinder.
Before installing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe piston pin clip from falling into the crank-case.
Make sure to install each piston in its respec-tive cylinder.
3. Install:Gasket (cylinder) Dowel pins
4. Position:Piston rings
Offset the piston ring end gaps as shown.
a Top ring endb Oil ring end (lower)c Oil ring end (upper)d 2nd ring end
5. Lubricate:Piston outer surfacePiston ringCylinder inner surface
6. Install:Gasket (cylinder) 1 Cylinder 2
Install the cylinder with one hand while com-pressing the piston rings with the other hand.
Pass the timing chain and timing chain guide(exhaust side) through the timing chain cavity.
4-26
CLUTCH ENG
Order Job name/Part name Q’ty Remarks
123456
Crankcase cover (right) removalDrain the engine oil
NutFoot rest (right)Clutch cableCrankcase cover (right)Crankcase cover gasket (right)Dowel pins
111112
Remove the parts in order.Refer to “ENGINE OIL REPLACEMENT”section in CHAPTER 3.
Reverse the removal procedure forinstallation.
45 Nm (4.5 mkg)
7 Nm (0.7 mkg)
CLUTCHCRANKCASE COVER (RIGHT)
4-27
CLUTCH ENG
Order Job name/Part name Q’ty Remarks
123456789
1011
4143
1/111111
1/1
Remove the parts in order.Refer to “ENGINE REMOVAL” section.
Refer to “CLUTCH INSTALLATION” section.
Clutch removalSprocket coverClutch springsPressure plateFriction platesClutch platesNut/Lock washerClutch bossPlate washerPrimary driven gearBallPush rod #2Push lever screw/Gasket
Refer to “CLUTCH INSTALLATION” section.
Refer to “CLUTCH REMOVAL/INSTALLATION” section.
8 Nm (0.8 mkg)70 Nm (7.0 mkg)
12 Nm (1.2 mkg)
6 Nm (0.6 mkg)
CLUTCH
4-28
CLUTCH ENG
Order Job name/Part name Q’ty Remarks
12131415161718
Push lever axleTorsion springCirclipOil sealNut/WasherPush rod #1/O-ringPush plate
1111
1/11/11
Refer to “CLUTCH INSTALLATION” sec-tion.
Refer to “CLUTCH INSTALLATION” sec-tion.
Reverse the removal procedure forinstallation.
8 Nm (0.8 mkg)70 Nm (7.0 mkg)
12 Nm (1.2 mkg)
6 Nm (0.6 mkg)
4-29
CLUTCH ENG
NOTE:
SR401061
CLUTCH REMOVAL1. Remove:Nut 1 (clutch boss)Lock washer 2Clutch boss 3Straighten the lock washer tab 2 .
Loosen the clutch boss nut 1 while holding theclutch boss with a clutch holding tool 4 .
Clutch holding tool:90890-04086
SR402181
CLUTCH INSPECTION1. Inspect:Friction platesDamage/wear Replace the friction platesas a set.
2. Measure:Friction plate thicknessOut of specification Replace the frictionplates as a set.Measure at four places.
Thickness (friction plate):2.9 3.1 mm<Limit: 2.7 mm>
3. Inspect:Clutch platesDamage Replace the clutch plates as aset.
4. Measure:Clutch plate warpageOut of specification Replace the clutchplates as a set.Use a surface plate and a feeler gauge 1 .
Warp limit (clutch plate):Less tan 0.05 mm
5. Inspect:Clutch springsDamage Replace the clutch springs as aset.
4-30
CLUTCH ENG
NOTE:
New12 Nm (1.2 mkg)
NOTE:
6. Measure:Free length (clutch spring) aOut of specification Replace the clutchsprings as a set.
Free length (clutch spring):34.5 mm<Lilmit: 32.9 mm>
7. Inspect:Dogs on the primary driven gear 1Scoring/wear/damage Deburr or re-place.
Clutch boss splines 2Scoring/wear/damage Replace clutchboss.
Scoring on the clutch housing dogs and theclutch boss splines will cause erratic operation.
SR********
PUSH ROD INSPECTION1. Inspect:Push rod #1 1Ball 2Push rod #2 3Wear/crack/damage Replace.
SR******
CLUTCH INSTALLATION1. Install:Push lever axle 1Gasket 2 Screw 3
2. Install:Primary driven gear 1Plate washer 2Clutch boss 3
Tighten the nut (primary drive gear) while hold-ing the rotor with the sheave holder 3 .
4-31
CLUTCH ENG
New70 Nm (7.0 mkg)
NOTE:
NOTE:
New
6 Nm (0.6 mkg)
NOTE:
3. Install:Lock washer 1 Nut 2 (clutch boss)
Install the clutch boss nut 2 while holding theclutch boss with a clutch holding tool 3 .
Clutch holding tool:90890-04086
4. Bend:Lock washer tab(along a flat side of the end)
5. Install:Friction plate 1Clutch plate 2
Install the clutch plates and friction plates al-ternately on the clutch boss, starting with a fric-tion plate and ending with a friction plate.
Coat all clutch and friction plates with engineoil before installation.
6. Install:Push rod #2Ball
7. Install:Push rod #1 1O-ring 2 Push plate 3Plate washer 4Nut 5 (push rod #1)
8. Install:Pressure plate 1Compression springs 2Bolts 3 (clutch springs)
Tighten the clutch spring bolts in stage, using acrisscross pattern.
4-32
CLUTCH ENG
***************************************
CAUTION:
***************************************8 Nm (0.8 mkg)
9. Check:Push lever positionPush the push lever assembly in the arrowdirection and make sure that match marksare be aligned Adjust.
a Match mark on the push lever assemblyb Match mark on the crankcase
10. Adjust:Push lever position
Adjustment steps:Loosen the locknut 1 .Turn the adjuster 2 clockwise or counter-clockwise to match alignment marks.
Hold the adjuster to prevent it from moving andtighten the locknut to specification.
Take care not to overtighten the adjuster 2and to remove the free play between bothpush rods.
Tighten the lock nut 1 .
4-33
OIL PUMP ENG
Order Job name/Part name Q’ty Remarks
12345
6
Oil pump removalClutch
NutLock washerPrimary drive gearOil pump coverOil pump assembly
Gasket (oil pump cover)
11111
1
Remove the parts in order.Refer to “CLUTCH” section.
Refer to “PRIMARY DRIVE GEAR REMOVAL/INSTALLATION” section.
Refer to “OIL PUMP REMOVAL/INSTAL-LATION” section
Reverse the removal procedure forinstallation.
7 Nm (0.7 mkg)
50 Nm (5.0 mkg)
OIL PUMP
4-34
OIL PUMP ENG
Order Job name/Part name Q’ty Remarks
Oil pump disassemblyOil pump housingDowel pinOil pump driven gearDowel pinsInner rotorOuter rotorHousing
1112111
Disassemble the parts in order.
Reverse the disassembly procedure forassembly.
7 Nm (0.7 mkg)
11111111111111112111111111111111
34567
4-35
OIL PUMP ENG
NOTE:
NOTE:
SR401070
PRIMARY DRIVE GEAR REMOVAL
Straighten the lock washer tab.
1. Remove:Nut (primary drive gear) 1Lock washer 2Primary drive gear 3
Place a folded aluminium plate or copper wash-er a between the teeth of the balancer drivegear 4 and balancer driven gear 5 .
T402140
OIL PUMP INSPECTION1. Measure:Tip clearance A(between the inner rotor 1 and the outer ro-tor 2 )
Side clearance B(between the outer rotor 2 and the pumphousing 3 )Out of specification Replace the oil pumpassembly.
Housing and rotor clearance C(between the pump housing 3 and the ro-tors 1 , 2 .)Out of specification Replace the oil pumpassembly.
Tip clearance A :0.03 0.09 mm <Limit: 0.14 mm>
Side clearance B :0.10 0.15 mm <Limit: 0.35 mm>
Housing and rotor clearance C :0.03 0.09 mm <Limit: 0.14 mm>
SR******
OIL DELIVERY PASSAGE INSPECTION (CR-ANK CASE COVER (right))1. Check:Oil delivery passageBlockage Blow by the compressed air.
4-36
OIL PUMP ENG
New
50 Nm (5.0 mkg)
NOTE:
SR404010
OIL PUMP INSTALLATION1. Lubricate:Oil delivery passage (crankcase right)Oil pump assembly
Recommended lubricant:Engine oil
SR404140
PRIMARY DRIVE GEAR INSTALLATION1. Install:Primary drive gear 1Lock washer 2 Nut (primary drive gear) 3
Place a folded aluminium plate or copperwasher a between the teeth of the balancerdrive gear 4 and balancer driven gear 5 .
Bend the lock washer tab, after tighten the nutflats.
4-37
BALANCER GEAR ENG
Order Job name/Part name Q’ty Remarks
12
3456789
10
Balancer gear removalClutchPrimary drive gearNut/Lock washerBalancer driven gear
Woodruff keyClaw washerBalancer drive gearBuffer bossCompression springDowel pinsWoodruff keyPlate washer
1/11
11116311
Remove the parts in order.Refer to “CLUTCH” section.Refer to “OIL PUMP” section.Refer to “BALANCER DRIVEN GEAR REMOVAL/BALANCER GEAR INSTALLATION” section.
Reverse the removal procedure forinstallation.
Refer to “BALANCER DRIVE GEAR ASSEMBLY” section.
50 Nm (5.0 mkg)
BALANCER GEAR
4-38
BALANCER GEAR ENG
NOTE:
NOTE:
NOTE:
NOTE:
SR******
BALANCER DRIVEN GEAR REMOVAL
Straighten the lock washer tab.
1. Remove:Nut (balancer driven gear) 1Lock washer 2Balancer driven gear 3
Place a folded aluminium plate or copper wash-er a between the teeth of the balancer drivegear 4 and balancer driven gear 3 .
SR******
DRIVE GEAR INSPECTION1. Inspect:Balancer drive gear 1Buffer boss 2Compression spring 3Dowel pins 4Wear/Pitting/Scratches Replace.
SR******
BALANCER DRIVE GEAR ASSEMBLY1. Assembly:Dowel pins 1Compression springs 2
Install the dowel pins and compression springsalternately as shown as.
2. Install:Buffer boss 1
Align the punched mark a on the buffer bosswith the one on the balancer drive gear.
4-39
BALANCER GEAR ENG
NOTE:
New
50 Nm (5.0 mkg)
NOTE:
SR******
BALANCER GEAR INSTALLATION1. Install:Balancer driven gear 1
Install the balancer driven gear, then mesh thebalancer driven gear match mark a and ba-lancer drive gear assembly match mark b .
2. Install:Lock washer 1 Nut (balancer drive gear) 2
Place a folded aluminium plate or copperwasher a between the teeth of the balancerdrive gear 3 and balancer driven gear 4 .
Bend the lock washer tab, after tighten the nutflats.
4-40
SHIFT SHAFT AND SEGMENT ENG
Order Job name/Part name Q’ty Remarks
123456789
Shift shaft and segment removalClutchShift pedalShift shaftPlate washerTorsion springStopper leverPlate washerCirclipTorsion springCollarTension spring
111111111
Remove the parts in order.Refer to “CLUTCH” section.Refer to “ENGINE REMOVAL” section.
Refer to “SHIFT SHAFT REMOVAL/INSTALLATION” section.
12 Nm (1.2 mkg)
SHIFT SHAFT AND SEGMENT
4-41
SHIFT SHAFT AND SEGMENT ENG
Order Job name/Part name Q’ty Remarks
10111213
ScrewSegmentDowel pins (short length)Dowel pins (long length)
1141
Reverse the removal procedure forinstallation.
Refer to “SEGMENT INSTALLATION” section.
12 Nm (1.2 mkg)
4-42
SHIFT SHAFT AND SEGMENT ENG
NOTE:
NOTE:
SR******
SHIFT SHAFT REMOVAL1. Remove:Shift shaft assembly 1
Push the shift lever arm 2 and the stopper lever3 to the arrow direction and remove them fromthe segment.
T402200
SHIFT SHAFT INSPECTION1. Inspect:Stopper leverRoller turns roughly Replace.Bends/damage Replace.
2. Inspect:Torsion springs (stopper lever and shift arm)Wear/damage Replace.
3. Inspect:Shift shaft assembly 1Shift lever 2Bends/wear/damage Replace.
SR******
SEGMENT INSTALLATION1. Install:Segment 1Dowel pins 2 (short length)Dowel pin 3 (long length)
Install the dowel pin 2 (long length) into thehole beside the match mark a position.
4-43
SHIFT SHAFT AND SEGMENT ENG
NOTE:
12 Nm (1.2 mkg)
***************************************
***************************************
2. Install:Segment 1
Fit the dowel pin 2 (long length) on the seg-ment to the locating hole a on the sift cam andinstall the segment.
3. Tighten:Screw 1
SR******
SIFT SHAFT INSTALLATION1. Install:Shift shaft assembly
Instaling steps:Set the stopper lever and return spring to theshift shaft.
Mesh the stopper lever 1 with the shift camsegment.
Install the shift lever 2 to the shift cam seg-ment.
After installing the shift shaft, check the shiftcam for smooth operation by turning the shiftshaft with your hand.
2. Check:Shift lever 1 positionGaps a and b are not equal Replace thedefective parts.
4-44
CDI MAGNETO AND STARTER CLUTCH ENG
Order Job name/Part name Q’ty Remarks
1234
Crankcase cover (left) removalDrain the engine oil
Side cover
Drive sprocket coverDCI magneto lead couplersNeutral switch lead connectorCrankcase cover (left)GasketDowel pins
1112
Remove the parts in order.Refer to “ENGINE OIL REPLACEMENT”section in CHAPTER 3.Refer to “SIDE COVER, SEAT ANDFUEL TANK” section in CHAPTER 3.
Refer to “ENGINE REMOVAL” section.
Reverse the removal procedure forinstallation.
7 Nm (0.7 mkg)
CDI MAGNETO AND STARTER CLUTCHCRANKCASE COVER (LEFT)
4-45
CDI MAGNETO AND STARTER CLUTCH ENG
Order Job name/Part name Q’ty Remarks
1234
Pickup coil and stator coil removalClamp (stator coil)Clamp (pickup coil)Pickup coilStator coil
1111
Remove the parts in order.
Reverse the removal procedure forinstallation.
3 Nm (0.3 mkg)
7 Nm (0.7 mkg)
PICKUP COIL AND STATOR COIL
4-46
CDI MAGNETO AND STARTER CLUTCH ENG
Order Job name/Part name Q’ty Remarks
1
23456789
1011
CDI magneto and starter clutch removalCDI magneto
Idle shaft /collarStarter idle gearWoodruff keyStarter wheel gearShimDowel pins (Inner)Spring capsCompression springsDowel pins (outer)Starter clutch
1
1111133331
Remove the parts in order.
Refer to “CDI MAGNETO REMOVAL/INSTALLATION” section.
Refer to “CDI MAGNETO INSTALLATION” section.
Refer to “STARTER CLUTCH INSTALLATION” seciton.
Remove the removal procedure torinstallation.
30 Nm (3.0 mkg)
50 Nm (5.0 mkg)
CDI MAGNETO AND STARTER CLUTCH
4-47
CDI MAGNETO AND STARTER CLUTCH ENG
NOTE:
NOTE:
***************************************
***************************************
YP401081
C.D.I. MAGNETO REMOVAL1. Remove:Bolt 1 (magneto)Plain washer 2
Loosen the bolt (magneto) 1 while holdingthe rotor with a sheave holder 3 .
Do not allow the sheave holder to touch theprojection on the magneto.
Sheave holder:90890-01701
2. Remove:CDI magneto assembly 1Woodruff key
Remove the magneto using sheave holder 2 ,rotor puller 3 and rotor puller attachment 4 .
Rotor puller:90890-01080
Rotor puller attachment:90890-04052
SR402163
STARTER CLUTCH INSPECTION1. Check:Starter clutch operationPush the dowel pins to the arrow direction.Unsmooth operation Replace.
Checking steps:Hold the starter clutch.When turning the starter wheel gear clockwise
a , the starter clutch and the starter wheelgear should be engaged.
If not, the starter clutch is faulty. Replace it.When turning the starter wheel gear counter-clockwise b , it should turn freely.
If not, the starter clutch is faulty. Replace it.
2. Inspect:Dowel pins 1Compression springs 2Spring caps 3Wear/Damage Replace.
4-48
CDI MAGNETO AND STARTER CLUTCH ENG
30 Nm (3.0 mkg)
NOTE:
3. Inspect:Starter wheel gear(contacting surface)Pitting/Wear/Damage Replace.
SR******
STARTER CLUTCH INSTALLATION1. Install:Starter clutch assembly 1
2. Unloosen the starter clutch assembly by us-ing the center punch.
3. Install:Compression springs 1Spring caps 2Dowel pins 3
YP404131
C.D.I. MAGNETO INSTALLATION1. Install:Shim 1Starter wheel gear 2Woodruff key 3
2. Install:C.D.I. magneto assembly 1
Clean the tapered portion of the crankshaftand the magneto hub.
When installing the magneto rotor, make surethe woodruff key is properly seated in the keyway of the crankshaft and turning the staterwheel gear 2 clockwise.
4-49
CDI MAGNETO AND STARTER CLUTCH ENG
50 Nm (5.0 mkg)
NOTE:
3. Tighten:CDI magneto assembly 1
Tighten the bolt while holding the CDI magnetoassembly with the sheave holder 2 .
Sheave holder:90890-01701
4-50
CRANKCASE AND CRANK SHAFT ENG
Order Job name/Part name Q’ty Remarks
1
Crankcase separationEngineCylinder headCylinder and piston
ClutchPrimary drive gear/oil pumpBalancer weight drive gear
Shift shaft and segment
CDI magneto/starter clutch
Timing chain guide (intake) 1
Remove the parts in order.Refer to “ENGINE REMOVAL” section.Refer to “CYLINDER HEAD” section.Refer to “CYLINDER AND PISTON”section.
Refer to “CLUTCH” section.Refer to “OIL PUMP” section.Refer to “BALANCER DRIVE GEAR”section.Refer to “SHIFT SHAFT AND SEGMENT” section.Refer to “CDI MAGNETO AND STARTER CLUTCH” section.
8 Nm (0.8 mkg)
7 Nm (0.7 mkg)
CRANK CASE AND CRANKSHAFTCRANKCASE
4-51
CRANKCASE AND CRANK SHAFT ENG
Order Job name/Part name Q’ty Remarks
23
4
Timing chainCrankcase
Dowel pins
11
2
Refer to “CRANKCASE SEPARATION/INSTALLATION” section.
Reverse the removal procedure forinstallation.
8 Nm (0.8 mkg)
7 Nm (0.7 mkg)
4-52
CRANKCASE AND CRANK SHAFT ENG
Order Job name/Part name Q’ty Remarks
1234567
Crankshaft and balancer weight removalBalancer weightCrankshaft assemblyDowel pinPlunger sealCompression springBearing (balancer weight)Bearing (crankshaft right)
1111111
Remove the parts in order.
Refer to “BALANCER WEIGHT INSTALLATION” seciton.
Refer to “PLUNGER SEAL REMOVAL/INSTALLATION” section.
Reverse the removal procedure forinstallation.
CRANKSHAFT AND BALANCER WEIGHT
4-53
CRANKCASE AND CRANK SHAFT ENG
NOTE:
NOTE:
CAUTION:
NOTE:
SR401132
CRANKCASE SEPARATION1. Remove:Crankcase screws
The numbers embossed on the crankcase in-dicate the tightening sequence. Loosen thescrews in decreasing numerical order (seenumbers on the illustration).
Loosen each screw 1/4 turn at a time and re-move them after all are loose.
2. Remove:Right crankcase half
Set the left crankcase half under then put in theflat head screw driver to the separating slit a .
Do not use the flat head screw driver ex-cept place as shown.
The left crankcase half should be under.Separate the crankcase after first checkingthat the shift cam segments and the driveaxle circlip can be removed.
Do not damage the crankcase mating sur-faces.
SR******
PLUNGER SEAL REMOVAL1. Remove:Dowel pin 1Plunger seal 2Compression spring 3
Remove the plunger seal and compressionspring, push the plunger seal lightly and removethe dowel pin.
4-54
CRANKCASE AND CRANK SHAFT ENG
NOTE:
T******
CRANKSHAFT INSPECTION1. Measure:Crankshaft runoutOut of specification Replace crankshaftand/or bearing.
Measure the crankshaft runout with the crank-shaft assembly turning slowly.
Runout limit:0.03 mm
2. Measure:Big end side clearanceOut of specification Replace big end bear-ing, crank pin and/or connecting rod.
Big end side clearance:0.35 0.65 mm
Limit0.1 mm
3. Measure:Crank widthOut of specification Replace crankshaft.
Crank width:55.95 56.00 mm
4. Inspect:Timing chain sprocket 1Wear/Damage Replace crankshaft.
Bearing 2Wear/Crack/Damage Replace crank-shaft.
5. Inspect:Crankshaft journalClogged Blow out the journal with com-pressed air.
4-55
CRANKCASE AND CRANK SHAFT ENG
CAUTION:
NOTE:
7 Nm (0.7 mkg)
NOTE:
SR******
PLUNGER SEAL INSTALLATION1. Install:Compression spring 1Plunger seal 2Dowel pin 3
2. Check the plunger seal smooth operationpushing the plunger seal by your finger.
T*****
BALANCER WEIGHT INSTALLATION1. Install:Crankshaft assembly 1Balancer weight assembly 2
Do not use the hammer forcefully duringinstallation of the crankshaft. Damage thecrankcase oil seal lip and gear teeth.
SR404073
CRANKCASE INSTALLATION1. Clean all the gasket mating surface and
crankcase mating surface thoroughly.2. Apply:Sealant(onto the crankcase mating surfaces)
Yamaha bond No.1215:90890-85505
DO NOT ALLOW any sealant to come in con-tact with the oil gallery a .
3. Tighten:Crankcase right half
Tighten the screws in decreasing numerical or-der (see numbers on the illustration).
4-56
TRANSMISSION SIFT CAM AND SHIFT FORK ENG
Order Job name/Part name Q’ty Remarks
123456789
10
Transmission, shift cam and shift fork removalCrankcase separating
Shift fork guide bar 2 (short length)Shift fork guide bar 1 (long length)Shift camShift fork 1 “C” (center)Shift fork 2 “R” (right)Shift fork 3 “L” (left)Main axle assemblyPlate washerDrive axle assemblyPlate washer
1111111111
Remove the parts in order.
Refer to “CRANKCASE AND CRANKSHAFT” section.
Refer to “TRANSMISSION, SHIFT CAMAND SHIFT FORK INSTALLATION” section.
Reverse the removal procedure forinstallation.
Refer to “TRANSMISSION, SHIFT CAMAND SHIFT FORK REMOVAL/INSTALLATION” section.
TRANSMISSION, SHIFT CAM AND SHIFT FORK
4-57
TRANSMISSION SIFT CAM AND SHIFT FORK ENG
Order Job name/Part name Q’ty Remarks
Drive axle and main axle disassemblySecond wheel gearFirst wheel gearFifth wheel gearCirclip/washerThird wheel gearForth wheel gearDrive axleSecond pinion gearForth pinion gearThird pinion gearCirclip/washerFifth pinion gear gearMain axle
111
1/1111111
1/111
Disassemble the parts in order.
Reverse the disassembly procedure forassembly.
8
1234567
910111213
DRIVE AXLE AND MAIN AXLE
4-58
TRANSMISSION SIFT CAM AND SHIFT FORK ENG
WARNING
SR******
TRANSMISSION, SHIFT CAM AND SHIFTFORK REMOVAL1. Install:O-Ring 1To the drive sprocket groove.
2. Remove:Drive axle assembly 1Main axle assembly 2Remove them at same the time.
T402190
SHIFT FORK SHIFT CAM INSPECTION1. Inspect:Shift fork cam follower 1Shift fork pawl 2Scoring/bends/wear/damage Replace.
2. Inspect:Shift cam groovesWear/damage/scratches Replace.
Shift cam segmentDamage/wear Replace.
3. Inspect:Shift fork 1 “C” (center) 1Shift fork 2 “R” (right) 2Shift fork 3 “L” (left) 3Guide bar 4Shift cam 5Dowel pin 6Roll the guide bar on a flat surface.Bends Replace.
Do not attempt to straighten a bent guidebar.
4-59
TRANSMISSION SIFT CAM AND SHIFT FORK ENG
NOTE:
NOTE:
NOTE:
4. Check:Shift fork movement(on the guide bar)Unsmooth operation Replace the shiftfork and the guide bar.
When damaged the shift fork and mission gear,replace the facing each gear as set.
SR******
TRANSMISSION, SHIFT CAM AND SHIFTFORK INSTALLATION1. Measure:Main axle assembled length a
Assembled length (main axle):90.9 91.1 mm
2. Install:O-ring 1To the drive sprocket folder groove.
3. Install:Shift fork 3 “L” (left) 1(face the “L” side for the clutch side.)
Shift fork 2 “R” (right) 2(face the “R” side for the clutch side.)
Shift fork 1 “C” (center) 3(face the “C” side for the magneto side.)
Shift fork guide bar 1 4 (long)Shift fork guide bar 2 5 (short)
Install the shift forks with the embossed mark tothe right and in sequence (R, C, L) beginningfrom the right.
4. Check:Shift cam operationUnsmooth operation Repair.
Check the transmission and shift forks forsmooth operation by turning the shift cam withyour hand.
ENG
CHAPTER 5.CARBURETION
CARBURETOR 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR ASSEMBLY 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LEVEL ADJUSTMENT 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
CARBURETOR CARB
Order Job name/Part name Q’ty Remarks
1234
Carburetor removalSide coverSeatFuel tankHeater unit lead
Carburetor joint clamp screwAir filter joint clamp screwCarburetor assemblyCarburetor top
1111
Remove the parts in order.
NOTE:
Refer to “SIDE COVER, SEAT AND FUEL TANK” section in CHAPTER 3.
Disconnect the cable from wireharness.
Loosen.
Reverse the removal procedure forinstallation.
NOTE:
EB600000
CARBURETIONCARBURETOR
5-2
CARBURETOR CARB
Order Job name/Part name Q’ty Remarks
Carburetor disassemblyThrottle cableThrottle valve assemblyThrottle valve springMixing chamber top/O-ringDrain screw assemblyFloat chamberGasket (float chamber)Float pin/floatNeedle valve assemblyMain jetMain nozzle/O-ring
111
1/1111
1/111
1/1
Disassemble the parts in order.
Refer to “CARBURETOR ASSEMBLY” section.
1
10
23456789
11
5-3
CARBURETOR CARB
Order Job name/Part name Q’ty Remarks
Pilot screw assemblyPilot jetThrottle stop screw assemblyStarter plunger assemblyScrew/gasketHeater unit /washer
1111
1/11/1
Reverse the disassembly procedure forassembly.
Refer to “CARBURETOR ASSEMBLY” section.
121314151617
5-4
CARBURETOR CARB
CAUTION:
New
SR******
CARBURETOR ASSEMBLY
Do not use a wire for cleaning.Before assembling, wash all parts in cleanpetroleum based solvent.
Always use a new gasket.
1. Install:Pilot jet 1Pilot screw assembly 2
Pilot screw (turn out):2 turns out
2. Install:O-ring Main nozzle 1Main jet 2
3. Install:Valve seat 1Needle valve 2
4. Install:Float 1Float pin 2
5-5
CARBURETOR CARB
***************************************
***************************************
YP600060
FUEL LEVEL ADJUSTMENT1. Measure:Fuel level aOut of specification Adjust.
Fuel level:2.5 3.5 mm below the float chamber line
Measurement and adjustment steps:Place the motorcycle on a level surface.Put a garage jack under the engine to ensurethat the carburetors are positioned vertically.
Connect the fuel level gauge 1 to the drainpipe 2 .
Fuel level gauge:90890-01312
Loosen the drain screw 3 .Hold the gauge vertically next to the floatchamber line.
Measure the fuel level a with the gauge. If the fuel level is incorrect, adjust the fuel level.Remove the carburetor. Inspect the valve seat and needle valve. If either is worn, replace them both. If both are fine, adjust float level by bending thefloat tang 4 slightly.
Install the carburetor.Recheck the fuel level.
CARB
CHAPTER 6.CHASSIS
FRONT WHEEL AND BRAKE DISC 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL DISASSEMBLY 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL INSPECTION 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DISC INSPECTION 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL ASSEMBLY 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL INSTALLATION 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL STATIC BALANCE ADJUSTMENT 6-6. . . . . . . . . . . . . . . . . . . .
FRONT BRAKE 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD REPLACEMENT 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER INSPECTION 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER ASSEMBLY 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER INSTALLATION 6-13. . . . . . . . . . . . . . . . . . . . . . . . . CALIPER 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE CALIPER DISASSEMBLY 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER INSPECTION 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE CALIPER ASSEMBLY 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER INSTALLATION 6-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN 6-20. . . . . . . . . . . . . . . . REAR WHEEL AND REAR BRAKE 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CHAIN 6-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL DISASSEMBLY 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL INSPECTION 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE INSPECTION 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CHAIN INSPECTION 6-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SHOE PLATE ASSEMBLY 6-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL ASSEMBLY 6-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CHAIN INSTALLATION 6-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK 6-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK DISASSEMBLY 6-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSPECTION 6-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK ASSEMBLY 6-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSTALLATION 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR 6-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR REMOVAL 6-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR INSPECTION 6-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR INSTALLATION 6-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING 6-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDER BRACKET 6-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING REMOVAL 6-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING INSPECTION 6-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING INSTALLATION 6-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER AND SWINGARM 6-43. . . . . . . . . . . . . . . . . . . . SWINGARM INSPECTION 6-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
FRONT WHEEL AND BRAKE DISC CHAS
Order Job name/Part name Q’ty Remarks
12
34567
Front wheel and brake disc removal
Speedometer cableAxle pinch bolt
Wheel axleFront wheel assemblyCollarMeter gear unit assemblyBrake disc
11
11111
Remove the parts in order.
Loosen the axle pinch bolt.NOTE:
59 Nm (5.9 mkg)
20 Nm (2.0 mkg)
23 Nm (2.3 mkg)
Securely support the motorcycle sothere is no danger of it falling over.
Refer to “FRONT WHEEL INSTALLATION” section.
Refer to “FRONT WHEEL ASSEMBLY”section.Reverse the removal procedure forinstallation.
WARNING
EB700000
CHASSISFRONT WHEEL AND BRAKE DISC
6-2
FRONT WHEEL AND BRAKE DISC CHAS
Front wheel disassemblyOil seal
BearingSpacerSpacer flangeBearing
Order Job name/Part name Q’ty Remarks
1
1111
Disassemble the parts in order.Refer to “FRONT WHEEL ASSEMBLY”section.
Refer to “FRONT WHEEL DISASSEMBLY/ASSEMBLY” section.
Reverse the disassembly procedure forreassembly.
1
2345
6-3
FRONT WHEEL AND BRAKE DISC CHAS
CAUTION:
WARNING
NOTE:
NOTE:
T******
FRONT WHEEL DISASSEMBLY1. Remove:Bearings 1SpacerRemove the bearings using a general bear-ing puller 2 .
Handle the wheel with care not to damagethe brake disc. If the brake disc is damaged,replace.
T700021
FRONT WHEEL INSPECTION1. Inspect:Front wheel axle(by rolling it on a flat surface)Bends Replace.
Do not attempt to straighten a bent axle.
Wheel axle bending limit:0.25 mm
2. Inspect:Front tireWear/damage Replace.Refer to “TIRE INSPECTION” in CHAPTER3.
Front wheelRefer to “WHEEL INSPECTION” in CHAP-TER 3.
3. Check:SpokesBends/damage Replace.Loose spokes Retighten.Turn the wheel and tap the spokes with ascrewdriver.
A tight spoke will emit a clear, ringing tone; aloose spoke will sound flat.
4. Tighten:Loose spokesNipple
Check the front wheel runout after tighteningthe spokes.
6-4
FRONT WHEEL AND BRAKE DISC CHAS
NOTE:
5. Measure:Front wheel runoutOver the specified limits Replace.
Front wheel runout limits:Radial 1 : 2.0 mmLateral 2 : 2.0 mm
6. Inspect:Front wheel bearingsBearings allow free play in the wheel hub orthe wheel does not turn smoothly Replace.
Oil sealsWear/damage Replace.
7. Inspect:CollarGrooved wear Replace the collar and theoil seal as a set.
YP******
BRAKE DISC INSPECTION1. Measure:Brake disc deflection
Maximum deflection:0.15 mm
Out of specification Replace.2. Measure:Brake disc thickness
Brake disc thickness:4.0 mm
Minimum thickness:3.5 mm
Out of specification Replace.YP******
FRONT WHEEL ASSEMBLY1. Install:Bearing 1Spacer 2Spacer flange 3Bearing 4Oil seal 5
Apply the lithium soap base grease on thebearing and oil seal lip when installing.
Use a socket that matches the outside diame-ter of the race of the bearing.
Always use a new oil seal. Install the oil seal with its manufacturer’smarks or numbers facing outward.
6-5
FRONT WHEEL AND BRAKE DISC CHAS
CAUTION:
23 Nm (2.3 mkg)
NOTE:
NOTE:
NOTE:
Do not strike the inner race of balls of thebearing. Contact should be made only withthe outer race.
2. Install:Brake disc 1
Tighten the bolts (brake disc) in stage using acrisscross pattern.
SR700030
FRONT WHEEL INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Lubricate:Front wheel axleBearingsOil seal (lips)Drive/driven gear (speedometer)
Recommended lubricant:Lithium soap base grease
2. Install:Speedometer gear unit 1
Make sure that the wheel hub and thespeedometer gear unit are installed with the twoprojections a meshed into the two slots b .
3. Install:Front wheel
Make sure that the slot a in the speedometergear unit fits over the stopper b on the front forkouter tube.
6-6
FRONT WHEEL AND BRAKE DISC CHAS
59 Nm (5.9 mkg)
20 Nm (2.0 mkg)
CAUTION:
WARNING
NOTE:
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***************************************
4. Tighten:Front wheel axleAxle pinch bolt
Before tightening the wheel axle, stroke thefront fork several times to check for properfork operation.
Make sure that the brake hose is routedproperly.
YP700040
WHEEL STATIC BALANCE ADJUSTMENT
After replacing the fire and/or rim, the wheelstatic balance should be adjusted.
Adjust the front wheel static balance with thebrake disc installed.
1. Remove:Balancing weight 1
2. Set:Wheel(on a suitable stand)
3. Find:Heavy spot
Procedure:a. Spin the wheel and wait for it to rest.b. Put an “X1” mark on the wheel’s bottom spot.c. Turn the wheel so that the “X1” mark is 90
up.d. Release the wheel and wait for it to rest.
Put an “X2” mark on the wheel’s bottom spot.e. Repeat the above b., c., and d. several times
until all marks come to the same spot.f. This spot is the wheel’s heavy spot “X”.
6-7
FRONT WHEEL AND BRAKE DISC CHAS
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NOTE:
***************************************
***************************************
***************************************
4. Adjust:Wheel static balance
Adjusting steps: Install a balancing weight 1 on the rim exactlyopposite to the heavy spot “X”.
Start with the smallest weight.
Turn the wheel so that the heavy spot is 90up.
Check that the heavy spot is at rest there. Ifnot, try another weight until the wheel is bal-anced.
5. Check:Wheel static balance
Checking steps:Turn the wheel so that it comes to each pointas shown.
Check that the wheel is at rest at each point.If not, readjust the front wheel static balance.
6-8
FRONT BRAKE CHAS
Order Job name/Part name Q’ty Remarks
123
Brake pad removalBolt (caliper support bolt)Brake padsPad support
121
Remove the parts in order.
Refer to “BRAKE PAD REPLACEMENT”section.
Reverse the removal procedure forinstallation.
23 Nm (2.3 mkg)
FRONT BRAKEBRAKE PAD
6-9
FRONT BRAKE CHAS
NOTE:
NOTE:
CAUTION:
23 Nm (2.3 mkg)
SR702010
BRAKE PAD REPLACEMENT
It is not necessary to disassemble the brake cal-iper and brake hose to replace the brake pads.
1. Remove:Bolt (caliper support bolt) 1Move the direction brake caliper 2 to the ar-row mark.
2. Remove:Brake pads 1
Install new brake pad springs 2 when thebrake pads have to be replaced.
Replace the brake pads as a set if either isfound to be worn to the wear limit.
3. Push the caliper piston into the brake caliperby finger.
When pushing the caliper piston into thebrake caliper, brake fluid level in reservoirtank is increasing higher.
4. Install:Brake pad 1Install the brake pad, and move the brakecaliper to the allow mark direction.
5. Install:Bolt (caliper support bolt)
6. Inspect:Brake fluid levelRefer to “BRAKE FLUID LEVEL INSPEC-TION” section in CHAPTER 3.
7. Check:Brake lever operationSoft spongy feeling Bleed the brake sys-tem.Refer to “AIR BLEEDING (HYDRAULICBRAKE SYSTEM)” in CHAPTER 3.
6-10
FRONT BRAKE CHAS
Order Job name/Part name Q’ty Remarks
12345678
Master cylinder removalDrain the brake fluidRear view mirror (right)Brake lever/compression springBrake switchUnion boltPlate washerBrake hoseBracket (master cylinder)Master cylinder
11/1112111
Remove the parts in order.
Refer to “MASTER CYLINDER INSTALLATION” section.
Reverse the removal procedure forinstallation.
2 Nm (0.2 mkg)
9 Nm (0.9 mkg)
30 Nm (3.0 mkg)
MASTER CYLINDER
6-11
FRONT BRAKE CHAS
Master cylinder disassemblyRubber bootsCirclipMaster cylinder kitSpring
Order Job name/Part name Q’ty Remarks
111
Disassemble the parts in order.
Refer to “MASTER CYLINDER ASSEMBLY” section.
Reverse the disassembly procedure forreassembly.
1234
6-12
FRONT BRAKE CHAS
WARNING
YP702040
MASTER CYLINDER INSPECTION1. Inspect:Master cylinder piston 1Wear/scratches Replace the master cyl-inder kit.
Master cylinder cup 2Cracks/damage Replace.
2. Inspect:Master cylinderScratches/wear/damage Replace themaster cylinder assembly.
3. Inspect:DiaphragmWear/damage Replace.
YP******
MASTER CYLINDER ASSEMBLY
All internal brake components should becleaned and lubricated with new brakefluid only before installation.
Recommended brake fluid:DOT #4 or DOT #3
Replace the piston seals and dust sealswhenever a master cylinder is disas-sembled.
1. Install:Spring 1Install the spring with its smaller diameter tothe master cylinder piston.
Master cylinder kit 2
6-13
FRONT BRAKE CHAS
A
New
9 Nm (0.9 mkg)
CAUTION:
New
New30 Nm (3.0 mkg)
NOTE:
CAUTION:
2. Install:Circlip 1 Install the circlip securely into the master cyl-inder groove.
Rubber boot 2
YP******
MASTER CYLINDER INSTALLATION1. Install:Master cylinder 1Master cylinder bracket 2
Install the master cylinder bracket 2 withthe “UP” mark facing upward.
2. Install:Plain washer 1 Brake hose 2Plain washer 3 Union bolt 4
Install the brake hose as shown.
3. Fill:Reservoir tank
Recommended brake fluid:DOT #4 or DOT #3
Brake fluid may damage painted surfaces orplastic parts. Always clean up spilled brakefluid immediately.
6-14
FRONT BRAKE CHAS
WARNING
Use only designated quality brake fluid:Otherwise, the rubber seals may deterio-rate, causing leakage and poor brake per-formance.
Refill with the same type of brake fluid:mix-ing fluids may result in a harmful chemicalreaction and lead to poor performance.
Be careful that water does not enter the sig-nificantly lower the boiling point of thefluid may result in vapor lock.
4. Air bleed:Brake systemRefer to “AIR BLEEDING” section in CHAP-TER 3.
5. Inspect:Brake fluid levelBrake fluid level is under the “LOWER” levelline Fill up.Refer to “BRAKE FLUID INSPECTION” section in CHAPTER 3.
6-15
FRONT BRAKE CHAS
Order Job name/Part name Q’ty Remarks
123456
Caliper removalDrain teh brake fluidBrake hose holderUnion boltPlain washerBrake hoseCaliper support boltCaliper assembly
111111
Remove the parts in order.
Refer to “CALIPER INSTALLATION”section.
23 Nm (2.3 mkg)
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
Reverse the removal procedure forinstallation
CALIPER
6-16
FRONT BRAKE CHAS
Order Job name/Part name Q’ty Remarks
Caliper disassemblyBrake padCaliper pistonDust sealPiston sealBleed screw/Cap
2221
Disassemble the parts i order.Refer to “BRAKE PAD” section.
Refer to “BRAKE CALIPER DISASSEMBLY/ASSEMBLY” section.
Reverse the disassembly procedure forreassembly.
6 Nm (0.6 mkg)
1234
6-17
FRONT BRAKE CHAS
NOTE:
***************************************
WARNING
***************************************
WARNING
SR******
BRAKE CALIPER DISASSEMBLY
Before disassembling either brake caliper,drain the brake fluid from the brake hose, mas-ter cylinder, brake caliper and reservoir tank.
1. Remove:Brake caliper pistonsCaliper piston seals/dust seals
Removal steps:Use a piece of wood 1 to secure the smallerside caliper pistons.
To force out the bigger side caliper pistonsfrom the brake caliper body blow compressedair into the hose joint opening a .
Remove the caliper piston seals and reinstallthe bigger side caliper pistons.
Repeat the previous steps to force out thesmaller side caliper pistons from the brake cal-iper body.
Never try to pry out the caliper piston.
YP******
CALIPER INSPECTION1. Inspect:Caliper cylinder 1Caliper piston 2Scratches, wear Replace caliper assem-bly.
EB702050
BRAKE CALIPER ASSEMBLY
All internal brake components should becleaned and lubricated with new brakefluid only before installation.
Recommended brake fluid:DOT #4 or DOT #3
Replace the caliper piston seals whenevera brake caliper is disassembled.
6-18
FRONT BRAKE CHAS
New
New
WARNING
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)
New
30 Nm (3.0 mkg)
CAUTION:
CAUTION:
1. Install:Piston seals 1 Dust seal 2
Always use new caliper piston seals.
2. Install:Caliper piston 1Apply brake fluid to the outer surface andinstall.
YP******
CALIPER INSTALLATION1. Install:Caliper 1Caliper support bolt 2
Brake hose 3Plain washer 4 Union bolt 5
When installing the brake hose to the cali-per, lightly touch the brake hose with thestopper a on the caliper.
2. Fill:Reservoir tank
Recommended brake fluid:DOT #4 or DOT #3
Brake fluid may damage painted surfaces orplastic parts. Always clean up spilled brakefluid immediately.
6-19
FRONT BRAKE CHAS
WARNING
Use only the designated quality brakefluid: other brake fluids may deteriorate therubber seals, causing leakage and poorbrake performance.
Refill with the same type of brake fluid:mixing brake fluids may result in a harmfulchemical reaction and lead to poor brakeperformance.
Be careful that water does not enter themaster cylinder when refilling. Water willsignificantly lower the boiling point of thebrake fluid and may result in vapor lock.
3. Air bleed:Brake systemRefer to “AIR BLEEDING (HYDRAULICBRAKE SYSTEM)” in CHAPTER 3.
4. Inspect:Brake fluid levelBrake fluid level is under the “LOWER” levelline Fill up.Refer to “BRAKE FLUID LEVEL INSPEC-TION” in CHAPTER 3.
6-20
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN CHAS
Order Job name/Part name Q’ty Remarks
123456
789
1011
Rear wheel and rear brake removalAdjusterBrake rodPinCompression springCotter pinTension bar
Chain caseAxle nutChain pullerWheel axleCollar
111111
11211
Remove the parts in order.
Bend the end after installing.NOTE:
40 Nm (4.0 mkg)
65 Nm (6.5 mkg)
20 Nm (2.0 mkg)
REAR WHEEL, REAR BRAKE AND DRIVE CHAINREAR WHEEL AND REAR BRAKE
6-21
REAR WHEEL REAR BRAKE AND DRIVE CHAIN CHAS
Order Job name/Part name Q’ty Remarks
12131415161718
Rear wheel assemblyCollarShoe plateNut (driven sprocket)CirclipWasherDriven sprocket
1114111
Reverse the removal procedure forinstallation.
Refer to “REAR WHEEL ASSEMBLY” section.
65 Nm (6.5 mkg)
20 Nm (2.0 mkg)
40 Nm (4.0 mkg)
6-22
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN CHAS
Order Job name/Part name Q’ty Remarks
Rear wheel disassemblyBearingCollarSpacerOil sealBearing
11111
Disassemble the parts in order.
Refer to “REAR WHEEL DISASSEMBLY/ASSEMBLY” section.
Reverse the disassembly procedure forreassembly.
12345
6-23
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN CHAS
Order Job name/Part name Q’ty Remarks
Brake shoe plate disassemblyBrake shoe kitTension springsCam leverIndicator plateCamshaft
22111
Disassemble the parts in order.
Refer to “BRAKE SHOE PLATE ASSEMBLY” section.
Reverse the disassembly procedure forreassembly.
12345
9 Nm (0.9 mkg)
6-24
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN CHAS
Order Job name/Part name Q’ty Remarks
1
23456789
Drive chain removalChain case
Axle nut
Shift pedalSprocket coverSprocket holderClipPlateChain jointDrive chainDrive sprocket
1
11111111
Remove the parts in order.Refer to “REAR WHEEL, REAR BRAKEAND DRIVE CHAIN” section.NOTE:
Refer to “DRIVE CHAIN INSTALLATION”section.
Loosen the axle nut and slacken thedrive chain.
Reverse the removal procedure forinstallation.
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)
65 Nm (6.5 mkg)
8 Nm (0.8 mkg)
DRIVE CHAIN
6-25
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN CHAS
WARNING
T******
REAR WHEEL DISASSEMBLY1. Remove:Bearings 1Spacer 2Collar 3Refer to “FRONT WHEEL”.
SR701020
REAR WHEEL INSPECTION1. Inspect:Rear wheel axleRear wheelRear wheel bearingsOil sealsRefer to “FRONT WHEEL”.
2. Inspect:Clutch hub damperWear/damage Replace.
SR701021
REAR BRAKE INSPECTION1. Inspect:Brake lining surfaceWear/damage Replace.
2. Measure:Brake lining thickness aOut of specification Replace.
Brake lining thickness:Standard:
4 mmLimit:
2 mm
When inspecting the brake lining, do notspill oil or grease on the brake lining.
3. Inspect:Brake drum inner surfaceOilScratchesWear/damage Replace.
4. Measure:Brake drum inside diameter aOut of specification Replace.
Brake drum inside diameter:Standard:
110 mmLimit:
111 mm
6-26
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN CHAS
NOTE:
5. Inspect:Cam shaft face
T701020
DRIVE CHAIN INSPECTION1. Inspect:Drive chain stiffnessStiffness Clean and lubricate or replace.
2. Inspect:Drive chain 1Driven sprocket 2More than 1/2 tooth a wear Replace thedrive chain.Use new driven sprocket.
3. Measure:10 link length a (drive chain)Out of specification Replace the drivechain.
10 link length limit:122 mm
Tighten the drive chain with a finger beforemeasuring.
10 link length is the distance between the inside edge of roller 1 and 11 as shown.
10 link length measurement should be done attwo or three different places.
6-27
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN CHAS
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***************************************9 Nm (0.9 mkg)
NOTE:
New
NOTE:
WARNING
4. Clean:Drive chainPut it in kerosene, and brush off as much dirtas possible. Then remove the drive chainfrom the kerosene and dry it.
Drive chain lubricant:Engine oil
SR******
BRAKE SHOE PLATE ASSEMBLY1. Install:Camshaft 1 Indicator plate 2
Installation steps:Align the projection a on the indicator platewith the camshaft notch b and install.
Check the proper position of the brake shoe.
2. Install:Cam lever 1
Align the punch mark c on the cam shaft withthe mark made on the cam lever d .
Apply lithium soap base grease onto the brakecam shaft and pin.
3. Install:Brake shoes 1Tension springs 2
When installing the springs and brake shoes,take care not to damage the springs.
Replace the tension spring as a set when re-place the brake shoes.
After installing the rear brake cam shaft, re-move the excess grease.
6-28
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN CHAS
NOTE:
CAUTION:
New40 Nm (4.0 mkg)
New
CAUTION:
SR******
REAR WHEEL ASSEMBLY1. Install:Bearing 1Spacer 2Collar 3Bearing 4
Apply the lithium soap base grease on thebearing and oil seal lip when installing.
Use a socket that matches the outside diame-ter of the race of the bearing.
Always use a new oil seal. Install the oil seal with its manufacturer’smarks or numbers facing outward.
Do not strike the inner race of balls of thebearing. Contact should be made only withthe outer race.
2. Install:Driven sprocket 1Washer 2Circlip 3 Nut 4
T*****
DRIVE CHAIN INSTALLATION1. Install:Drive chain 1Chain joint 2Plate 3
2. Install:Clip 1
Be sure to install the chain joint clip to thedirection as shown.
6-29
FRONT FORK CHAS
Order Job name/Part name Q’ty Remarks
123456
78
Front fork removalFront wheel
Brake hose holderCaliperFront fenderCoverBolt/washerBolt (under bracket)
Front fork assembly (left)Front fork assembly (right)
1111
1/11
11
Remove the parts in order.Refer to “FRONT WHEEL AND BRAKEDISC” section.
Loosen the bolt.NOTE:
Refer to “FRONT FORK INSTALLATION”section.
Reverse the removal procedure forinstallation.
48 Nm (4.8 mkg)
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
FRONT FORK
6-30
FRONT FORK CHAS
10
Order Job name/Part name Q’ty Remarks
Front fork disassemblyCap bolt /O-ringCollar/washerFork springDust coverRetaining clipWasher (oil seal)Inner tube assemblyOil sealPiston metalDamper rodOuter tube
1/11/1111111111
Drain the fork oil.NOTE:
Refer to “FRONT FORK DISASSEMBLY/ASSEMBLY” section.
Refer to “FRONT FORK ASSEMBLY” section.
Disassemble the parts in order.
Reverse the disassembly procedure forassembly.
123456789
11
65 Nm (86.5 mkg)
6-31
FRONT FORK CHAS
CAUTION:
***************************************
CAUTION:
***************************************
WARNING
SR******
FRONT FORK DISASSEMBLY1. Remove:Cap bolt 1Collar 2Washer 3Fork spring 4
2. Remove:Dust cover 1Retaining clip 2(using a slotted-head screwdriver)
Washer (oil seal) 3
Take care not to scratch the inner tube.
3. Remove: Inner tube
Removal steps:Hold the fork leg horizontally.Securely clamp the outer tube in a vise withsoft jaws.
Separate the inner tube from the outer tube bypulling forcefully but carefully the inner tube.
Excessive force will damage the oil sealand/or the metal. damaged oil seal and met-al must be replaced.
YP703030
FRONT FORK INSPECTION1. Inspect: Inner tube bending
Inner tube bending limit:0.2 mm
Scratches/bends/damage Replace.
Do not attempt to straighten a bent innertube as this may dangerously weaken thetube.
6-32
FRONT FORK CHAS
CAUTION:
NOTE:
NOTE:
2. Measure:Fork spring a
Front fork spring free length:326.1 mm
<Wear limit>321 mm
Over the specified limit Replace.
3. Inspect:Rod assembly 1Bends/damage Replace.
The front fork has a built-in piston rod anda very sophisticated internal constructionwhich are particularly sensitive to foreignmaterial.
When disassembling and assembling thefront fork do not allow any foreign materialto enter the oil.
SR******
FRONT FORK ASSEMBLYReverse the “DISASSEMBLY” procedure.Note the following points.
When assembling the front fork be sure to re-place the following parts.* Piston metal* Slide metal* Oil seal* Dust seal
Before assembling the fork, make sure that allof the components are clean.
1. Install:Damper rod 1 Inner tube 2
Install the damper rod into the inner tube beforeinstall to the outer tube.
6-33
FRONT FORK CHAS
New
New
NOTE:
CAUTION:
New
NOTE:
2. Install:Piston metal 1 Oil seal 2 Use the fork seal driver weight 3 and the at-tachment 4 .
Before installing the oil seal 2 , apply lithiumsoap base grease onto the oil seal lips.
Make sure that the oil seal numbered sidefaces upward.
Fork seal driver weight:90890-01400
Attachment:90890-01367
3. Install:Washer (oil seal) 1Retaining clip 2 Dust seal 3
Adjust the retaining clip so that it fits into the out-er tube groove.
4. Inspect: Inner tube operationUnsmooth operation Disassembly and re-check.
5. Fill:Fork oil 1
Oil quantity:0.177 L
Recommended oil:Fork oil 15WT or equivalent
6. After filling up, slowly pump the fork up anddown to distribute the fork oil.
6-34
FRONT FORK CHAS
NOTE:
NOTE:
New65 Nm (6.5 mkg)
NOTE:
48 Nm (4.8 mkg)
30 Nm (3.0 mkg)
7. Measure:Oil level aOut of specification Adjust.
Oil level:165 mm
(from the top of the inner tube fully compressed and without the fork spring)
Hold the fork in an upright position.
8. Install:Front fork spring 1
Install the fork spring with its smaller pitch up-ward.
Before installing the cap bolt, apply grease tothe O-ring.
Temporarily tighten the cap bolt.
9. Install:Plate washerSpacerO-ring Cap bolt
EB70307250
FRONT FORK INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Install:Front fork 1Plate washer 2Temporary tighten the pinch bolts.
Pull up the inner tube until its end flushes the topof the under bracket, then temporarily tightenthe bolt (under bracket lower).
2. Tighten:Cap bolts 3Pinch bolts (under bracket)
6-35
HANDLEBAR CHAS
Order Job name/Part name Q’ty Remarks
12
3456789
10
Handlebar removalHeadlight assemblyHandlebar switch lead (left and right),front brake switch lead and clutchswitch leadMaster cylinder bracketMaster cylinderHousing (throttle grip)Throttle cableThrottle grip assemblyHandle bar switch (right)Clutch switchClutch cable
11
11111111
Remove the parts in order.
Disconnect the connector.NOTE:
Refer to “HANDLEBAR INSTALLATION”section.
9 Nm (0.9 mkg)
20 Nm (2.0 mkg)
HANDLEBAR
6-36
HANDLEBAR CHAS
Order Job name/Part name Q’ty Remarks
1112
131415
Handlebar switch (left)Grip (left)
Lever holder (left)Upper holderHandlebar
11
121
Refer to “HANDLEBAR REMOVAL” section.
Refer to “HANDLEBAR INSTALLATION”section.
Reverse the removal procedure forinstallation.
9 Nm (0.9 mkg)
20 Nm (2.0 mkg)
6-37
HANDLEBAR CHAS
***************************************
***************************************
WARNING
20 Nm (2.0 mkg)
NOTE:
NOTE:
WARNING
YP******
HANDLEBAR REMOVAL1. Remove:Grip (Left)
Removal steps:Remove the grip end (left).Blow with compressed air between the hadle-bar and adhesive side of the grip to remove.
YP704020
HANDLEBAR INSPECTION1. Inspect:HandlebarBends/Cracks/Damage Replace.
Do not attempt to straighten a bent handle-bar as this may dangerously weaken thehandlebar.
SR******
HANDLEBAR INSTALLATION1. Install:Handlebar 1Upper handlebar holder 2
Apply a light coat of lithium soap base greaseonto the handlebar right end.
The upper handlebar holders should beinstalled with the longer side a to the forward,then tighten the front bolt as shown.
2. Install:Handlebar switch (right) 1Grip assemblyThrottle cableCover (throttle grip)
Align the projection a on the handlebar switchwith the hole b in the handlebar.
Check the throttle grip for smooth opera-tion.
6-38
HANDLEBAR CHAS
9 Nm (0.9 mkg)
NOTE:
3. Install:Master cylinder 1Master cylinder bracket 2
Install the master cylinder bracket with the “UP”mark facing upward.
4. Adjust:Throttle cable free playBrake operation.Refer to “THROTTLE CABLE ADJUST-MENT/BRAKE LEVER ADJUSTMENT”section in CHAPTER 3.
6-39
STEERING CHAS
Order Job name/Part name Q’ty Remarks
1234567
89
Under bracket removalFront forkHandlebarFlasher light assembly (left)Flasher light assembly (right)CoverMeter cable/Meter leadMeter assembly/Handlebar crownHornRing nut
Ball race coverUnder bracket
111
1/11/111
11
Remove the parts in order.Refer to “FRONT FORK” section.Refer to “HANDLEBAR” section.
Disconnect the connector.NOTE:
Refer to “STEERING REMOVAL/INSTALLATION” section.
40 Nm (4.0 mkg)1st step:38 Nm (3.8 mkg)2nd step:7 Nm (0.7 mkg)
STEERINGUNDER BRACKET
6-40
STEERING CHAS
Order Job name/Part name Q’ty Remarks
1011121314
Ball race (upper)BallBallBall race (center)Ball race (lower)
1221911
Reverse the removal procedure forinstallation.
Refer to “STEERING REMOVAL/INSTALLATION” section.
40 Nm (4.0 mkg)1st step:38 Nm (3.8 mkg)2ndstep:7 Nm (0.7 mkg)
6-41
STEERING CHAS
WARNING
WARNING
***************************************
***************************************NOTE:
CAUTION:
YP704010
STEERING REMOVAL
Securely support the motorcycle so thatthere is no danger of it falling over.
Stand the motorcycle on a level surface.
1. Remove:Ring nut 1Use a exhaust and steering nut wrench 2 .
Exhaust and steering out wrench:90890-01268
Securely support the steering shaft so thatthere is no danger of it falling down.
STEERING INSPECTION1. Wash the bearing and ball races with a sol-
vent.2. Inspect:BearingsBall racesPitting/Damage Replace.
Bearing race replacement steps:Remove the ball races on the head pipe usinglong rod 1 and the hammer as shown.
Remove the ball race on the under bracket us-ing the floor chisel 2 and the hammer asshown.
Install the new dust seat and races.
Always replace bearings and races as a set.Replace the dust seal whenever a steeringhead disassembled.
If the bearing race is not fitted squarely, thehead pipe could be damaged.
6-42
STEERING CHAS
7 Nm (0.7 mkg)
EB704030
STEERING INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Lubricate:Bearings (upper and lower)Ball races
Recommended lubricantLithium-soap base grease
2. Install:Ring nut 1Refer to “STEERING HEAD INSPECTION”section in CHAPTER 3.
6-43
REAR SHOCK ABSORBER AND SWINGARM CHAS
Order Job name/Part name Q’ty Remarks
123456789
Rear shock absorber and swingarmremovalRear wheelChain caseDrive chainRear shock absorberNutFootrest assembly (right)Pivot shaftFootrest assembly (left)SwingarmTension barCover (swingarm)Bush
211111112
Remove the parts in order.
Refer to “REAR WHEEL, REAR BRAKEAND DRIVE CHAIN” section.
Reverse the removal procedure forinstallation.
40 Nm (4.0 mkg)
45 Nm (4.5 mkg)
20 Nm (2.0 mkg)
30 Nm (3.0 mkg)
REAR SHOCK ABSORBER AND SWINGARM
6-44
REAR SHOCK ABSORBER AND SWINGARM CHAS
T*****
SWINGARM INSPECTION1. Inspect:Swingarm side playFree play exists Check side clearance.
Swingarm up and down movementUnsmooth movement/bending/rough spots Grease or replace bearings, solid bushesand collars.
CHAPTER 7.ELECTRICAL
ELECTRICAL COMPONENTS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH INSPECTION 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION STEPS 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH CONNECTION AS SHOWN IN THIS MANUAL 7-2. . . . . . . . . SWITCH CONTINUITY INSPECTION 7-3. . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT OPERATION 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 7-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHTING SYSTEM CHECK 7-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM 7-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNAL SYSTEM CHECK 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
ELECTRICAL COMPONENTS ELEC
15 C.D.I. unit8 Neutral relay9 Thermo switch
10 Sidestand switch11 Rear brake switch12 Neutral switch13 Spark plug cap14 Ignition coil
1 Horn2 Flasher relay3 Main switch4 Starter relay5 Rectifier /Regulator6 Battery7 Fuse holder assembly
EB800000
ELECTRICALELECTRICAL COMPONENTS
7-2
SWITCH INSPECTION ELEC
NOTE:
YP-N
SWITCH INSPECTIONINSPECTION STEPSUsing pocket tester, check switches for continu-ity between their terminals to determine wheth-er they are correctly connected.Replace the switch component if any of thecombinations does not produce the correctreading.
Pocket tester:90890-03112
Turn the switch to the “ON”, “OFF” positionsseveral times.
Adjust the pocket tester to correct “0” positionbefore checking switches.
Set the pocket tester selector to “1” Ω.
SWITCH CONNECTION AS SHOWN IN THISMANUALThis manual contains connection charts, likethe one shown on the left, showing the terminalconnections of switches (e.g. the main switch,handlebar switch, brake switch, lighting switchetc.)
The column on the extreme left indicates the dif-ferent switch positions, the top line indicates thecolors of the leads connected to the terminalson the switch.
“—” indicates terminals between whichthere is continuity, i.e. a closed circuit, in the giv-en switch position.
In this chart:“Br and R” have continuity with the switch in the“ON” position.
7-3
1 Clutch switch2 Turn switch3 Dimmer switch4 Horn switch5 Main switch6 Front brake switch
7 Engine stop switch8 Start switch9 Rear brake switch
10 Neutral switch11 Sidestand switch12 Fuse
13 Thermo switch
SWITCH INSPECTION ELEC
SWITCH CONTINUITY INSPECTIONRefer to “SWITCH INSPECTION” and check for continuity between lead terminals.Poor connection, no continuity Correct or replace.* The coupler locations are circled.
7-4
1 C.D.I. magneto6 Main switch
10 Engine stop switch12 C.D.I. unit13 Ignition coil14 Spark plug15 Sidestand switch
IGNITION SYSTEM ELEC
EB802000
IGNITION SYSTEMCIRCUIT DIAGRAM
7-5
IGNITION SYSTEM ELEC
NOTE:
1. Spark plug
Check the spark plug condition.Check the spark plug type.Check the spark plug gap.Refer to “SPARK PLUG INSPECTION” sec-tion in CHAPTER 3.
Spark plug gap:0.6 0.7 mm
Standard spark plug:DR8EA/NGK
OUT OF SPECIFICATION
Repair or replace the spark plugMEETSSPECIFICATION
SR802010
TROUBLESHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE.(NO SPARK OR INTERMITTENT SPARK)
ProcedureCheck:1. Spark plug2. Ignition spark gap3. Spark plug cap resistance4. Ignition coil5. Pickup coil resistance
6. Source coil resistance7. Main switch8. Engine stop switch9. Sidestand switch
10. Wiring connection(entire ignition system)
Remove the following parts before trouble-shooting.
1) Side cover (left and right)2) Seat3) Fuel tank4) Headlight unit
Use the special tools specified in the troubleshooting section.
Ignition checker:90890-06754
Pocket tester:90890-03112
YP*****
7-6
IGNITION SYSTEM ELEC
Remove the spark plug cap.Connect the pocket tester (Ω 1k) to thespark plug cap.
When removing the spark plug cap, do notpull the spark plug cap from high tensioncord.Remove Turning counterclockwise.Connect Turning clockwise.
Check the high tension cord when connect-ing the spark plug cap.
When connecting the spark plug cap, cut thehigh tension cord about 5 mm.
NOTE:
Disconnect the spark plug cap from thespark plug.
Connect the ignition checker as shown. Spark plug cap
Turn the main switch to “ON”.Check the ignition spark gap .Check the spark by pushing the starterswitch, and increase the spark gap until amisfire occurs.
2. Ignition spark gap
Minimum spark gap:6 mm
The ignition system is not faulty.
MEETS SPECIFICATION
12
a
OUT OF SPECIFICA-TION OR NO SPARK
3. Spark plug cap resistance
Spark plug cap resistance:10 kΩ (20C)
MEETSSPECIFICATION
Tester (+) lead Spark plug side
Tester (–) lead High tension cord side
Replace the spark plug cap.
OUT OF SPECIFICATION
1
2
YP*****
YP*****
7-7
IGNITION SYSTEM ELEC
Tester (+) lead Spark plug lead
Tester (–) lead Orange Terminal
Disconnect the ignition coil connector fromthe wireharness.
Connect the pocket tester (Ω 1) to theignition coil.
Check if the primary coil has the specified re-sistance.
4. Ignition coil resistance
Secondary coil resistance:5.68 8.52 kΩ (20C)
BOTH MEETSPECIFICATION
Tester (+) lead Orange Terminal
Tester (–) lead Ground Terminal
Replace the ignition coil.
OUT OF SPECIFICATION
1
2
Primary coil resistance:0.32 0.48 Ω (20C)
1
2
Connect the pocket tester (Ω 1k) to theignition coil.
Check the secondary has the specified re-sistance.
YP*****
7-8
Tester (+) lead White Terminal
Tester (–) lead Red Terminal
Tester (+) lead Brown Terminal
Tester (–) lead Green Terminal
Disconnect the pickup coil coupler from thewireharness.
Connect the pocket tester (Ω 100) to thepickup coil coupler.
5. Pickup coil resistance
Replace the pickup coil.
OUT OF SPECIFICATION
Pickup coil resistance:659 984 Ω (20C)
1
2
Check the pickup coil has the specified re-sistance.
MEETSSPECIFICATION
Disconnect the source coil coupler from thewireharness.
Connect the pocket tester (Ω 100) to thecharging coil coupler.
6. Source coil resistance
Source coil resistance:624 936 Ω (20C)
1
2
Check the source coil has the specified re-sistance.
Replace the source coil.
OUT OF SPECIFICATION
MEETSSPECIFICATION
Refer to “SWITCH INSPECTION” section.
7. Main switch
CONTINUITY
Replace the main switch.
NO CONTINUITY
IGNITION SYSTEM ELEC
YP******
T******
YP*****
7-9
IGNITION SYSTEM ELEC
Refer to “SWITCH INSPECTION” section.
8. Engine stop switch
Replace the handlebar switch (right).
NO CONTINUITY
CONTINUITY
Refer to “SWITCH INSPECTION” section.
9. Sidestand switch
Replace the sidestand switch
NO CONTINUITY
CONTINUITY
Check the connection of the entire ignitionsystem.Refer to “CIRCUIT DIAGRAM”.
10.Wiring connection
Correct.
POOR CONNECTIONS
CORRECT
Replace the C.D.I. unit.
YP*****
YP*****
YP*****
7-10
3 Starter relay4 Battery5 Fuse6 Main switch10 Engine stop switch11 Start switch15 Clutch switch16 Sidestand switch17 Neutral relay24 Neutral switch38 Starter motor
ELECTRIC STARTING SYSTEM ELEC
EB80300
ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM
7-11
ELECTRICAL STARTING SYSTEM ELEC
SR******
STARTING CIRCUIT OPERATIONThe starting circuit on this model consists of thestarter motor, starter relay, and the neutral relay.If the engine stop switch and the main switchare both closed, the starter motor can operateonly if:
The transmission is in neutral (the neutralrelay is closed).
or if
The clutch lever is pulled to the handlebar(the clutch switch is closed) and the side-stand is up (the sidestand switch is closed).
WHEN THE TRANSMISSION IS INNEUTRAL
WHEN THE SIDESTAND IS UP ANDTHE CLUTCH LEVER IS PULLEDIN
1 Battery2 Main fuse3 Main switch4 Engine stop switch5 Neutral relay6 Clutch switch7 Sidestand switch8 Neutral switch9 Start switch10 Starter relay11 Starter motor
7-12
ELECTRICAL STARTING SYSTEM ELEC
NOTE:
1. Fuse
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the fuse.
2. Battery
Check the battery condition.Refer to “BATTERY INSPECTION” sectionin CHAPTER 3.
Specific gravity:1.280 at 20C
CORRECT Refill the battery fluid.Clean battery terminals.Recharge or replace the battery.
INCORRECT
YP803020
TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO OPERATE.
ProcedureCheck:1. Fuse2. Battery3. Starter motor4. Starter relay5. Neutral relay6. Main switch
7. Engine stop switch8. Neutral switch9. Sidestand switch
10. Clutch switch11. Start switch12. Wiring connection (entire starting system)
Remove the following parts before trouble-shooting.
1) Side cover (left and right)2) Headlight unit3) Seat4) Fuel tank
Use the special tools specified in the trouble-shooting section.
Pocket tester:90890-03112
YP******
YP******
7-13
ELECTRICAL STARTING SYSTEM ELEC
Connect the battery positive terminal and starter motor cable using a jumperlead *.
Check the starter motor operation.
*
1
3. Starter motor
23
MOVES
DOES NOT MOVE
Repair or replace the starter motor.
4. Starter relay
Disconnect the relay unit coupler from thewireharness.
Connect the pocket tester (Ω 1) and bat-tery (12 V) to the relay unit coupler terminals.
Battery (+) lead Blue/White terminal
Battery (–) lead Red/White terminal
1
2
Check the starter relay for continuity.
Tester (+) lead terminalTester (–) lead terminal
34
CONTINUITY
NO CONTINUITY
Replace the starter relay.
WARNING
YP******
YP******
A wire used as a jumper lead must have theequivalent capacity as that of the batterylead or more, otherwise it may burn.
This check is likely to produce sparks, sobe sure that no flammable gas or fluid is inthe vicinity.
7-14
ELECTRICAL STARTING SYSTEM ELEC
1
2
3
4
5. Neutral relay
Remove the relay from the frame.Connect the pocket tester (Ω 100) to theBattery and the relay connecter.
Tester (+) lead Terminal 1
Tester (–) lead Terminal 3
Battery (+) lead Terminal 2
Battery (–) lead Terminal 4
Check the Terminal 1 and 3 for continuity.
CONTINUITY
NO CONTINUITY
Replace the neutral relay.
6. Main switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the main switch
7. Engine stop switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the handlebar switch (right).
8. Neutral switch
Refer to “SWITCH INSPECTION” section.
NO CONTINUITY (at NEUTRAL position)
CONTINUITY(at NEUTRAL position) Replace the neutral switch.
9. Sidestand switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the sidestand switch.
YP******
YP******
YP******
YP******
YP******
7-15
ELECTRICAL STARTING SYSTEM ELEC
10.Clutch switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the clutch switch.
11.Start switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the handlebar switch (right).
12.Wiring connection
Check the connections of the entire startingsystem.Refer to “CIRCUIT DIAGRAM”.
POOR CONNECTION
Correct.
YP******
YP******
YP******
7-16
Order Job name/Part name Q’ty Remarks
123
Starter motor removalDrain the engine oil
Crankcase cover (right)
Starter motor leadStarter motorO-ring
111
Remove the parts in order.Refer to “ENGINE OIL REPLACEMENT”section in CHAPTER 3.Refer to “CLUTCH REMOVAL” section inCHAPTER 4.
Reverse the removal procedure forinstallation.
Refer to “Assembly” section.
7 Nm (0.7 mkg)
Starter motor disassemblyFront bracketWasher setRear bracketWasher setBrush holder/brushArmature coil
111111
Disassemble the parts in order.
Reverse the disassembly procedure forassembly.
123456
ELECTRICAL STARTING SYSTEM ELEC
STARTER MOTOR
7-17
ELECTRICAL STARTING SYSTEM ELEC
NOTE:
A
B
YP803034
Inspection and repair1. Inspect:CommutatorDirt Clean it with #600 grit sandpaper.
2. Measure:Commutator diameter a
Commutator wear limit:27 mm
Out of specification Replace the startermotor
3. Measure:Mica undercut a
Mica undercut:0.7 mm
Out of specification Scrape the mica to theproper value (a hacksaw blade can beground to fit).
The mica insulation of the commutator must beundercut to ensure proper operation of commu-tator.
4. Inspect:Armature coil resistances(installation/continuity)Defects Replace the starter motor.If commutator is dirty, clean it with sandpa-per.
Goodcondition Bad condition
: Continuity: No continuityBad condition Replace.
5. Measure:Brush length aOut of specification Replace.
Brush length wear limit:3.5 mm
7-18
ELECTRICAL STARTING SYSTEM ELEC
NOTE:
New
3 Nm (0.3 mkg)
NOTE:
6. Measure:Brush spring forceFatigue/out of specification Replace as aset.
Brush spring force:540 660 g
7. Inspect:Oil sealWear/damage Replace.
YP******
AssemblyReverse the “Disassembly” procedure.Note the following points.1. Install:Brush holder 1
Align the lib on the brush holder with the slot aon the bracket, before assembly.
2. Install:Washer set 1Armature coil 2
3. Install:Ring 1 Stator assembly 2Washer set 3Front bracket
Apply molybdenum grease lightly on to thebearings of the starter motor.
Align the match marks on the yoke with thematch marks on the brackets.
7-19
1 C.D.I. magneto2 Rectifier /Regulator4 Battery5 Fuse
CHARGING SYSTEM ELEC
YP804000
CHARGING SYSTEMCIRCUIT DIAGRAM
7-20
CHARGING SYSTEM ELEC
NOTE:
1. Fuse
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the fuse.
2. Battery
Check the battery condition.Refer to “BATTERY INSPECTION” sectionin CHAPTER 3.
Specific gravity:1.280 at 20C
CORRECT
INCORRECT
Refill the battery fluid.Clean battery terminals.Recharge or replace the battery.
YP804010
TROUBLESHOOTING
IF THE BATTERY IS NOT CHARGED
ProcedureCheck:1. Fuse2. Battery3. Charging voltage
4. Stator coil resistance5. Wiring system (entire charging system)
Remove the following parts before trouble-shooting.
1) Side cover (left and right)2) Seat3) Fuse
Use the special tools specified in the trouble-shooting section.
Engine tachometer90890-03113
Pocket tester:90890-03112
YP******
YP******
7-21
CHARGING SYSTEM ELEC
Tester (+) lead Battery (+) terminal
Tester (–) lead Battery (–) terminal
1
2
3. Charging voltage
Connect the engine tachometer to the sparkplug lead.
Connect the pocket tester (DC20V) to thebattery.
Measure the battery terminal voltage.Start the engine and accelerate to about5,000 r/min.
Check the terminal voltage.
Charging voltage:14.5 V at 5,000 r/min
NOTE:Use a fully charged battery.
OUT OFSPECIFICATION
MEETS SPECIFICATION
The charging circuit is not faulty.Replace the battery.
4. Stator coil resistance
Remove the C.D.I. magneto coupler fromwireharness.
Connect the pocket tester (Ω 1) to the sta-tor coil.
Tester (+) lead White terminalTester (–) lead White terminal
Measure the stator coil resistance.
Stator coil resistance:0.48 0.72 Ω (20C)
MEETSSPECIFICATION
OUT OF SPECIFICATION
Replace the stator coil.
Left side Right side
YP******
YP******
7-22
5. Wiring connection
Check the entire charging system for connec-tions.Refer to “CIRCUIT DIAGRAM” section.
CORRECT
Replace the rectifier/regulator.
POOR CONNECTION
Correct.
CHARGING SYSTEM ELEC
YP******
7-23
4 Battery5 Fuse6 Main switch22 High beam indicator light23 Meter light26 Tail /Brake light30 Auxiliary light34 Lights switch36 Dimmer switch39 Headlight
LIGHTING SYSTEM ELEC
EB804000
LIGHTING SYSTEMCIRCUIT DIAGRAM
7-24
LIGHTING SYSTEM ELEC
NOTE:
1. Fuse
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the fuse.
2. Battery
Check the battery condition.Refer to “BATTERY INSPECTION” sectionin CHAPTER 3.
Specific gravity:1.280 at 20C
CORRECT
INCORRECT
Refill the battery fluid.Clean battery terminals.Recharge or replace the battery.
3. Main switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the main switch.
YP805010
TROUBLESHOOTING
IF THE HEADLIGHT, AUXILIARY LIGHT, HIGH BEAM INDICATOR LIGHT,TAILLIGHT AND/OR METER LIGHT FAIL TO COME ON.
ProcedureCheck:1. Fuse2. Battery3. Main switch
4. Lights switch5. Dimmer switch6. Wiring connection (entire lighting system)
Remove the following parts before trouble-shooting.
1) Seat2) Fuel tank3) Side cover (left and right)4) Headlight unit
Use the special tools specified in the trouble-shooting section.
Pocket tester:90890-03112
YP******
YP******
YP******
7-25
Headlight:Tester (+) lead Green or Yellow leadTester negative (–) lead Black lead
High beam indicator light:Tester (+) lead Yellow leadTester (–) lead Black lead
When the dimmer switch is on low beam.When dimmer switch is on high beam.
1
3
45
B
A
4. Lights switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the handlebar switch (left).
5. Dimmer switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the handlebar switch (left).
6. Wiring connection
Check the connections of the entire lightingsystem.Refer to “WIRING DIAGRAM”.
CORRECT
Check the condition of each of the lightingsystem’s circuits.Refer to “LIGHTING SYSTEM CHECK”
POOR CONNECTIONS
Correct.
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the bulb and/or bulb socket.
2. Voltage
Connect the pocket tester (DC20V) to theheadlight and high beam indicator light cou-plers.
B
2
LIGHTING SYSTEM ELEC
YP******
YP******
YP******
SR805020
LIGHTING SYSTEM CHECK1. If the headlight and the high beam indicator light fail to come on.
7-26
LIGHTING SYSTEM ELEC
Tester (+) lead Blue terminal
Tester (–) lead Black terminal
Turn the main switch to on position.Turn the lights switch to on position.Turn the dimmer switch to low beam or highbeam.
Check for voltage (12 V) on the lead at bulbsocket connectors.
1
2
MEETSSPECIFICATION
This circuit is not faulty.
OUT OF SPECIFICATION
The wiring circuit from the main switch to bulbsocket connector is faulty. Repair.
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to thebulb socket coupler.
Turn the main switch to on.Turn the lights switch to on position.Turn the dimmer switch to low beam or highbeam.
Check the voltage (12 V) of the leads on thebulb socket connector.
MEETSSPECIFICATION
This circuit is not faulty.
NO CONTINUITY
Replace the bulb and/or bulb socket.
OUT OF SPECIFICATION
The wiring circuit from main switch to bulbsocket is faulty. Repair.
SR805021
2. If the meter light fails to come on.
7-27
Tester (+) lead Blue/Red terminal
Tester (–) lead Black terminal 2
Tester (+) lead Blue terminal
Tester (–) lead Black terminal
1
2
1
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to thebulb socket connector.
Turn the main switch to on position.Turn the lights switch to on position.Turn the dimmer switch to low beam or highbeam.
Check the voltage (12 V) on the bulb socketconnector.
MEETSSPECIFICATION
This circuit is not faulty.
NO CONTINUITY
Replace the bulb and/or bulb socket.
OUT OF SPECIFICATION
The wiring circuit from main switch to bulbconnector is faulty. Repair.
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to thebulb socket connector.
Turn the main switch to on position.Turn the lights switch to on position.Turn the dimmer switch to low beam or highbeam.
Check the voltage (12 V) on the bulb socketconnector.
MEETSSPECIFICATION
This circuit is not faulty.
NO CONTINUITY
Replace the bulb and/or bulb socket.
OUT OF SPECIFICATION
The wiring circuit from main switch to bulbconnector is faulty. Repair.
LIGHTING SYSTEM ELEC
YP805022
3. The taillight fails to come on.
SR******
4. The auxiliary light fails to come on.
7-28
4 Battery5 Fuse6 Main switch7 Thermo switch8 Heater unit19 Neutral indicator light20 Turn indicator light (left)21 Turn indicator light (right)24 Neutral switch25 Rear flasher lights26 Tail /Brake light27 Front brake switch
28 Rear brake switch29 Front flasher lights31 Flasher relay32 Horn35 Horn switch37 Turn switch
SIGNAL SYSTEM ELEC
EB806000
SIGNAL SYSTEMCIRCUIT DIAGRAM
7-29
SIGNAL SYSTEM ELEC
NOTE:
1. Fuse
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the fuse.
2. Battery
Check the battery condition.Refer to “BATTERY INSPECTION” sectionin CHAPTER 3.
Specific gravity:1.280 at 20C
CORRECT
INCORRECT
Refill the battery fluid.Clean battery terminals.Recharge or replace the battery.
3. Main switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the main switch.
YP806010
TROUBLESHOOTING
IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON.IF THE HORN FAILS TO SOUND.
ProcedureCheck:1. Fuse2. Battery
3. Main switch4. Wiring connection (entire signal system)
Remove the following parts before trouble-shooting.
1) Headlight unit2) Side cover (left and right)
Use the special tools in the troubleshootingsection.
Pocket tester:90890-03112
YP******
YP******
YP******
7-30
SIGNAL SYSTEM ELEC
4. Wireharness
Check the connections of the entire signalsystem.Refer to “CIRCUIT SYSTEM WIRING DIA-GRAM” section.
CORRECT
Check condition of each of the signal sys-tem’s circuits.Refer to “SIGNAL SYSTEM CHECK” section.
POOR CONNECTION
Correct.
YP******
7-31
Tester (+) lead Pink terminalTester (–) lead Frame ground
Tester (+) lead Brown terminal Tester (–) lead Frame ground
1
1
1. Horn switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to thehorn lead.
Turn the main switch to on.Check for voltage (12V) on the “Brown” leadat the horn terminal.
MEETSSPECIFICATION
3. Horn
Connect the pocket tester (DC20V) to thehorn at the “Pink” terminal.
Turn the main switch to on.Check for voltage (12V) on the “Pink” lead toframe ground.
MEETSSPECIFICATION
Adjust or replace horn.
NO CONTINUITY
Replace the left handlebar switch (left).
OUT OF SPECIFICATION
The wiring circuit from the main switch to thehorn is faulty. Repair.
OUT OF SPECIFICATION
Replace the horn.
SIGNAL SYSTEM ELEC
YP806020
SIGNAL SYSTEM CHECK1. If the horn fails to sound.
7-32
Tester (+) lead Yellow terminal Tester (–) lead Black terminal
12
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
CONTINUITY
2. Brake switch (Front/Rear)
Refer to “SWITCH INSPECTION” section.
3. Voltage
Connect the pocket tester (DC20V) to thebulb socket connector.
Turn the main switch to on.The brake lever (or brake pedal) is pulled in(down).
Check for voltage (12V) of the “Yellow” leadon the bulb socket connector.
MEETSSPECIFICATION
This circuit is not faulty.
NO CONTINUITY
Replace the bulb and/or bulb socket.
NO CONTINUITY
Replace brake switch.
OUT OF SPECIFICATION
4. Wiring connection
Wiring circuit from the main switch to the bulbsocket connector is faulty. Repair.Refer to “SIGNAL SYSTEM WIRING DIA-GRAM”.
CONTINUITY
SIGNAL SYSTEM ELEC
YP806022
2. If the brake light fails to come on:
7-33
Tester (+) lead Brown/White terminal Tester (–) lead Frame ground
Tester (+) lead Brown terminal Tester (–) lead Frame ground
1
1
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
CONTINUITY
2. Turn switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
3. Voltage
Connect the pocket tester (DC20V) to theflasher relay coupler.
Turn the main switch to on.Check for voltage (12V) of the “Brown” lead at the flasher relay terminal.
1
MEETSSPECIFICATION
4. Flasher relay
Connect the pocket tester (DC20V) to theflasher relay coupler.
Turn the main switch to on.Check for voltage (12V) on the “Brown/White” lead at the flasher relay terminal.
MEETSSPECIFICATION
NO CONTINUITY
Replace the bulb and/or bulb socket.
NO CONTINUITY
Replace the left handlebar switch (left).
OUT OF SPECIFICATION
The wiring circuit from main switch to flasherrelay connector is faulty. Repair.
OUT OF SPECIFICATION
The flasher relay is faulty. Replace.
SIGNAL SYSTEM ELEC
YP806023
3. If the flasher light and/or turn indicator lightfails to blink.
7-34
At flasher light (right)Tester (+) lead Dark green lead Tester (–) lead Black terminal
At flasher light (left)Tester (+) lead Chocolate lead Tester (–) lead Black terminal
13
23
5. Voltage
Connect the pocket tester (DC20V) to thebulb socket connector.
Turn the main switch to on.Turn the turn switch to left or right.Check for voltage (12V) on the “Chocolate”lead and “Dark green” at the flasher light ter-minal.
MEETSSPECIFICATION
This circuit is not faulty.
OUT OF SPECIFICATION
Wiring connection
Wiring circuit from the turn switch to bulbsocket connector is fault. Repair.Refer to “CIRCUIT DIAGRAM”.
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
CONTINUITY
2. Neutral switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
NO CONTINUITY
Replace the bulb and/or bulb socket.
NO CONTINUITY
Replace the left neutral switch.
SIGNAL SYSTEM ELEC
SR806027
4. If the neutral indicator lights fails to operate.
7-35
Tester (+) lead Black terminal Tester (–) lead Black terminal
1
2
12
COOL DOWN
HEAT UP
A
B
3. Voltage
Connect the pocket tester (DC20V) to thefuel gauge coupler.
Tester (+) lead Brown terminal
Tester (–) lead Sky blue terminal
Turn the main switch to on position.Select the gear position in neutral.Check for voltage (12V) of the “Sky blue”lead on the neutral switch.
MEETSSPECIFICATION
This circuit is not faulty.
OUT OF SPECIFICATION
Check the connection of the entire signal sys-tem.Refer to “CIRCUIT DIAGRAM”.
1. Thermo switch
Disconnect the thermo switch connectorfrom the wireharness.
Connect the pocket tester (Ω 1) to thethermo switch lead.
Check the Terminal 1 and 3 for continuity.
MEETSSPECIFICATION
OUT OF SPECIFICATION
Replace the thermo switch.
SIGNAL SYSTEM ELEC
SR******
5. If the carburetor heater fails to operate.
7-36
SIGNAL SYSTEM ELEC
Tester (+) lead Terminal Tester (–) lead Terminal
12
2. Heater unit resistance
Remove the heater unit from the carburetor.Connect the pocket tester (Ω 1) to theheater unit.
Check the heater unit for specificated resis-tance.
Heater unit resistance:6 10 Ω (20C)
MEETSSPECIFICATION
3. Wiring connection
Check the connections of the entire signalsystem.Refer to “WIRING DIAGRAM”.
OUT OF SPECIFICATION
Replace the heater unit.
CHAPTER 8.TROUBLE SHOOTING
STARTING FAILURE/HARD STARING 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR IDLE SPEED PERFORMANCE 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR MEDIUM AND HIGH SPEED PERFORMANCE 8-3. . . . . . . . . . . . .
POOR SPEED PERFORMANCE 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH SLIPPING/DRAGGING 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY GEAR SHIFTING 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVER HEATING OR OVER-COOLING 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY BRAKE 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK MALFUNCTION 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTABLE HANDLING 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR DOES NOT OPERATE 8-7. . . . . . . . . . . . . . . . . . . . . . . .
FAULTY SIGNAL AND LIGHTING SYSTEM 8-8. . . . . . . . . . . . . . . . . . . . . .
8-1
STARTING FAILURE/HARD STARTINGTRBLSHTG
NOTE:
EB90000
TROUBLESHOOTING
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection,adjustment and replacement of parts.
SR90000
STARTING FAILURE/HARD STARTINGFUEL SYSTEMFuel tankEmptyClogged fuel tank cap breather holeDeteriorated fuel or fuel containing water orforeign material
Fuel cockClogged fuel hoseClogged fuel cock
CarburetorDeteriorated fuel or fuel containing water orforeign material
Clogged pilot jetClogged air passage Improperly set pilot screwClogged pilot air passage Improperly sealed valve seat Improperly adjusted fuel levelClogged starter jetDamaged carburetor joint Improperly tightened carburetor joint clamphose
Starter plunger malfunctionClogged emulsion (heated water) tubeSucked-in airAir filterClogged air filter element Improper air filter setting
COMPRESSION SYSTEMCylinder and cylinder headLoose spark plugLoose cylinder headBroken cylinder head gasketBroken cylinder gasketWorn, damaged or seized cylinderPiston and piston ringWorn pistonWorn, fatigued or broken piston ringSeized piston ringSeized or damaged piston
Valve system Improperly adjusted valve clearance Improperly sealed valve Improperly contacted valve and valve seat Improper valve timingBroken valve springSeized valve
8-2
POOR IDLE SPEED PERFORMANCETRBLSHTG
IGNITION SYSTEMBattery Improperly charged batteryFaulty batteryFuseBurnt out, improper connectionSpark plug Improper plug gapWorn electrodesWire between terminals broken Improper heat rangeFaulty spark plug capIgnition coilBroken or shorted primary/secondary coilFaulty high tension cordBroken ignition coil body
Ignition systemFaulty C.D.I. unitFaulty pick up coilBroken magneto woodruff keySwitchFaulty main switchFaulty “ENGINE STOP” switchFaulty front and/or rear brake switchFaulty sidestand switchWiringLoose battery terminalLoose coupler connection Improperly groundedBroken wireharness
SR901000
POOR IDLE SPEED PERFORMANCEPOOR IDLE SPEED PERFORMANCECarburetor Improperly returned starter plunger loose or clogged pilot jetDamaged carburetor joint Improperly tightened carburetor joint clamphose
Improperly adjusted idle speed(Pilot screw), (Throttle stop screw)
Improperly adjusted throttle cableFlooded carburetor
Air filterClogged air filter elementIgnition systemFaulty spark plugFaulty high tension cordFaulty C.D.I. unitFaulty pick up coilFaulty ignition coilValve system Improperly adjusted valve clearance
8-3
POOR MEDIUM AND HIGH SPEED PERFORMANCETRBLSHTG
EB902000
POOR MEDIUM AND HIGH SPEED PERFORMANCEPOOR MEDIUM AND HIGH SPEED PERFORMANCERefer to “STARTING FAILURE/HARD STARTING” section. (Fuel system, electrical system, compres-sion system and valve train)Carburetor Improperly adjusted fuel levelClogged main nozzleClogged or loose pilot jet
Air filterClogged air filter element
SR******
POOR SPEED PERFORMANCEPOOR SPEED PERFORMANCEIgnition systemDirty spark plug Improper heat rangeFaulty C.D.I. unitFaulty pick up coilFuel systemClogged fuel tank cap breather holeClogged air cleaner elementClogged jet Improperly adjusted fuel level
Compression systemWorn cylinderWorn or seized piston ringCylinder head gasket brokenCylinder gasket brokenCarbon deposit build-up Improperly adjusted valve clearance Improperly contacted valve and valve seatFaulty valve timingClutchRefer to “CLUTCH SLIPPING/DRAGGING”section
Engine oil Improper oil level (low or over oil level) Improper quality (Low oil viscosity)DeteriorationClogged oil passageBrakesDragging brake
8-4
FAULTY CLUTCH/FAULTY GEAR SHIFTINGTRBLSHTG
EB904000
CLUTCH SLIPPING/DRAGGINGCLUTCH SLIPPINGClutch Improperly adjusted clutch cableLoose clutch springFatigued clutch springWorn friction plate/clutch plate Incorrectly assembled clutchEngine oil Improper oil level Improper quality/(low viscosity)Deterioration
CLUTCH DRAGGINGClutchWarped pressure plateUnevenly tensioned clutch springBent push rodBroken clutch bossBurnt primary driven gear bushingBent clutch plateSwollen friction plateMatch marks not alignedEngine oil Improper oil level Improper quality/(high viscosity)Deterioration
EB903000
FAULTY GEAR SHIFTINGHARD SHIFTINGRefer to “CLUTCH DRAGGING”.SHIFT PEDAL DOES NOT MOVEShift shaft Improperly adjusted shift rodBent shift shaftShift cam, shift forkGroove jammed with impuritiesSeized shift forkBent shift fork guide barTransmissionSeized transmission gearJammed impurities Incorrectly assembled transmissionJUMP-OUT GEARShift shaft Improperly adjusted shift lever position Improperly returned stopper leverShift forkWorn shift forkShift cam Improper thrust playWorn shift cam grooveTransmissionWorn gear dog
8-5
OVER HEATING/FAULTY BRAKETRBLSHTG
SR905000
OVER HEATING OR OVER-COOL-INGOVER HEATINGIgnition system Improper spark plug gap Improper spark plug heat rangeFaulty C.D.I. unitFuel system Improper carburetor setting Improper fuel level adjustmentClogged air filter elementCompression systemHeavy carbon deposit build-up Improperly adjusted valve timing Improperly adjusted valve clearanceEngine oil Incorrect engine oil level Improper engine oil quality (High viscosity)Low engine oil qualityBrakesDragging brake
SR906001
FAULTY BRAKEPOOR BRAKING EFFECTFront brakeWorn brake padWorn brake discAir in brake fluidLeaking brake fluidFaulty master cylinder kitFaulty caliper seal kitLoose union boltBroken brake hoseOily or greasy brake padOily or greasy brake discRear brake Improper brake pedal adjustmentWorn brake shoe Improper brake shoe contactWorn camshaftWorn brake drumMud or water into brake drum insideOily or greasy brake liningFaulty brake cableBroken or fatigued tension springFaulty camshaft, cam lever
8-6
FRONT FORK MALFUNCTION/INSTABLE HANDLINGTRBLSHTG
SR907000
FRONT FORK MALFUNCTIONOIL LEAKAGEBent, damaged or rusty inner tubeDamaged or cracked outer tubeDamaged oil seal lipLoose hexagon boltDamaged cap bolt O-ring Improperly installed oil sealMALFUNCTIONBent inner tubeDeformed outer tubeDamaged fork springBent cylinder complete Improper oil viscosity (High viscosity) Improper oil levelWorn or damaged slide metal
SR908000
INSTABLE HANDLINGINSTABLE HANDLINGHandlebars Improperly installed or bentLoose handlebar tightening boltSteering Improperly installed handlebar crownLoose or overtightening steering nutBent under bracket Improperly installed steering shaft(improperly tightened ring nut)
Damaged bearing or ball raceFront forksUneven oil levels on both sidesUneven spring tensionBroken front fork springFatigued front fork springTwisted front forksWheels Incorrect wheel balanceLoose spooksDeformed wheel rimUnevenly worn tires Incorrect tire pressureLoose bearingBent or loose wheel axleExcessive wheel runoutFrameTwisted Improperly installed bearing raceDamaged head pipe bearingsRear armFaulty bearingsWorm or damagedFaulty bushingBent rear armRear shock absorberFatigued spring Improperly adjusted spring preloadOil leakageDrive chain Improperly adjusted chain line
8-7
STARTER MOTOR DOES NOT OPERATETRBLSHTG
SR******
STARTER MOTOR DOES NOT OPERATESTARTER MOTOR DOES NOT OPERATEBattery Insufficient battery capacityFaulty batteryFuseBurnt out, improper connectionSwitchFaulty main switchFaulty starter switchFaulty clutch switchFaulty neutral switchFaulty sidestand switchFaulty starting circuit cut-off relayFaulty starter relayWireharnessLoose battery terminalLoosely connected coupler Improperly groundedBroken wireharnessStarter motorWorn brushFaulty commutatorBroken armature coilEngineFaulty starter clutchSeized engine
8-8
FAULTY SIGNAL AND LIGHTING SYSTEMTRBLSHTG
YP909000
FAULTY SIGNAL AND LIGHTING SYSTEMHEADLIGHT DARK Improper bulbToo many electric accessoriesHard chargingFaulty rectifier/regulatorFaulty battery Improperly connected coupler, connector,wireharness
Improperly groundedFaulty main switch or Lights (dimmer) switchBulb life expiredBULB BURNT OUT Improper bulbFaulty batteryFaulty rectifier/regulator Improperly grounded Improperly mounting light unitBulb life expiredFLASHER DOES NOT BLINK Improperly grounded Insufficient battery capacityFaulty fuseFaulty turn switchFaulty flasher relayBroken wireharness, incorrect coupler con-nection
Bulb burnt outFLASHER KEEPS ONFaulty flasher relay Insufficient battery capacity(nearly discharged)
Bulb burnt out (front or rear)
FLASHER BLINKS SLOWERFaulty flasher relay Insufficient battery capacity(nearly discharged)
Improper bulbFaulty main and/or turn switchFLASHER BLINKS QUICKER Improper bulbFaulty flasher relayHORN DOES NOT SOUNDFaulty batteryFaulty fuseFaulty main and/or horn switch Improper horn adjustmentFaulty horn (burnt coil, connector)Broken wireharness
COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . L Blue. . . . . O Orange. . . .
Sb Sky blue. . . . P Pink. . . . . R Red. . . . . Y Yellow. . . . . W White. . . . Br /L Brown/Blue. . Br /W Brown/White.
G/Y Green/Yellow. . L/B Blue/Black. . . L/R Blue/Red. . . L/W Blue/White. . L/Y Blue/Yellow. . . Y/R Yellow/Red. . . R/W Red/White. .
W/L White/Blue. . W/R White/Red. .
1 C.D.I. magneto2 Rectifier /Regulator3 Starter relay4 Battery5 Fuse6 Main switch7 Thermo switch8 Heater unit9 Handlebar switches (right)10 Engine stop switch11 Start switch12 C.D.I. unit13 Ignition coil14 Spark plug15 Clutch switch16 Sidestand switch17 Neutral relay18 Speedometer19 Neutral indicator light20 Turn indicator light (left)21 Turn indicator light (right)22 Hi-beam indicator light23 Meter light24 Neutral switch25 Rear flasher lights26 Tail/Brake light27 Front brake switch28 Rear brake switch29 Front flasher lights30 Auxilialy light31 Flasher relay32 Horn33 Handlebar switches (left)34 Lights switch35 Horn switch36 Dimmer switch37 Turn switch38 Starting motor39 Headlight
SR125 ’97 WIRING DIAGRAM