Yamaha Motor India Private Fazer Service manual

SERVICE
MANUAL
L-1
FAZER
SERVICE MANUAL
YAMAHA MOTOR INDIA PVT. LIMITED
All rights reserved.
Any reprinting or unauthorised use without
the written permission of
YAMAHA MOTOR INDIA PVT. LIMITED
is expressly prohibited.
R-1
FOREWORD
This Workshop Manual has been prepared for use by the Yamaha Motor
India Private Ltd. Authorised Dealerships and their service personnel to attend
to servicing of Fazer Motorcycles. It is not possible to include entire service
education into this Manual. It is assumed that persons using this book to
perform maintenance and repairs on Fazer Motorcycles have a basic
understanding of mechanical concepts and procedures inherent to Motorcycle
repair technology. Without such knowledge, attempted repairs or service of
this model may render it unfit for use and / or unsafe.
Yamaha Motor India Private Ltd. continually strives to improve all its
models. Modifications and significant changes in specifications or procedures
will be informed to all Yamaha Motor India Private Ltd. Authorised Dealerships
through Service Actions and will wherever considered necessary, appear in
future editions of this Workshop Manual.
Service Department
Yamaha Motor India Private Ltd.
L-2
HOW TO USE THIS MANUAL
MANUAL ORGANISATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1 : This is the Title of the Chapter with its symbol 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 each section. It is located in the centre of the page.
3rd title 3 : This title indicates a Subsection that is followed by step-by-step procedures
accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are Exploded Diagrams at start of
each Removal and 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 part.
3. An explanation of jobs and notes are presented in an easy-to-read way by the use of Symbol
Marks 6 . The meaning of the Symbol Marks are given on the next page.
4. For jobs requiring more information, the step-by-step format supplements 7 are given in
1
addition to the exploded diagram.
4
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
ENGINE ASSEMBLY
2
PISTON RING, PISTON AND CYLINDER
INSTALLATION
1. Install in following sequence
3
• Expander Spacer (Oil Ring) ¿
5
• Side Rails (Oil Ring) À
• 2nd Ring Á
• Top Ring Â
NOTE :
• Make sure to install the Piston Rings so that
the RN marks are located on the upper side
of the 2nd Ring.
• Lubricate the Piston and Piston Rings with
Engine Oil.
2. Install :
• Piston ¿
• Piston Pin À using piston pin tool
6
À
¿
Piston Pin replacer tool
YSST - 607
• Piston Pin Circlip Á New
Á
7
R-3
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number
and content.
1. General
Information
GEN
INFO
2. Specifications
3. Periodic inspection
and adjustment
INSP
ADJ
4. Engine
ENG
5. Carburetion
CARB
6. Chassis
CHAS
7. Electrical
ELEC
8. Troubleshooting
TRBL
SHTG
SPEC
Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text.
9. Filling fluid
10.Lubricant
11.Special Tool
12.Torque
13.Wear Limit,
Clearance
14.Engine speed
15.Resistance,
Voltage, Current
Illustrated symbols 16 to 21 in the exploded diagrams indicate the types of lubricants and
lubrication points.
16. Apply engine oil
19. Apply wheel
bearing grease
17. Apply gear oil
20.Apply lightweight
lithium-soap base
grease
18. Apply molybdenum
disulfide oil
21. Apply molybdenum disulfide
grease
Illustrated symbols 22 and 23 in the exploded diagrams indicate where to apply locking
agent and when to install new parts
22. Apply locking
agent (LOCKTITE*)
23. Use New One
INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENTS
ENGINE
CARBURETION
CHASSIS
ELECTRICAL
TROUBLE SHOOTING
GEN
INFO
1
SPEC
2
INSP
ADJ
3
ENG
4
CARB
5
CHAS
6
ELEC
7
TRBL
SHTG
8
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER .........................................................1-1
ENGINE SERIAL NUMBER .......................................................1-1
IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY ...................................... 1-2
ALL REPLACEMENT PARTS ....................................................1-3
GASKETS, OIL SEALS, AND O-RINGS ....................................1-3
LOCK WASHERS/PLATES AND COTTER PINS ...................... 1-3
BEARINGS AND OIL SEALS .....................................................1-3
CIRCLIPS ...................................................................................1-3
SPECIAL TOOLS
SPECIAL SERVICE TOOLS ...................................................... 1-4
SERVICE INSTRUMENTS .........................................................1-7
SPECIAL SERVICE MATERIALS .............................................. 1-8
MOTORCYCLE IDENTIFICATION
GEN
INFO
MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER
The Frame Serial Number ¿ is stamped into the
right side of the Steering Head Pipe.
ENGINE SERIAL NUMBER
The Engine Serial Number À is stamped on the
top portion of RH Crankcase. ( Engine Serial
Number does not contain Year and Month of
production)
XX
X
5YY
XXXXXX
YEAR OF
PRODUCTION
MONTH
CODE
MODEL
CODE
UNIT PRODUCTION
NUMBER
Year of Production
:
Month Code
:
Starting Serial Number
:
2 Digits standing for last two digits of year
Eg. 0 0 - 2000, 0 1 - 2001 ......
One alphabet standing for Month
Eg. A - January, B - February........
M - December ( I - Not Used for Month)
5YY 000001
WARNING
Do not tamper with any of these numbers. It
may lead to legal action.
NOTE :
Designs and sepecifications are subject to
change without notice.
1-1
IMPORTANT INFORMATION
GEN
INFO
IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY
1. Remove all dirt, mud, dust and foreign material before disassembly.
2. Use proper Tools and Cleaning Equipment.
Refer to “YAMAHA SPECIAL SERVICE
TOOLS”.
3. When disassembling the Motorcycle, keep
mated parts together. This includes gears,
Cylinder, Piston and other mated parts that
have been “mated” through normal wear.
Mated parts must be reused as an assembly or replaced.
4. During the Motorcycle disassembly, clean
all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts
are correctly reinstalled.
5. Keep Motorcycle and its parts away from
any source of fire.
1-2
IMPORTANT INFORMATION
GEN
INFO
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use Yamalube Oil and
Grease recommended by Yamaha for
assembly and adjustment. Other brands
may be similar in function and appearance,
but inferior in quality.
GASKETS, OIL SEALS, AND O-RINGS
1. All Gaskets, Seals and O-rings should be
replaced when the Engine is overhauled.
2. All surfaces where Gasket, Oil Seal lips and
O-rings contact must be cleaned and
Lubricated.
LOCK WASHERS/PLATES AND COTTER
PINS
1. All Lock Washers/plates ¿ and Cotter Pins
must be replaced when they are removed.
Lock tab (s) should be bent along the Bolt
BEARINGS AND OIL SEALS
1. Install the bearing (s) ¿ and Oil Seal (s)
À with their manufacturer’s marks or
numbers facing outward. (In other words,
the stamped letters must be on the side
exposed to view.) When installing Oil Seal
(s), lubricate a light coating of lightweight
lithium base grease to the seal lip(s). Oil the
Bearings liberally when installing.
CAUTION:
WARNING
Do not use compressed air to spin the
Bearings dry. This causes damage to the
Bearing surfaces.
CIRCLIPS
1. All Circlips should be inspected carefully
before reassembly. Always replace Piston
Pin Clips after one use. Replace distorted
Circlips. When installing a circlip ¿, make
sure that the sharp-edged corner À is
positioned opposite to the thrust Á it
receives. See the sectional view of shaft Â.
WARNING
If the Circlip is fitted the wrong way it would
cause it to jump off its groove and damage
related components.
1-3
YAMAHA SPECIAL SERVICE TOOLS
GEN
INFO
YAMAHA SPECIAL SERVICE TOOLS
The appropriate Yamaha Special Service Tools are necessary for proper maintenance of the Motorcycle.
Using the correct Yamaha Special Service Tool will help to prevent damage caused by the use of
improper tools or improvised techniques. The following is the detailed list of all Yamaha Special Service
Tools with their application.
Refer to the list provided to avoid errors when placing an order for Yamaha Special service tools.
1. Magneto Holder
YSST -627
5. Valve Clearance Adjusting Tool.
YSST - 606
This tool is used to hold the Magneto when
removing or installing the Magneto Securing
Nut and Primary Drive Gear Nut
This tool is used to adjust Valve
clearance.
2. Magneto Puller with Spacer
YSST-628
6. Piston Pin Replacer
YSST -607
This tool is used to remove the Magneto
This tool is used to replace Piston Pin.
7. Rocker Arm Shaft Puller
YSST - 608 B
3. Valve Spring Compressor
YSST - 603
This tool is used to to remove and install
Valve Spring Assemblies.
This tool is used to remove/install
Rocker Arm Shaft.
4. Piston Base
YSST - 604
8. Clutch Hub Holder
YSST - 233
This tool is needed to support the Piston
while installing Cylinder.
This tool is used to hold the Clutch Hub when
removing or installing Clutch Main Shaft Nut.
1-4
YAMAHA SPECIAL SERVICE TOOLS
9. Crank Shaft Removal Tool.
YSST - 265
14.
This tool is used to remove the Crank Shaft
from the Crank Case.
Scraper
YSST - 612
This tool is used for scraping the sealent
from Crankcase surface.
15.
10. Crank Shaft Installing Tool with spacer
(a) YSST - 266
è
ç
(b) YSST - 267
These tools are used for installation of
Crank Shaft.
Feeler Gauge
YSST - 615
This tool is used to check Valve
Clearance.
11. Driving Sprocket Holder
YSST- 605
16.
This tool is used to hold the Driving Sprocket when
removing or installing Driving Sprocket Nut
T.F.F. Oil Seal Removing Tool.
YSST - 270
This tool is used to remove T.F.F. oil seal.
12. Torx Bit (T - 30)
YSST - 611
17
T -Handle
YSST - 213
This tool is used to hold the TFF plunger
for loosening and tightening of Hex
Socket Head Bolt
This tool is used to loosen or tighten the
Cam Shifter Segment Screw.
13.
GEN
INFO
Steering Nut Socket
YSST - 621
18.
This tool is used to loosen or tighten the
Steering Ring Nut.
T.F.F. Oil Seal Installation Tool
YSST-275
This tool is used when installing the TFF
Oil Seal.
1-5
SPECIAL SERVICE TOOLS
19 Racer Installing Tool
YSST-626
GEN
INFO
24. Bearing Puller
YSST - 623
To install upper and lower Racer Bearing
This tool is used to remove the Bearing
6201 of the Axle Main.
25. Bearing Puller
YSST - 624
20 TFF Top Plug Spanner
YSST-214
To loosen & tighten the front fork top plug.
This tool is used to remove the Bearing
6202 of the Axle Drive
21. Spanner - Speedometer Gear Nut.
YSST - 237
26. Center Plug Spanner
YSST-625
This tool is used to loosen or tighten the
Speedometer Gear Nut.
This tool is used to remove/install the Center
Plug from Crank case Cover#1 (L.H.)
22. Engine Stand
27. Spoke Tighting Tool
YSST- 629
This fixture is used to hold the Engine
for its disassembly and assembly.
To Tighten / Loosen the Spoke.
23. Oil Seal Installing Tool.
YSST - 622
28. Plastic Bush - Rear Shock Absorber
YSST-703
This tool is used to install Oil Seal in
Crank Case Cover#2.
This tool is used to protect the plastic shell
and painted parts.
1-6
SERVICE INSTRUMENTS
GEN
INFO
SERVICE INSTRUMENTS
The following Service Instruments are necessary for complete and accurate tune up of Motorcycle
1. Tachometer
YSST - 613
5. Vernier Calliper
(150 mm)
This Instrument is
used for checking the Engine RPM
2. Timing light
This instrument is used for measuring
length, width & thickness of components
6. Micrometer
(0-25 mm) & (50-75 mm)
(SKC S14-121)
OR NATIONAL
This instrument is used for measuring
Piston size, Valve stem size etc.
This instrument is used for
checking ignition timing
7. ’CO’ Gas Analyser
3. Compression Gauge
This instrument is used for checking the
engine compression
This instrument is used for measuring ‘CO’
concentration in exhaust of motorcycle
4. Mutimeter
8.Hydrometer
This instrument is
used for checking the
electrical system.
This instrument is used for measuring
specific gravity of Battery Electrolyte
1-7
SERVICE INSTRUMENTS
9. Tyre pressure gauge
GEN
INFO
11. Torque Wrench
(10-50 Ft-Lb)
(20-100 Ft-Lb)
This instrument is used for checking the
Tyre Pressure
This tool is used to tighten the Nuts/Bolts
at a specified torque.
10. Vaccum Gauge
12. Feeler gauge
This instrument is used for checking intake
vaccum.
This instrument is used to check clearance/
gaps between parts.
13. Temperature Meter
This instrument is used for measuring the
oil temperature of Engine
SPECIAL SERVICE MATERIAL
The following Service material are necessary to use at the time of assembly of various parts.
1. YAMAHA Bond
TG-1215
2. LOCTITE
Three Bond 1322
This adhesive is used on mating surfaces
while assembling Crankcase#1 and #2.
This adhesive is used for
Torx Screw tightening.
1-8
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS .................................................... 2-1
MAINTENANCE SPECIFICATIONS
ENGINE ...................................................................................... 2-4
CHASSIS .................................................................................... 2-10
ELECTRICAL .............................................................................. 2-13
GENERAL TORQUE SPECIFICATIONS ................................... 2-15
LUBRICATION POINTS AND LUBRICANT TYPE
ENGINE ...................................................................................... 2-16
CHASSIS .................................................................................... 2-17
ENGINE LUBRICATION ROUTE ..................................................... 2-18
ENGINE BEARINGS ........................................................................ 2-20
CABLE ROUTING ............................................................................ 2-21
GENERAL SPECIFICATIONS
SPEC
GENERAL SPECIFICATIONS
DESCRIPTION
Model :
Model Code :
Engine model code:
DIMENSIONS:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Dry weight :
Basic weight :
(With Oil and full Fuel Tank)
ENGINE :
Engine type
Cylinder arrangement
Displacement
Bore X Stroke
Compression ratio
Starting system
Lubrication system
Max power
Torque
Oil type or grade :
Engine oil
SPECIFICATION
FAZER
5YY1
5YY1
2065
730
1060
800
1300
160
2065
115
125
mm
mm
mm
mm
mm
mm
mm
kg
kg
Air-cooled 4-stroke, SOHC
Forward-inclined, single cylinder
123.7 cm³
54 X 54 mm
10:1
Kick starter
Wet sump
11 BHP (8.0 KW) @ 8500 RPM
1.06 Kgm, 10.4 NM @ 6500 rpm
Yamalube 4-stroke Oil
(20W40 Type SG)
Oil capacity :
Engine oil
Periodic oil replacement
Total amount
Air filter :
1.0 L
1.2 L
Washable, Dual Foam, Wet type
(Oil soaked)
FUEL :
Fuel Tank capacity
Fuel reserve amount
Carburetor :
Type
Manufacturer
Spark plug :
Type/manufacturer
Spark Plug gap
13 Ltrs.
1.2 Ltrs.
BS-25
(UCAL)
R-CR7HSA/NGK
0.6 ~ 0.7 mm
2-1
GENERAL SPECIFICATIONS
DESCRIPTION
Clutch type :
Transmission :
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio
SPEC
SPECIFICATION
Wet, Multiple disc
Helical gear
68/19 (3.579 : 1)
Chain drive
45/14 (3.214 : 1)
Constant mesh 4-speed
Left foot operation
33/12 (2.750)
27/16 (1.688)
24/20 (1.200)
21/23 (0.913)
1st
2nd
3rd
4th
Primary Drive Grading
Matching of Grades
DRIVEN GEAR ASSY.
Gear Primary
Drive
B
C
GRADE
D
E
F
GEAR PRIMARY DRIVE
Chassis :
Frame type
Caster angle
Trail
Tyre :
Type
Size
Manufacturer
Type
•
•
•
•
•
GRADE
Primary Driven
Gear Assy.
•A
•B
•C
•D
•E
Diamond
26.4º
83 mm
With tube
2.75 - 18, 4 PR
3.00 - 18, 6 PR
LOCAL MADE
LOCAL MADE
RIB TYPE/ZAPPER TYPE
UNIVERSAL/ZAPPER TYPE
Front
Rear
Front
Rear
Front
Rear
Tyre pressure (cold tyre) :
Loading condition A*
0 ~ 90 kg (0 ~ 198 lbs)
25 PSI (1.75 kgf/cm²)
28 PSI (2.00 kgf/cm²)
Loading condition B*
90 ~ 162 kg (198~408 lbs)
Front
25 PSI (1.75 kgf/cm²)
Rear
32 PSI (2.30 kgf/cm²)
*Load is total weight of cargo, rider, passenger and accessories.
Front
Rear
2-2
GENERAL SPECIFICATIONS
DESCRIPTION
Brake :
Front brake
Rear brake
SPEC
SPECIFICATION
Type
Operation
Type
Operation
Drum Brake (Dia 150 mm)
Right hand operation
Drum brake (Dia 130 mm)
Right foot operation
Suspension :
Front suspension
Rear suspension
Shock absorbser :
Front shock absorber
Rear shock absorber
Wheel travel :
Front wheel travel
Rear wheel travel
Electrical :
Ignition system
Generator system
Battery type
Battery capacity
Headlight type :
Headlight bulb type
Bulb (voltage - wattage x quantity) :
Headlight
Tail/Brake light
Flasher light
Meter light
“NEUTRAL” indicator light
“HIGH BEAM” indicator light
“TURN” indicator light
Telescopic fork
Swingarm
Coil spring/Oil damper
Coil spring/Oil damper
120 mm
90 mm
CDI (Digital)
Flywheel magneto
LOCAL MADE
12V - 2.5 AH
Bulb type
S-1 Type Bulb
12V - 25W/25W x 2
12V - 5W/21W x 1
12V - 10W x 4
12V - 3.4W x 2
12V - 3.4W x 1
12V - 3.4W x 1
12V - 1.7W x 2
HORN
12V - 1.5 Amp
2-3
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
DESCRIPTION
Cylinder :
Bore size
SPECIFICATION
54.000 ~ 54.018 mm
(in five grades)
Piston :
Piston to Cylinder Clearance
<Limit>
Piston size “D”
Cylinder Piston Grading
0.020 ~ 0.027 mm
<0.15mm>
53.977 ~ 53.996 mm
(in five grades)
Matching of Grades
Piston
Mark
Colour/Letter Mark
Punch
Mark
Colour Letter
A
Red
B
Orange
C
Green
Violet
D
Blue
E
H
D
Measuring point “H”
Piston offset
Piston offset direction
Piston pin bore inside diameter
Piston pin outside diameter
Piston rings :
Top ring :
Type
Dimensions (B x T)
End gap (installed)
<Limit>
Side clearance (installed)
<Limit>
2nd ring :
Type
Dimensions (B x T)
End gap (installed)
<Limit>
Side clearance
<Limit>
Oil ring :
Dimensions (B x T)
End gap (installed)
Side Clearance
(For Rail Upper and Rail Lower)
Cylinder
Letter
Punch Mark
A
B
C
D
E
4.5 mm
0.5 mm
Intake side
15.002 ~ 15.013 mm
15.991 ~ 15.000 mm
Barrel
1.0 x 2.1 mm
0.15 ~ 0.30 mm
<0.40mm>
0.030 ~ 0.07 mm
<0.12 mm>
Taper
1.0 x 2.1 mm
0.30 ~ 0.45 mm
<0.55mm>
0.020 ~ 0.060 mm
<0.12 mm>
2.0 x 2.2 mm
0.2 ~ 0.7 mm
0.040
2-4
MAINTENANCE SPECIFICATIONS
DESCRIPTION
Cylinder head :
<Warp limit>
SPECIFICATION
<0.03 mm (0.0012 in)>
* Lines indicate straightedge
measurement.
Camshaft :
Drive method
Cam dimensions
Intake
Chain Drive
“A”
<Limit>
“B“
<Limit>
“C“
“A“
<Limit>
“B“
<Limit>
“C“
Exhaust
25.881 ~ 25.981 mm
<25.851 mm>
21.195 ~ 21.295 mm
<21.165 mm>
4.931 mm
25.841 ~ 25.941 mm
<25.811 mm>
21.05 ~ 21.15 mm
<21.02 mm>
0.03 mm
Rocker Arm/ Rocker Arm Shaft :
Inside diameter (Rocker Arm)
10.000 ~ 10.015 mm
<10.03 mm>
9.981 ~ 9.991 mm
<9.95 mm>
<Limit>
Outside diameter (Rocker Armshaft)
<Limit>
Cam chain/Sprocket :
Cam chain type/No. of links
No. of Teeth Sprocket
Cam chain adjustment method
Valve, Valve Seat, Valve Guide :
Valve clearance (cold)
IN
EX
Valve dimensions :
Head Dia.
“A” head diameter
“B” face width
“C” seat width
“D” margin thickness
SPEC
SILENT CAM CHAIN / 90
36
Automatic
0.08 ~ 0.12 mm
0.10 ~ 0.14 mm
Face Width
Seat Width
IN
EX
IN
EX
IN
EX
IN
EX
33.9 ~ 34.1 mm
28.4 ~ 28.6 mm
2.26 mm
2.26 mm
0.9 ~ 1.1 mm
0.9 ~ 1.1 mm
0.8 ~ 1.2 mm
0.8 ~ 1.2 mm
2-5
Margin Thickness
MAINTENANCE SPECIFICATIONS
DESCRIPTION
Stem outside diameter
<Limit>
Guide inside diameter
<Limit>
Stem to guide clearance
<Limit>
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
SPECIFICATION
5.975 ~ 5.990 mm
5.960 ~ 5.975 mm
<5.950 mm>
<5.935 mm>
6.000 ~ 6.012 mm
6.000 ~ 6.012 mm
<6.042 mm>
<6.042 mm>
0.010 ~0.037 mm
0.025 ~ 0.052 mm
<0.08 mm>
<0.010 mm>
0.010 mm
IN
EX
IN
EX
0.9 ~ 1.1 mm
0.9 ~ 1.1 mm
<1.6 mm>
<1.6 mm>
Stem runout limit
Valve seat width
<Limit>
Valve spring :
Free length
IN
EX
<Limit>
IN
EX
Set length (valve closed )
IN
EX
<Tilt limit>
IN
EX
Compression pressure (installed) IN
EX
Direction of winding (top view)
Crankshaft :
Crank width “A”
<Runout limit “C”>
Big end side clearance “D”
<Small end free play limit “F”>
Balancer
Balancer Drive Method
Shifter :
Shifter type
Kick starter :
Kick starter type
Kick clip friction force
SPEC
39.62 mm
39.62 mm
38.17 mm
38.17 mm
25.6 mm
25.6 mm
2.5°/1.7 mm
2.5°/1.7 mm
104 ~ 119.7 Nm (10.60 ~ 12.21 kgf)
104 ~ 119.7 Nm (10.60 ~ 12.21 kgf)
Clockwise
46.95 ~ 47.00 mm
<0.03 mm>
0.15 ~ 0.45 mm
<0.8 mm>
Gear - Riged Type
MATCHING OF GRADE
BALANCER
GEAR
D
E
F
G
H
Cam Drum and Guide bar
Kick and Ratchet Type
7.8 ~ 11.8 Nm (0.8 ~ 1.2 kgf)
2-6
CRANK
GEAR
X
Y
Z
A
B
MAINTENANCE SPECIFICATIONS
DESCRIPTION
Clutch :
Friction plate thickness
Quantity
<Friction plate wear limit>
Clutch Plate thickness
Quantity
<Wrap limit>
Clutch Spring free length
Quantity
Minimum length
Clutch release method
<Push rod bendinglimit>
Carburetor :
I. D. Mark
Main Jet
Main Air Jet size
Jet needle
Needle jet
Pilot Air Jet
Pilot outlet
Pilot jet
Valve seat size
Starter jet
SPEC
SPECIFICATION
2.90 ~ 3.10 mm
5 pcs.
<2.80 mm>
1.6 ± 0.15 mm
4 pcs.
0.05 mm
32 mm
4 pcs.
30.5 mm
Inner push, cam push
<0.5 mm>
5YY1
#127.5
85
4DG9-2
E-3M (906)
1.4
0.8
# 15
1.8
25
0.8
6.5 ± 0.5 above the joint line of MCB
(Main Body Chamber) and F.C.B. (Float
Chamber Body)
29 mm ± 0.5 Below the Venturi Axis
1,300 ~1,500 r/min.
(M.J.)
(M.A.J.)
(J.N.)
(N.J.)
(PAJ-1)
(P.O.)
(P. J.)
(V.S.)
(G.S.1)
(G.S.2)
Fuel Level
Float Height
Engine idle speed
Intake vaccum
New Vehicle
Market Run Vehicle
Lubrication system :
Oil filter type
Oil filter type
Tip Clearance “A” or “B”
<Limit>
Side clearance
<Limit>
Housing and rotor clearance
<Limit>
26.0 ~ 31.4 kPa
31.3 ~ 36.7 kPa
Wire mesh type
Trochoid type
0.15 mm
<0.2 mm>
0.06 ~ 0.10 mm
<0.15 mm>
0.08 ~ 0.13 mm
<0.18 mm>
2-7
MAINTENANCE SPECIFICATIONS
SPEC
TIGHTENING TORQUE (ENGINE)
Part to be tightened
Cylinder Head
Spark Plug
Cylinder Head Side Cover
Valve Cover
CDI Magneto Rotor
Stopper Guide
Adjust Screw
Sprocket (Timing Chain)
Plate To Head Cylinder
Plug (Tensioner Assembly)
Tensioner Assembly
Oil Pump Assembly
Drain Plug
Pump Cover
Intake Manifold
Carburetor Joint (Manifold)
Carburetor Joint (Air filter)
Air filter Case
Muffler (Cylinder Head)
Muffler Assembly
Crankcase 1 and 2
Crankcase Cover 1
Cover Chain Case 1
Crankcase Cover 2
Timing Mark Check Plug
Center Plug
Kick Crank Assembly
Primary Drive Gear
Pressure Plate
Clutch Boss
Push Rod
Plate
Drive Sprocket
Shift Pedal
Segment
Parts
name
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Plug
Bolt
Screw
Screw
Screw
Bolt
Screw
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
Screw
Screw
Nut
Nut
Bolt
Nut
Nut
Screw
Nut
Bolt
Screw
Thread
size
M8
M6
M10
M6
M45
M6
M6
M5
M8
M6
M8
M6
M6
M12
M5
M6
M4
M4
M6
M6
M8
M6
M6
M6
M6
M6
M6
M6
M6
M14
M32
M12
M12
M5
M12
M6
M6
M6
M6
M6
Q’ty
4
2
1
2
2
1
1
2
1
1
1
2
2
1
1
2
1
1
2
1
1
2
6
2
5
2
2
7
2
1
1
1
1
4
1
1
2
1
1
1
2-8
Tightening torque
Remark
Nm m.kg
ft.lb
22
2.2
17
10
1.0
7.2
12.5 1.25 9
10
1.0
7.2
17.5 1.75 13
70
7.0
51
10
1.0
7.2
8
0.8
5.8
20
2.0
14.5
10
1.0
7.2
8
0.8
5.8
10
1.0
7.2
7
0.7
5.1
20
2.0
14.5
4
0.4
3.6
10
1.0
7.2
2
0.2
1.5
2
0.2
1.5
7
0.7
5.1
7
0.7
5.1
15
1.5
11
10
1.0
7.2
10
1.0
7.2
10
1.0
7.2
10
1.0
7.2
10
1.0
7.2
7
0.7
5.1
10
1.0
7.2
10
1.0
7.2
7
0.7
5.1
7
0.7
5.1
50
5.0
36
70
7.0
51
6
0.6
4.3
60
6.0
43.5 Use Lock W.
8
0.8
5.8
7
0.7
5.1
10
1.0
7.2
10
1.0
7.2
12
1.2
9
Torx Bolt
MAINTENANCE SPECIFICATIONS
SPEC
TIGHTENING TORQUE (ENGINE)
Part to be tightened
Stopper lever
Sensor Assembly
Neutral Switch Assembly
Parts
name
Bolt
Bolt
-
Thread
size
M6
M6
M10
Q’ty
1
2
1
Tightening torque
Nm m.kg
ft.lb
10
1.0
7.2
10
1.0
7.2
4
0.4
3
Remark
Tightening sequence
Cylinder Head
Ä
Ã
À
Á
¿
Crankcase
t
Â
È
¿
Ä
Ã
Å
Â
Æ
Á
À
Left - hand
Right - hand
2-9
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
DESCRIPTION
Steering system :
Steering Bearing type
No./size of steel balls
Front suspension :
Front Fork travel
Fork Spring free length
<Limit>
Spring rate
Stroke
Oil grade
Rear suspension :
Shock Absorber travel
Spring free length
Fitting length
Spring rate
Stroke
Swingarm :
<Free play limit>
Front wheel :
Type
Rim size
Rim material
<Rim run out limit>
Rear wheel :
Type
Rim size
Rim material
<Rim rounout limit>
SPECIFICATION
Retainer Ball Cage
19 pcs. / 1/4 in
16 pcs. / 1/4 in
(upper)
(lower)
120 mm
316.9 mm
311.9 mm
7.4 N/mm
10.8 N/mm
0 ~ 70 mm
70 ~ 120 mm
Special YAMAHA oil. 10W or Equivalent
(K1)
(K2)
(K1)
(K2)
(K1)
(K2)
(K1)
(K2)
90 mm
343.2 ± 2 mm
231.9 mm
15.08 N/mm
22.64 N/mm
0 ~ 38 mm
38 ~ 90 mm
End
Side
<1.0 mm>
<1.0 mm>
Radial
Lateral
Spoke wheel
1.6 x 18”
Steel
<1.0 mm>
<0.5 mm>
Radial
Lateral
Spoke wheel
1.6 x 18”
Steel
<1.0 mm>
<0.5 mm>
Drive chain :
Type/manufacturer
Number of links
Chain slack
R-428HCS-120-1/M/S - LGB
120
20 ~ 30 mm
2-10
MAINTENANCE SPECIFICATIONS
DESCRIPTION
Front Drum Brake :
Type
Brake Drum inside diameter
<Wear limit>
Lining Thickness
<Wear limit>
Shoe Spring free length
Spring 1
Spring 2
Rear drum brake :
Type
Brake Drum inside diameter
<Wear limit>
Lining Thickness
<Wear limit>
Shoe spring free length
Spring 1
Spring 2
Free Plays :
Brake Lever free play (At lever end)
Brake Pedal free play
Clutch Lever free play (at lever end)
Throttle Grip free play
SPECIFICATION
Leading, Trailing
150mm
<151>
4.0 mm
<2 mm>
57.0 mm
63.0 mm
Leading, Trailing
130mm
<131>
4.0 mm
<2 mm>
52.0 mm
48.0 mm
25 ~ 30 mm
20 ~ 30 mm
10 ~ 15 mm
3 ~ 7mm
2-11
SPEC
SPEC
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUE (CHASSIS)
PARTS TO BE TIGHTENED
THREAD
SIZE
TIGHTENING TORQUE
Nm
m.kg
ft.lb
Front Engine Stay and Mount
M 8 X 1.25
38
3.8
27.5
Front Engine Stay and Frame
M 10 X 1.25
55
5.5
40
Rear Engine Mount and Frame
M 8 X 1.25
38
3.8
27.5
Upper Engine Stay and Mount
M 8 X 1.25
38
3.8
27.5
Upper Engine Stay and Frame
M 8 X 1.25
38
3.8
27.5
Front Lower Engine Mount and Frame
M 8 X 1.25
38
3.8
27.5
Handle Crown and Inner Tube
M 8 X 1.25
23
2.3
17
Handle Crown and Steering Shaft
M 10 X 1.25
35
3.5
25
Under Bracket and Inner Tube
M 10 X 1.25
28
2.8
20
*
M 25 X 1.25
23
2.3
17
M 8 X 1.25
23
2.3
17
Front Fender
M 6 X 1.0
7
0.7
5.1
Speedometer Cable and Speedometer
M 12 X 1.0
2.5
0.25
2
Handle Crown and Main Switch
M 6 X 1.0
13
1.3
9.4
Front Wheel Axle Nut
M 14 X 1.5
59
5.9
43
Rear Wheel Axle Nut
M 14 X 1.5
91
9.1
66
Wheel Sprocket and Clutch Hub
M 8 X 1.25
40
4.0
29
Tensioner Bar
M 8 X 1.25
19
1.9
14
Camshaft Lever
M 6 X 1.0
9.8
0.98
7.1
Fuel Cock
M 6 X 1.0
7
0.7
5.1
Ignition Coil
M 6 X 1.0
3.8
0.38
3
Battery Box
M 6 X 1.0
3.8
0.38
3
Rear Fender
M 6 X 1.0
3.8
0.38
3
Pivot Axle Nut
M 12 X 1.25
59
5.9
43
Rear Shock Absorber
M 10 X 1.25
40
4.0
29
Tension Bar and Rear Arm
M 8 X 1.25
19
1.9
14
Side Stand
M 8 X 1.25
25
2.5
18
Footrest and Frame
M 8 X 1.25
23
2.3
17
Footrest Mounting Lower
M 8 X 1.25
16
1.6
12
Steering Shaft and Ring Nut
Handle Crown and Handle
*
Note :
1. First tighten the Ring Nut approximately 33 Nm (3.3 m.kg 25 ft.lb) by using the torque
wrench then loosen the Ring Nut 1/4 turn.
2. Retighten the Ring Nut to specifications
2-12
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
DESCRIPTION
Voltage :
Ignition system :
Ignition timing (B.T. D. C)
Advancer Type
CDI :
Magneto model/manufacturer
Sensor Coil (Color)
CDI Unit Model/manufacturer
IgnitionCoil :
Model/Manufacturer
Primary Coil Resistance
Secondary Coil Resistance
Spark Plug Cap :
Type
Resistance
Charging System :
Type
Flywheel Magneto :
Model/Manufacturer
Charging Voltage
Charging Coil Resistance
Lighting :
Lighting Voltage
SPECIFICATION
12V
7º ± 2º BTDC at 1400 rpm.
Electrical type
Digitally Controlled
5YY/DENSO
240 Ω ± 20%
5KA/ Denso
5YY/Wings Automobiles Pvt. Ltd.
0.22 Ω ± 15%
3.0 KΩ ± 20%
Resistance Type
5 kΩ at 20 ºC (68ºF)
Flywheel Magneto
5YY/DENSO
14 ~ 15V @ 5000 RPM
0.75 Ω ± 20% (68ºF)
14 V ± 0.5 @ 5000 RPM
Lighting Coil Resistance
Rectifier/Regulator :
Type
Model/Manufacturer
No load regulated voltage
Capacity
Withstand voltage
Battery :
Specific Gravity
Horn:
Type
Quantity
Model/Manufacturer
Maximum Amperage
Flasher relay:
Type
Model/Manufacturer
Self cancelling device
Flasher frequency
Wattage
0.62Ω ± 20 % (68ºF)
Semi conductor-Short Circuit Type
5YY/M/s Nappino Auto
14.5 ± 0.5 V at 5000 rpm
8A
400 V
1.230
Plane type
1 pc.
5YY/Local Made
1.5 A
Semi transistor type
5KA3/Local Made
No
85 ± 15 cycles/min
10W X 2
2-13
MAINTENANCE SPECIFICATIONS
Circuit Breaker :
Type
Amperage for individual circuit X quantity :
Main
Reserve
Fuse
10A X 1pc.
10A X 1pc.
2-14
SPEC
GENERAL TORQUE SPECIFICATION
SPEC
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specification for special components or assemblies are included in applicable section of this book. To
avoid warpage, tighten multi-fastener assemblied in a criss-cross fashion, in progressive stages,
until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry
threads. Components should be at room temperature.
A
(Nut)
B
(Bolt)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
6 mm
8 mm
10 mm
12 mm
14 mm
16 mm
General Torque
specifications
Nm
6
15
30
55
85
130
m•kg
ft•lb
0.6
1.5
3.0
5.5
8.5
13.0
4.3
11
22
40
61
94
A : Distance across flats
B : Outside thread diameter
2-15
LUBRICATION POINTS AND LUBRICANT TYPE
SPEC
LUBRICATION POINTS AND LUBRICANT TYPE
ENGINE
Lubrication points (part name)
Lubricant type
Oil Seal lips (all)
Bearing Retainer (all)
Bolt (Cylinder Head)
O-ring (Cylinder Head Side Cover and Valve Cover)
Crank Pin
Connecting Rod (big end)
Piston Pin
Valve Stem and Valve Guide
Oil Seal (Valve Stem End)
Rocker Arm Shaft and Rocker Arm
Cam and Bearing (Camshaft)
Push Rod
Primary Driven Gear and Main Axle
Push Lever Axle
Rotary Filter and Oil Pump
Sliding Gear (Transmission)
Kick Axle Shaft
Axle Drive
Shift Fork and Guide Bar
Shift Cam and Bearing (shift cam)
Crankcase Mating Surfaces
Yamaha bond No. 1215
Crankcase Cover 1 and Grommet
Yamaha bond No. 1215
2-16
LUBRICATION POINTS AND LUBRICANT TYPE
SPEC
CHASSIS
Lubrication points (part name)
Lubricant type
Gear Unit (Gear Meter and Drive)
Oil Seal Lips (all)
Pivot Shaft (Swingarm)
Pivoting Points (Brake Pedal Shaft and Frame)
Ball and Ball Race (Steering Head)
Tube Guide (Right Grip)
Pivoting points (Brake Lever and Clutch Lever)
Pivoting Point (Brake Shoe Plate)
Cable End (Front Brake and Clutch)
Pivoting Points (Sidestand Mainstand and Rear Footrest)
Brake Camshaft (Cam and Shaft)
2-17
ENGINE LUBRICATION ROUTE
SPEC
Engine Lubrication route
CAUTION:
WARNING
DO NOT DAMAGE CRANK CASE SURFACES, OTHERWISE OIL LEAKAGE WILL START
2-18
ENGINE LUBRICATION ROUTE
Engine Lubrication route
CAUTION:
WARNING
FOR IMPROVED PERFORMANCE, ALWAYS USE YAMALUBE OIL
2-19
SPEC
ENGINE BEARINGS
ENGINE BEARINGS
2-20
SPEC
SPEC
CABLE ROUTING
CABLE ROUTING
É Flasher light lead (left)
Æ through the Cable Guide of
Ê Flasher Light
the right side.
Ë Flasher light lead (right)
C Clamp Wireharness È and
A Pass the Clutch Cable À,
front fork.
Starter wire Á and D Pass the Wireharness È and
Handle-bar Switch Lead
Clutch Cable À.
through the cable guide of
the left side.
B Pass the Throttle Cable Å,
and the Brake Cable Ä and
the Front Brake switch lead
¿ Handlebar switch (left)
À Clutch cable
Á Starter Wire
 Speedometer
à Tachometer
Ä Brake Cable front
Å Throttle cable
Æ Brake switch lead
Ç Speedometer cable
È Wireharness
Ã
Â
A
B
À
Ä
¿
Å
Á
Æ
À
Ä
¿
Ê
Ê
Ë
É
Ç
À
D
È
À
2-21
C
CABLE ROUTING
¿ Headlight assembly
À Handlebar switch lead
Á Speedometer cable
 Cable guide
à Clutch cable
Ä Horn
Å Fuse
Æ CDI unit
Ç Clamp Battery
È Stop/tail light
É Flasher light lead (LH)
Ê Flasher light
Ë Battery
Ì Battery breather hose
Í Neutral switch lead
¿
Î Brake Cable
Ï H.T. Coil
Ð Air Induction system
A Pass the wireharness
through the cable guide.
B Pass the speedometer cable
Á and front brake cable Î
through the Cable Guide.
C Align the white marking of
Wireharness with the frame
clamp
D Connect
the
battery
negative (-) lead and
positive (+) lead with the
wireharness.
SPEC
E Pass the battery breather
hose Ì through the hole
of the lower left side of
the Battery Box
F Pass the magneto lead to
the outside of the flange of
the chain cover.
À
Ã
Ä
Ï
Æ
Ð
Å
É
C
È
A
Ê
D
Â
Î
Á
B
Ç
E
Í
Ì Ë
F
2-22
SPEC
CABLE ROUTING
¿ Throttle cable
À High tension cord
Á Ignition Coil
 Band - C.D.I.
à Brake cable front
Ä Speedometer
Å Brake switch lead
Æ Clutch cable
Ç Rr Brake Switch
È A.I.S. Unit
É Starter wire
Ê Carburettor Breather
Pipe
A Pass the high tension cord À through the
cable guide and starter wire.
B Pass the throttle cable ¿ and starter wire
É through cable guide.
C Pass the clutch cable Æ through cable
guide.
D Pass breather hose through upper right side
hole of frame bracket engine.
Ã
Å
Ä
A
Â
É
B
È
¿
Æ
Á
C
Ç
¿
D
À
Ê
2-23
CABLE ROUTING
SPEC
¿ C.D.I. Unit
à Stop/tail light lead
À Rectifier regulator
Ä Wireharness
Á Flasher relay
Å Carburettor Air Vent
 Flasher light lead
Æ Tail Light Assembly
A Clamp the Wire Harness lead.
B Pass the Wire Harness between Frame and Rear Fender
¿
À
Å
Ä
A
Ä
Á
Â
B
Æ
Ã
Â
2-24
INSP
ADJ
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENTS
PERIODIC MAINTENANCE / LUBRICATION INTERVALS ....... 3-1
SIDE COVER, SEAT AND FUEL TANK
REMOVAL ................................................................................... 3-3
INSTALLATION ........................................................................... 3-5
ENGINE
VALVE CLEARANCE CHECKING ADJUSTMENT ....................3-6
IDLING CO MEASUREMENT, AND ADJUSTMENT ................. 3-8
THROTTLE CABLE ADJUSTMENT
SPARK PLUG INSPECTION AND ADJUSTMENT....................3-10
IGNITION TIMING CHECK ........................................................3-11
COMPRESSION PRESSURE MEASUREMENT ......................3-13
ENGINE OIL LEVEL INSPECTION ............................................3-14
ENGINE OIL REPLACEMENT ................................................... 3-14
AIR FILTER CLEANING ............................................................... 3-15
CLUTCH CABLE ADJUSTMENT ............................................... 3-17
CHASSIS
FRONT BRAKE ADJUSTMENT ................................................. 3-18
REAR BRAKE ADJUSTMENT ................................................... 3-18
BRAKE SHOE INSPECTION ..................................................... 3-19
BRAKE LIGHT SWITCH ADJUSTMENT ................................... 3-19
DRIVE CHAIN SLACK ADJUSTMENT ......................................3-20
STEERING HEAD INSPECTION ............................................... 3-22
FRONT FORK INSPECTION ..................................................... 3-24
REAR SHOCK ABSORBER ADJUSTMENT ............................. 3-24
TYRE INSPECTION ................................................................... 3-25
SPOKE INSPECTION AND TIGHTENING ................................3-27
WHEEL INSPECTION ................................................................ 3-27
ELECTRICAL
BATTERY INSPECTION ............................................................3-28
FUSE INSPECTION ................................................................... 3-30
HEADLIGHT BEAM ADJUSTMENT ..........................................3-31
HEADLIGHT BULB REPLACEMENT ........................................3-31
INSP
ADJ
INTRODUCTION/
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable Motorcycle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to Motorcycles already in service as well as to new Motorcycles that are being
prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
SERVICES
S. NO.
OPERATION
ITEM
FREE
PAID
I
II
III
IV
V
VI
EVERY
2000
km
1
VALVES
Check valve clearances, adjust if necessary
2
SPARK PLUG
Check condition, gap
Clean and reset if necessary
3
CARBURETOR
Do not open butterfly slide valve screws.
Check idle speed, Starter Lever operation.
Tune if necessary. Don’t open/Tamper T.P.S.
4
*AIR FILTER
Clean, inspect & lubricate.(replace if necessary)
5
FUEL LINE
Check Fuel Hose, for cracks or damage.
Replace
Replace in necessary.
6
FUEL FILTER
Check for free flow of petrol cleanliness of
Every 10,000 kms
bowl/filter, Replace in necessary
7
ENGINE OIL
with recommended oil (Warm engine
before draining) - YAMALUBE
8
OIL STRAINER
Wash with petrol.
9
BRAKE-FRONT
& REAR
BRAKE SHOES
FRONT & REAR
CLUTCH
Checkoperation/Adjust in necessary.
Check for wear, replace in necessary.
Check alignment marks on Push Lever and
Every 10,000 kms
Every 10,000 kms
10
11
Grease the brake cam.
Crankcase L.H. Adjust if necessary.
12
13
REAR ARM PIVOT
Check Rear Arm assembly for looseness. Tighten
WHEELS
with specified torque if necessary Repack grease
Check runout, Spoke tightness, damage; Correct
it if necessary.
14
WHEEL BEARING
Check Bearing assembly fo looseness, damage;
15
STEERING RACE
BALL
Check Race Ball Assy. for loosness, Tighten/
FRONT FORK
Check operation/oil leakage, Repair if necessary.
Replace Oil
Repack grease
16
17
REAR SHOCK
ABSORBER
Every 10,000 kms
Repack grease
Replace if necessary.
Check operation/oil leakage, Replace if
necessary.
3-1
Every 10,000 kms
INSP
ADJ
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
SERVICES
S. NO.
18
ITEM
DRIVE CHAIN
OPERATION
FREE
PAID
EVERY
2000
km
I
II
III
IV
V
VI
Check electrolyte level and top it up with distilled water if necessary. Check specific gravity.
Check Breather Pipe for blockage and routing
Check chain stack, alignment, adjust if
necessary Clean and lubricate.
19
20
21
22
NUTS, BOLTS
AND FASTENERS
CENTER STAND
AND SIDE STAND
BATTERY
Check all Chassis fittings and fasteners for
looseness. Tighten as per specification.
Check operation and lubricate if necessary.
CONTROL CABLES Check operation, free play, Cable damage.
- THROTTLE
Readjust or replace as required
- CLUTCH
- FRONT BRAKE
EVERY MONTH
It is recommended that above be serviced by authorised YAMAHA MOTOR INDIA PRIVATE LIMITED
dealer *Service more frequently when the vehicle is driven in dusty areas.
3-2
SIDE COVERS, SEAT AND FUEL TANK
INSP
ADJ
SIDE COVERS, SEAT AND FUEL TANK
REMOVAL SIDE COVER (LH)
1. Remove
• Side Cover (LH)
¿
ææææææææææææææææææææææææææææææææææ
Removal steps :
• Open the Lock ¿ using Main Switch Key.
• Pull the Lug À / Lug Á towards you to remove
it from the Fuel Tank.
• Slide the Side Cover towards the front side of
the Motorcycle for removing the Lug  from
the Chassis.
ææææææææææææææææææææææææææææææææææ
Á
À
Â
REMOVAL SIDE COVER (RH)
1. Remove
• Side Cover (RH)
¿
ææææææææææææææææææææææææææææææææææ
Removal steps :
• Remove the Screw ¿
• Pull the lug À / Lug Á towards you to remove
it from the Fuel Tank.
• Slide the Side Cover towards the front side of
the Motorcycle for removing the lug  from the
chassis
ææææææææææææææææææææææææææææææææææ
Â
À
Á
3-3
SIDE COVERS, SEAT AND FUEL TANK
INSP
ADJ
REMOVAL SEAT
À
¿
1. Remove
• Side Cover LH and RH
• Bolts 2 Nos - Bolts ¿ and À from LH/RH
side
• Seat
ææææææææææææææææææææææææææææææææææ
Removal steps :
• Open bolts ¿ and À inside the side covers.
• Lift the front of the Seat and slide it forward.
À
WARNING
• Gasoline is highly flammable.
• Avoid spilling of fuel on the hot Engine.
REMOVAL FUEL TANK
1. Disconnect
• Fuel Hose
• Scoop Bracket - 2 Nos Bolts Â
Á
Â
NOTE :
• Position the Fuel Cock Lever Á to the ‘OFF’,
disconnect the Fuel Hose.
• Place a rag cloth under the Fuel Line to absorb any spilt fuel.
Â
Â
¿
2. Remove
• Bolt (Fuel Tank) ¿
• Plate À
• Damper Rubber Á
• Fuel Tank Â
À
Á
3-4
SIDE COVERS, SEAT AND FUEL TANK
INSP
ADJ
INSTALLATION
¿
Â
Á
À
Reverse the REMOVAL procedure.
Note the following points.
1. Install
• Fuel Tank ¿
• Damper Rubber À
• Plate Á
• Bolt Â
• Fuel Hose
Bolt (fuel tank)
20 Nm (2.0 mkg; 14.4 ft.lb)
NOTE :
• Keep the projection on plate Á downward.
¿
2. Install
• Scoop Bracket ¿
• Bolts - 2 Nos.
3. Install
• Seat
• Bolts - 2 Nos.
ç
è
NOTE :
• Insert the projection ç on the rear of the seat
into the respectable è on the Chassis, then
push down front of the seat and tighten the
bolts.
Bolt (Seat)
3.8 Nm (0.38 mkg, 3.0 ft.lb)
¿
4. Install
• Side Cover (LH) ¿ and lock with Key
Á
5. Install
• Side Cover (RH) À
À
6. Tighten
• Screw Á
3-5
VALVE CLEARANCE CHECKING AND ADJUSTMENT
INSP
ADJ
ENGINE
VALVE CLEARANCE CHECKING AND
ADJUSTMENT
NOTE :
Valve clearance checking and adjustment
should be made with the Engine in cold condition, at room temperature.
When the Valve clearance is to be measured or
adjusted, the Piston must be at Top Dead Center (T.D.C.) on the compression stroke and
marking on Cam Sprocket should be aligned
with the marking on Cylinder Head.
1. Remove :
• Side Covers
• Seat
• Fuel Tank
Refer to “SIDE COVERS, SEAT AND FUEL
TANK” section Page no 3-3
Á
Â
2. Remove :
• Spark Plug
• Bolts (Cylinder Head Side Cover) ¿ 2 Nos
• Cylinder Head Side Cover À
• Valve Cover - Intake Á/ Exhaust side Â
À
¿
3. Remove :
• Timing Check Plug (with O-ring) ¿
• Center Plug (with O-ring) À
¿
À
4. Measure :
• Valve clearance (Intake and Exhaust) ¿
using Feeler Gauge
Out of specification Ÿ Adjust.
Feeler Gauge :
YSST - 615
¿
Valve clearance (cold)
Intake : 0.08 ~ 0.12 mm
Exhaust : 0.10 ~ 0.14 mm
3-6
VALVE CLEARANCE CHECKING AND ADJUSTMENT
è
ç
INSP
ADJ
ææææææææææææææææææææææææææææææææææ
Checking steps :
Measurement steps :
• Rotate the Crankshaft anticlockwise to align
the slit ç third mark on the rotor with the stationary pointer è on the Crankcase Cover LH
when the Piston is at Top Dead Center (T.D.C.)
and in compression stroke.
• Measure the Valve clearance by using a feeler
gauge.
Feeler Gauge
YSST 615
Out of specification Ÿ Adjust clearance.
ææææææææææææææææææææææææææææææææææ
5. Adjust :
• Valve clearance
¿
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
• Loosen the Locknut ¿
• Turn the Adjuster À in or out with the Valve
adjusting tool Á until specified clearance is
obtained.
Valve adjusting tool :
YSST - 606
À
Turning in ŸValve clearance is decreased.
Turning outŸValve clearance is increased.
Á
• Hold the Adjuster to prevent it from moving
and tighten the Locknut.
Locknut :
8 Nm (0.8 m • kg, 5.8 ft • lb)
• Measure the Valve clearance.
• If the clearance is incorrect, repeat above
steps until specified clearance is obtained.
ææææææææææææææææææææææææææææææææææ
6. Install
• Timing Check Plug (with O-ring ) ¿
• Center Plug (with O-ring) À
¿
À
3-7
IDLING CO. MEASUREMENT AND ADJUSTMENT
¿
INSP
ADJ
7. Install
• Valve Covers (with O-ring) ¿
• Spark Plug
• Cylinder Head Side Cover À
¿
Valve cover (intake and exhaust) :
17.5 Nm (1.75 m kg, 13 ft-lb)
Bolts (cylinder head side cover) :
10 Nm (1.0 m kg, 7.2 ft-lb)
À
8. Install
• Seat
• Side Covers
• Fuel Tank
Refer to the “SIDE COVERS, SEAT AND
FUEL TANK” section Page no 3-3
IDLING CO. MEASUREMENT
ADJUSTMENT
AND
1. Start the Engine and let it warm up by running the Motorcycle approx. 3~4 kms.
2. Attach :
• Inductive Tachometer to the Spark Plug
Lead.
Tachometer :
YSST - 613
3. Check :
• Engine idling speed (standard)
Out of specification Ÿ Adjust.
Turn the Throttle Stop Screw ¿ in or out
until specified idling speed is obtained.
Turning IN ” Increase in rpm
Turning OUT ” Decrease in rpm
Engine idling speed :
1,300 ~ 1,500 r/min
¿
NOTE :
Before checking Engine idle RPM always check
throttle cable free movement and free play.
4. Insert :
• Sampling probe ¿ (CO. tester ) to the
exhaust pipe À
À
¿
CO.concentration :
2.5% ± 1.5 V/V
Out of specification ” Adjust.
3-8
IDLING ‘CO’ MEASUREMENT AND ADJUSTMENT/
THROTTLE CABLE ADJUSTMENT
INSP
ADJ
5. Adjust :
• ‘CO’ concentration
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
• Turn the pilot screw ¿ in or out until the specified ‘CO’ concentration is obtained.
Turning in ” ‘CO’ concentratin decreases
Turning out ” ‘CO’ concentration increases
¿
NOTE :
For adjusting the Engine idling speed use the
throttle stop screw À. Do not adjust Engine Idle
RPM by using the Pilot Screw.
•
After adjusting, ‘CO’ concentration as
specified, remove the ‘CO’ tester, make
sure that the Engine idling speed has not
changed.
ææææææææææææææææææææææææææææææææææ
THROTTLE CABLE ADJUSTMENT
NOTE :
Prior to adjusting the Throttle Cable free play,
the Engine idling speed should be adjusted.
1. Check :
• Throttle cable free play ç
Out of specification Ÿ Adjust.
ç
Free play : 3 ~ 7 mm
At Throttle Grip flange
2. Adjust :
• Throttle Cable free play
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
NOTE :
Never accelerate the Throttle when stopping the
Engine.
3-9
THROTTLE CABLE ADJUSTMENT/
SPARK PLUG INSPECTION
• Loosen the Locknut ¿ on the Throttle
Cable.
• Turn the Adjuster À in or out until the
specified free play is obtained.
è
À
ç
INSP
ADJ
Turning IN ç Ÿ Free play is increased.
Turning OUT è Ÿ Free play is decreased.
¿
• Tighten the locknut ¿.
WARNING
After adjusting, turn the Handlebar to the
right and to the left to ensure that this does
not cause the Engine idling speed to
change.
SPARK PLUG INSPECTION
1. Remove :
• Spark Plug Cap
• Spark Plug
À
ç
WARNING
CAUTION:
¿
Before removing the Spark Plug, use compressed air to blow away any dirt accumulated in the Spark Plug wells to prevent it
from falling into the Cylinder.
2. Check :
• Spark Plug Type / Number
Incorrect ”Replace
Standard Spark Plug :
R-CR7 HSA - NGK
3. Inspect :
• Center Electrode ¿
Wear/damage Ÿ Replace Spark Plug.
• Ground Electorde À
Abnormal color Ÿ Replace Spark Plug.
Normal color is medium-to-light tan color
4. Clean :
• Spark Plug
(with Spark Plug cleaner or wire brush)
5. Measure :
• Spark Plug gap ç
(with a wire gauge)
Out of specification Ÿ Adjust gap.
Spark Plug Gap:
0.6 ~ 0.7 mm
3-10
SPARK PLUG INSPECTION/
IGNITION TIMING CHECKING PROCEDURE
INSP
ADJ
6. Install :
• Spark Plug
Spark Plug :
12.5 Nm (1.25 mkg, 9 ftlb)
NOTE :
• Before installing a Spark Plug, clean the Gasket surface and Plug surface.
• If a Torque Wrench is not available, a good
estimate of the correct tightening torque is to
finger tighten ¿ the Spark Plug and then
tighten it another 1/4 to 1/2 turn to À using
Box Spanner
IGNITION
TIMING
PROCEDURE :
¿
CHECKING
NOTE :
Prior to checking the ignition timing, check all
electrical connections related to the starting system. Make sure that all connections are intact.
1. Remove :
• Plug Straight Screw ¿
2. Attach :
• Timing light À
À
Timing light
SKC (S14-121) or any standard
brand
Engine tachometer
YSST - 613
3-11
IGNITION TIMING CHECKING PROCEDURE
INSP
ADJ
3. Check :
• Ignition timing
*********************************************
Checking steps :
• Start the Engine and let it warm up for several minutes or run the Motorcycle for approx.
4 kms.
• Maintain the Engine idling speed
Engine idling speed :
1,300 ~ 1,500 r/min
ç
è
A : Auto Advance reverse circuit not working
B : Auto Advance not working
C : Delay Auto Advance
D : STD Auto Advance working
¿ À Á Â Different stages of RPM
• Confirm that the stationary pointer on LH
Crankcase Cover ç falls within the ignition
timing range è marked on Rotor Assembly.
NOTE :
Ignition timing is not adjustable.
4. Check
• Auto advance mechanism
ææææææææææææææææææææææææææææææææææ
Checking steps
• Increase the Engine speed from 1400 r/min to
2250 r/min
• Check the stationery pointer ç should be
within the ignition timing range è marked on
the Rotor Assembly
• Further increase the Engine speed from 2250
r/min onwards.
• Observe that Rotor ignition timing mark moves
in clockwise direction gradually and later not
visible.
• If above phenomenon is not observed it confirms that the CDI unit is defective (Auto Advance mechanism not working)
ææææææææææææææææææææææææææææææææææ
5. Install :
• Plug straight screw (with O-ring)
3-12
COMPRESSION PRESSURE MEASUREMENT
INSP
ADJ
COMPRESSION PRESSURE MEASUREMENT
¿
NOTE :
Insufficient compression pressure will result in
performance loss.
1. Check :
• Valve clearance
Out of specification Ÿ Adjust.
Refer
to
“VALVE
CLEARANCE
ADJUSTMENT” section. Page no 3-6
2. Start the Engine and let it warm up for several minutes.
3. Turn off the engine.
4. Remove :
• Spark Plug
5. Attach:
• Compression gauge ¿
Compression Gauge :
COMPRESSION PRESSURE
(With oil applied into cylinder)
Reading
Diagnosis
Higher than without oil Worn or damaged
piston
Same as without oil
Possible defective
ring(s),Valves,Cylinder
head Gasket or Piston Ÿ Repair.
6. Measure :
• Compression pressure
If it exceeds the maximum pressure allowed
”Inspect the Cylinder Head, Valve surfaces
and Piston Crown for carbon deposits.
If it is below the minimum pressure ”
Squirt a few drops of oil into the affected
cylinder and measure again.
Follow the table
Compression pressure :
(at sea level)
Standard : 1200 kPa (12 Kg/cm²)
Minimum : 1040 kPa (10.4 Kg/cm²)
ææææææææææææææææææææææææææææææææææ
Measurement steps:
• Crank the Engine with the Throttle wide open
until the reading on the compression gauge
stabilizes.
WARNING
Before cranking the engine, ground Spark
Plug leads to prevent sparking
ææææææææææææææææææææææææææææææææææ
7. Install :
• Spark plug
3-13
ENGINE OIL LEVEL INSPECTION/
ENGINE OIL REPLACEMENT
INSP
ADJ
8. Install :
• Fuel tank
• Seat
• Side covers
Refer to “SIDE COVERS, SEAT AND
FUEL TANK” section Page no 3-3
ENGINE OIL LEVEL INSPECTION
1. Stand the Motorcycle on a level surface using the Center Stand.
NOTE:
Make sure the Motorcycle is upright when
inspecting the oil level.
2. Start the Engine and let it warm up for a few
minutes.
3. Turn off the Engine.
4. Remove the Dip Stick ¿ (oil level gauge).
Wipe off the Dip Stick (oil level gauge) using a clean cloth and rest it on the threads
of oil filler hole. Then remove the Dip Stick
(Oil Level Gauge)
5. Inspect:
• Engine oil level
Oil level should be between maximum ¿
and minumim À marks.
Oil level is below the minimum mark Ÿ
Add oil up to the proper level.
RECOMMENDED ENGINE OIL
¿
YAMALUBE (20W40)
SG grade.
¿
À
NOTE :
Wait a few minutes until the oil settles before
inspecting the oil level.
ENGINE OIL REPLACEMENT
1. Start the Engine and let it warm up for several minutes or drive approx 4 Kms.
2. Turn off the Engine and place an oil pan under the Engine.
3. Remove :
• Dip stick (oil level gauge)
• Drain plug ¿
• Gasket
Drain the oil from the Crankcase.
¿
3-14
ENGINE OIL REPLACEMENT/
EXHAUST SYSTEM INSPECTION
INSP
ADJ
4. Install :
• Drain plug ¿ with Washer
¿
Drain plug :
20 Nm (2.0 m.Kg, 14.5 ft. lb)
5. Fill :
• Oil in Crankcase
Oil quantity : Refill
1.0 L
6. Check :
• Engine oil level
Refer to “ENGINE OIL LEVEL INSPECTION”
section Page no 3-14
7. Install
• Dip Stick (Oil Level Gauge)
¿
EXHAUST SYSTEM INSPECTION
1. Inspect :
• Bolt ¿ (Exhaust Pipe) - 2 Nos.
Loose/ Damage Ÿ Tighten / replace.
• Gasket (Exhaust Pipe)
Exhaust gas leaks Ÿ Tighten /replace.
À
Bolt :
10 Nm, 1.0 m.kg, 7.2 ft. lb.)
2. Inspect :
• Bolt À (Muffler)
Loose/Damage Ÿ Tighten /replace.
Bolt :
15 Nm (1.5 m.kg, 7.2 ft. lb)
3. Inspect :
• Screw Á (Muffler Protector) - 6 Nos.
Loose/ damage Ÿ Tighten/replace
Á
Á
AIR FILTER CLEANING
¿
NOTE :
On the bottom of the Air Filter Case, there is a
Drain Hose ¿. If dust and/or water collects in
this Drain Hose, clean the Air Filter Element and
Air Filter Case.
3-15
AIR FILTER CLEANING
INSP
ADJ
1. Remove:
• Side Cover (R.H.)
• Air Filter Case Cap ¿ - Unscrew 4 Nos.
Screws
• Spring Wire À
• Air Filter Element Á
• Element guide Â
¿
WARNING
CAUTION:
À
Never operate the Engine without the Air
Filter element installed. Unfiltered air will
cause rapid wear of Engine parts and may
damage the Engine. Operating the Engine
without the Air Filter Element will also affect
the Carburetor tuning, leading to poor
Engine
performance
and
possible
overheating.
2. Inspect:
• Air Filter Element Á
Damaged Ÿ Replace.
3. Clean:
• Air Filter Element Á
Use kerosene to clean the Element.
NOTE :
After cleaning, remove the remaining kerosene
by squeezing rhe element.
WARNING
CAUTION:
Do not twist the Air Filter Element when
squeezing it.
4. Apply the recommended oil to the entire
surface of the Air Filter Element uniformly
and squeeze out the excess oil.
Recommended oil :
YAMALUBE (20W40) or equivalent
WARNING
Never use low flash point solvents such as
gasoline to clean the Air Filter Element. Such
solvents may cause a fire or an explosion
5. Assemble
• Air Filter Element on Element Guide
6. Install :
• Air Filter Element Assy.
• Spring Wire
• Air Filter Case Cap
• Side Cover (R.H.)
3-16
CLUTCH CABLE ADJUSTMENT
INSP
ADJ
CLUTCH CABLE ADJUSTMENT
1. Check :
• Clutch Cable free play ç
Out of specification Ÿ Adjust,
Free play (clutch lever) :
10 ~ 15 mm at lever end
ç
2. Adjust:
• Clutch Cable free play
ææææææææææææææææææææææææææææææææææ
Adjustment steps:
Lever side
• Loosen the Locknut ¿
• Turn the Adjuster À in or out until the specified free play is obtained.
À
è
Turning in ç Ÿ Free play is increased.
Turning out è Ÿ Free play is decreased.
ç
¿
• Tighten the locknut ¿
NOTE :
If not possible to achieve the specified free play
at the Clutch Lever end then adjust it by using
Adjuster below the Carburettor.
Â
Á
Below the Carburettor.
• Remove Side Covers, Seat and Fuel Tank
• Detach Clutch Cable from Push Lever
• Loosen the Locknut Á
• Turn the adjuster  in or out to increase or
decrease the length of the Clutch Cable outer.
• Tighten the locknut Á
• Attach the Clutch Cable end to the Push Lever.
• Adjust the Clutch Cable free play at Lever end
as before.
• Install Fuel Tank, Seat and Side Covers
ææææææææææææææææææææææææææææææææææ
3-17
FRONT BRAKE ADJUSTMENT/
REAR BRAKE ADJUSTMENT
INSP
ADJ
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check :
• Brake Lever free play a
Out of specification Ÿ Adjust.
Free play (Brake Lever):
25 ~ 30 mm at Brake Lever end
¿
À
2. Adjust :
• Brake Lever free play
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
Lever Side
• Loosen the Locknut ¿.
• Turn the Adjuster À in or out until the specified free play is obtained.
Turning in ç Ÿ Free play is increased.
Turning out è Ÿ Free play is decreased.
ç
è
WARNING
CAUTION:
Make sure that there is no Brake drag after
adjusting the Front Brake Lever free play.
NOTE :
If not possible to achieve the specified free play
in Brake Lever then adjust it with Adjuster on
the Wheel end of the Front Brake Cable.
è
ç
Wheel side
• Turn the Adjuster Á in or out until the specified free play is obtained.
Á
Turning in ç Ÿ Free play is decreased.
Turning out è Ÿ Free play is increased
ææææææææææææææææææææææææææææææææææ
REAR BRAKE ADJUSTMENT
1. Check :
• Brake Pedal free play ç
Free Play :
20 ~ 30 mm
Out of specification Ÿ Adjust
ç
3-18
REAR BRAKE ADJUSTMENT/
BRAKE SHOE INSPECTION
INSP
ADJ
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
• Turn the Adjuster ¿ in or until the specified
free play is obtained.
Turning out ç Ÿ Free play is increased.
Turning in è Ÿ Free play is decreased.
¿
WARNING
CAUTION:
Make sure that the Brake does not drag after adjusting it.
ææææææææææææææææææææææææææææææææææ
3. Adjust :
• Brake light switch
Refer to “BRAKE LIGHT SWITCH
ADJUSTMENT”. as given below
BRAKE SHOE INSPECTION
¿
1. Operate the brake lever or pedal.
2. Inspect :
• Brake shoes
Wear indicator ¿ reaches the wear limit line À
Ÿ Replace the brake shoes as a set.
Refer to “FRONT WHEEL” and “REAR
WHEEL” in CHAPTER 6 page no 6-6
À
BRAKE LIGHT SWITCH ADJUSTMENT
À
NOTE :
• The Brake Light Switch is operated by movement of the Brake Pedal.
• Adjustment is correct when the Brake Light
comes on just before the braking effect actually starts.
¿
¿
À
1. Check :
• Brake light operation timing
Incorrect ”Adjust.
2. Adjust:
• Brake light operating timing.
ææææææææææææææææææææææææææææææææææ
Adjustment steps:
• Hold the main body ¿ of the switch with your
hand so that it does not rotate, and turn the
adjuster À in or out until the proper operation
timing is obtained.
ææææææææææææææææææææææææææææææææææ
3-19
DRIVE CHAIN SLACK ADJUSTMENT
INSP
ADJ
DRIVE CHAIN SLACK ADJUSTMENT
NOTE:
• Before checking and adjusting, rotate the
Rear Wheel several revolutions and check
the slack at several points to find the tightest point.
• Check and if necessary adjust the Drive
Chain slack with the Rear Wheel in this “tightest” position.
WARNING
CAUTION:
Too little chain slack will overload the engine
and other vital parts; keep the slack within
the specified limits.
• Excessive Chain slack will cause abnormal
noise and will affect the life of chain, sprockets and low fuel efficiency.
WARNING
• Securely support the Motorcycle so that
there is no danger of it falling over.
• Stand the Motorcycle on its centerstand.
1. Stand the Motorcycle on its center stand.
2. Check :
• Drive chain slack ç
Out of specification Ÿ Adjust.
ç
Drive chain slack:
20 ~ 30 mm
Â
À
Á
¿
Á
3. Remove :
• Cotter pin ¿
4. Loosen :
• Axle Nut À
• Adjuster Locking Nut Á & Â
5. Adjust :
• Drive Chain slack
6. Align
• Chain adjuster marsk LH/RH Side.
ææææææææææææææææææææææææææææææææææ
Make sure that mark of chain adjuster should
be same position on LH/RH side chain adjuster
by Adjusting Nut Â
ææææææææææææææææææææææææææææææææææ
Â
3-20
DRIVE CHAIN SLACK ADJUSTMENT
Â
ç
Ã
Á
INSP
ADJ
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
• Loosen both the Locknuts Â.
• Turn the Adjuster Á in or out until the specified Drive Chain slack is obtained.
Turning in ç Ÿ Drive Chain slack is
decreased.
Turning out è Ÿ Drive Chain slack is
increased.
è
NOTE :
• Turn each Chain Adjuster exactly the same
amount to maintain correct Axle alignment. To
check the alignment there are marks on Chain
Adjuster Ã. Ensure that left hand and right
hand chain alignment marks are equally
matched. Use them when adjusting the slack
for proper alignment.
• Before tightening the Axle Nut À and Driven
Sprocket Locknut to specifications, make sure
that there is no clearance at the Adjuster (or
the Swing Arm end) on both sides by pushing
the Wheel forward.
Nut (driven sprocket axle ) :
91 Nm (9.1m. kg., 66 ft-lb)
Nut (rear wheel axle):
91 Nm (9.1 m.kg, 66 ft.lb)
6. Install :
• Cotter pin Å New
Into the Axle Nut and bend the end of the
Cotter Pin.
New
Å
WARNING
CAUTION:
Do not loosen the Axle Nut after tightening
the torque. If the axle nut grooves is not
aligned with the Cotter Pin hole, align the
groove with the hole by tightening up the
Axle Nut.
WARNING
Always use a new cotter pin.
7. Adjust :
• Brake Pedal free play
Refer to “BRAKE FREE PLAY“ section.
page no 3-18
3-21
STEERING HEAD INSPECTION
INSP
ADJ
STEERING HEAD INSPECTION
WARNING
Securely support the Motorcycle so that
there is no danger of it falling over.
1. Stand the Motorcycle on a level surface.
NOTE :
Stand the Motorcycle on its Center Stand.
2. Elevate the Front wheel by placing a suitable stand under the Engine.
3. Check:
• Handlebar assembly
Grasp the Handle Bar and gently rock the
Steering.
Looseness Ÿ Adjust the Handlebar.
• Steering assembly bearings
Grasp the bottom of the lower Front Fork
tubes and gently rock the Fork Assembly.
Looseness Ÿ Adjust the Steering Head.
4.
5.
Â
¿ À
Ã
Á
Ä
¿
Loosen - Pinch Bolt - (Handle Crown)
Remove :
• Bands ¿
• Bolts (Handlebar Upper holders) À - 4 Nos.
• Handlebar upper holders Á - 2 Nos.
• Handlebar Â
• Handle crown bolts Ã
• Handle crown Ä
5. Adjust :
• Steering head
ææææææææææææææææææææææææææææææææææ
Adjustment steps:
• Remove the lock washer ¿
• Remove the Ring Nut À (upper) and Dumper
Rubber Á , then loosen the Ring Nut  (lower)
using the Ring Nut wrench.
• Tighten the ring nut (lower) at initial tightening torque
Ring nut wrench :
YSST 621
Ring nut-lower (initial tightening ):
33 Nm (3.3 m.kg, 25 ft.lb)
• Loosen the ring nut  (lower) 1/4 turn.
• Tighten the Ring Nut (lower) using the Ring Nut
Wrench up to final tightening torque.
3-22
STEERING HEAD INSPECTION
INSP
ADJ
NOTE :
Set the Torque Wrench to the Ring Nut Wrench
so that they form a right angle.
Ring nut-lower (final tightening) :
23 Nm (2.3 m.kg, 17 ft. lb)
WARNING
Avoid over torquing.
• Check the Steering Stem by Turning it Lock to
Lock. If there is any binding, remove the Steering Stem Assembly and inspect the Steering
Bearings.
Refer to “STEERING HEAD AND HANDLEBAR” section in Chapter 6 Page no 6-29
• Install the Damper Rubber Á and Ring Nut À
(upper), then align the slots of both Ring Nut
 (lower) and tighten the other until they are
aligned.
• Install the Lock Washer ¿
NOTE :
Make sure the lock washer tab is placed in the
slots of Ring Nut.
6. Install :
• Handle crown ¿
• Handle Crown bolt À
• Handlebar Á
• Handlebar upper holder  - 2 Nos
• Bolts (handlebar upper holders) Ã-4 Nos.
• Bands Ä - 2 Nos.
Á
Ã
À
 Ä
¿
Bolts (handle crown and inner tube)
23 Nm (2.3 m.kg, 17 ft.lb)
Bolt (handle crown and Steering
Shaft )
35 Nm (3.5 m. kg, 25 ft.lb)
Bolts (handlebar upper holder)
23 Nm (2.3 m. kg, 17 ft. lb)
3-23
FRONT FORK INSPECTION
INSP
ADJ
FRONT FORK INSPECTION
WARNING
TFF OIL SEALS ¿
Securely support the motocycle so that there
is no danger of it falling over.
1. Stand the Motorcycle on a level surface.
2. Check:
• Inner tube
Scratches/damage ➔ Replace.
• Oil seal ¿
Excessive oil leakage ➔ Replace
1. Hold the Mitorcycle upright on level surface
and apply the Front Brake
2. Check:
• Operarion
Push down hard on the Handlebar several
times.
Unsmooth operation ➔ Repair.
Refer to “FRONT FORK” in Chapter 6,
Page no 6-21
REAR
SHOCK
ADJUSTMENT
ABSORBER
WARNING
• Always adjust each Rear Shock Absorber
preload to the same setting. Uneven adjustment can cause poor handling and loss
of stability.
• Securely support the Motorcycle so that
there is no danger of it falling over.
1. Adjust :
• Spring preload
Turn the adjuster ring ¿ to direction ç
or è using a plain rod.
¿
ç
è
3-24
INSP
ADJ
REAR SHOCK ABSORBER ADJUSTMENT
ææææææææææææææææææææææææææææææææææ
Adjustment steps:
• Turn the Adjuster Ring ¿ in or out.
¿
ç
è
Turning toward ç Ÿ
Turning toward è Ÿ
Spring preload is
increased.
Spring preload is
decreased.
Adjustment numbers:
Standard
2
Minimum
1
Maximum
5
WARNING
CAUTION:
• Never turn the Adjuster beyond the maximum or minimum setting.
• Always adjust each Shock Absorber to the
same setting.
ææææææææææææææææææææææææææææææææææ
TYRE INSPECTION
1. Measure :
• Tyre inflation pressure
Out of specification Ÿ Adjust.
WARNING
• Tyre inflation pressure should only be
checked and adjusted when the Tyre temperature equals the ambient air temperature. Tyre inflation pressure and suspension must be adjusted according to the
cargo, rider, pasenger and accessories
(fairing, saddlebags, etc. if approved for
this model), and according to whether the
Motorcycle will be operated at high speed
or not.
NEVER OVERLOAD THE MOTORCYCLE.
• Operation of an overloaded Motorcycle
could cause tyre damage, accident or injury.
3-25
TYRE INSPECTION
INSP
ADJ
2. Inspect :
• Tyre surfaces
Wear/damage Ÿ Replace
Minimum Tyre tread Depth :
(Front and Rear)
1.6 mm
¿ Tread Depth
À Side wall
Á Wear indicator
WARNING
Cold tyre pressure
Front
[1.75kg+1 cm2]
Single Rider or
with Pillion &
Rider
25 psi
Rear
32 psi
[2.25kg+1 cm2]
• It is dangerous to ride with a worn out
tyre. When the tyre tread begins to show
signs of wear, replace the tyre immediately.
• Patching a punctured tube is not recommended. If it is absolutely neccessary to
do so, use great care and replace the tube
as soon as possible with a good quality replacement tube.
• Do not use tubeless tyres on a wheel designed for tube type tyres only. Tyre failure
and personal injury may result from sudden deflation.
•
•
Be sure to install the correct Tube when
using Tube Type Tyres.
While installing Tyre on Wheel always check
that the Tyre lining is seated uniformly with
respect to wheel rim.
WARNING
After mounting a Tyre, ride conservatively
for a while to give the Tyre time to seat itself properly in the Rim, Failure to do so
could lead to an accident with possible injury to the rider or damage to the Motorcycle.
2. After a Tyre repair or replacement, be sure
to tighten the Valve Stem Locknut ¿ to
specification.
Locknut:
1.5 Nm (0.15 m.kg, 1.1 ft.lb)
3-26
SPOKE INSPECTION AND TIGHTENEING
¿
INSP
ADJ
SPOKES
INSPECTION
TIGHTENING
AND
1. Inspect :
• Spokes ¿
Bending/damage Ÿ Replace.
Loose spoke Ÿ Retighten
2. Tighten :
• Spokes
Nipple Tighting Tool
YSST - 629
NOTE :
Be sure to tighten the Spokes before and after
break-in.
Nipple Tighting Torque
2 Nm (0.2 m.kg, 1.5 ft.lb)
WHEEL INSPECTION
1. Inspect :
• Wheels
Damage/Bends Ÿ Replace.
NOTE :
Always balance the wheel when a tyre or wheel
has been changed or replaced.
WARNING
Never attempt to make any repairs to the
wheel rim.
3-27
BATTERY INSPECTION
INSP
ADJ
ELECTRICAL
BATTERY INSPECTION
1. Remove:
• Side Cover (L.H.)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section. Page no 3-3
• Battery
2. Inspect :
• Electrolyte level
Electrotyte level should be between the
Upper ¿ and Lower À level marks.
Electrolyte level is too low Ÿ add distilled
water to proper level.
¿
À
WARNING
CAUTION:
Use distilled water only for top up. Tap water contains minerals which are harmful to a Battery.
3. Inspect :
• Battery terminals
Poor connections Ÿ Correct
4. Inspect :
• Breather hose ¿
Obstruction Ÿ Remove
Damage Ÿ Replace
¿
5. Check :
• Specific gravity ç
Less than 1.230 Ÿ Recharge the Battery
Charging Current :
0.25 amp
Specific Gravity :
1.230±0.005
WARNING
CAUTION:
When inspecting the Battery, make sure that
the Breather Hose is routed correctly. If the
Breather Hose is positioned in such a way
as to allow Battery Electrotyte gas to come
into contact with the Frame, this could damage the Motorcycle and ruin its finish.Check
the proper seating of Battery top plugs.
3-28
BATTERY INSTALLATION
INSP
ADJ
Replace the battery if:
• Battery voltage does not rise to a specific
value or bubbles fail to rise during charging.
• Sulphation of one or more cells occurs, (as
indicated by the plates turning white, or material accumulating in the bottom of the cell ).
• Specific gravity readings after a long, slow
charge indicate that one cell is charged lower
than the rest.
• Warpage or buckling of plates or insulators is
evident.
WARNING
CAUTION:
Always charge a new Battery completely before installing it to ensure maximum performance.
WARNING
Battery electrolyte is dangerous. It contains sulfuric acid which is poisonous and highly caustic.
Always follow these preventive measures:
• Avoid body contact with electrolyte as it can cause severe burns and permanent eye injury.
• Wear protective eye gear when handling or working near batteries.
• Antidote (EXTERNAL):
• SKIN- Flush with water for 15 minutes and get immediate medical attention.
• Antidote (INTERNAL)
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical attention.
• Batteries generate explosive hydrogen gas.
• Always follow these preventive measures:
• Charge batteries away from fire, sparks or open flames (e.g., welding equipment, lighted
cigarettes, etc.)
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.
6. Install :
• Battery
7. Connect:
• Battery leads
8. Connect :
• Breather hose
Be sure the Hose is properly attached and
routed.
Refer to “CABLE ROUTING” section in
Chapter 2, Page no 2-21
9. Install :
• Side cover (left)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section on Page no 3-3
À
¿
WARNING
CAUTION:
Connect the positive lead ¿ first and then
connect the negative lead À
3-29
FUSE INSPECTION
INSP
ADJ
FUSE INSPECTION
WARNING
CAUTION:
¿
Always turn off the Main Switch when checking
or replacing the Fuse. Otherwise, a short circuit
may occur.
1. Remove:
• Side cover (left)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section Page no 3-3
• Fuse holder ¿
2. Inspect :
• Fuse
ææææææææææææææææææææææææææææææææææ
Inspection steps :
• Connect the Multimeter to the fuse and check
it for continuity.
NOTE :
Set the multimeter selector to “Ohm x 1 resistance ” position.
WARNING
Never use a Fuse with a rating other than
that specified. Never use other materials in
place of a Fuse. An improper Fuse may
cause extensive damage to the electrical
system, malfunction of lighting and ignition
and could possibly cause a fire.
Multimeter
ææææææææææææææææææææææææææææææææææ
• If the Multimeter is indicates non continuity
Ÿ Replace the fuse.
3. Replace :
• Blown Fuse
ææææææææææææææææææææææææææææææææææ
Replacement steps:
• Turn off the Main Switch.
• Install a new fuse with the proper current rating.
• Turn on switches to verify operation of related
electrical deveces.
• If the fuse blows again immediately, check the
electrical circuit.
ææææææææææææææææææææææææææææææææææ
Fuse Ampearage : 10A
4. Install :
• Fuse holder
• Side cover (left)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section Page no 3-3
3-30
HEADLIGHT BEAM ADJUSTMENT/
HEADLIGHT BULB REPLACEMENT
À
INSP
ADJ
HEADLIGHT BEAM ADJUSTMENT
1. Loosen:
• Bolt ¿
2. Loosen:
• Screw À - 2 Nos.
3. Adjust :
• Headlight beam (vertical)
¿
Push down Ÿ Headlight beam moves
lower.
Pull up Ÿ Headlight beam moves higher.
NOTE :
Punch Mark is given on the Adjuster Bracket for
reference to tighten the Bolt ¿.
HEADLIGHT BULB REPLACEMENT
1. Remove:
• Headlight Assy.
2. Disconnect :
• Headlight beam leads from both bulbs.
• Bulb cover
3. Remove :
• Bulbs - 2 Nos.
NOTE :
Unhook the Bulb spring.
WARNING
Keep flammable products and your hands
away from the Bulb while it is on, it will be
hot. Do not touch the bulb unit until it cools
down.
4. Install:
• Bulb (new)
Secure the new Bulb with the Bulb spring.
WARNING
CAUTION:
Avoid touching glass part of bulb. Also keep
it away from oil otherwise, transparency of
glass, bulb life and brightness will be adversely affected. If oil gets on bulb, clean it
with a cloth moistened thoroughly with alcohol or lacquer thinner.
3-31
ENG
CHAPTER 4
ENGINE OVERHAUL
ENGINE REMOVAL
SIDE COVERS, SEAT AND FUEL TANK REMOVAL ................4-1
ENGINE OIL DRAIN ................................................................... 4-1
BATTERY ....................................................................................4-1
CARBURETOR ........................................................................... 4-1
CLUTCH CABLE ........................................................................4-1
DRIVE CHAIN ............................................................................. 4-2
EXHAUST MUFFLER ................................................................. 4-2
FOOTREST ASSEMBLY ............................................................ 4-2
SHIFT PEDAL ............................................................................. 4-3
BATTERY BOX REMOVAL ........................................................4-3
LEADS ........................................................................................4-3
ENGINE REMOVAL ....................................................................4-3
MOUNTING ON ENGINE STAND ..............................................4-3
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER AND PISTON ........................... 4-4
CLUTCH ..................................................................................... 4-7
OIL PUMP ................................................................................... 4-8
KICK STARTER ..........................................................................4-9
SHIFT SHAFT ............................................................................. 4-9
C.D.I. MAGNETO ........................................................................4-10
CRANKCASE ............................................................................. 4-11
TRANSMISSION AND SHIFTER ................................................. 4-12
CRANKSHAFT ........................................................................... 4-12
CYLINDER HEAD ROCKER ARMS, CAMSHAFT & VALVES ..4-13
INSPECTION AND REPAIRS
CYLINDER HEAD ....................................................................... 4-15
VALVE SEATS ............................................................................4-16
VALVE SPRINGS AND VALVES ................................................4-18
CAMSHAFT ................................................................................4-19
ROCKER ARMS AND ROCKER ARM SHAFTS ....................... 4-20
TIMING CHAIN, SPROCKETS AND CHAIN GUIDES............... 4-21
TIMING CHAIN TENSIONER ..................................................... 4-21
CYLINDER AND PISTONS ........................................................4-22
PISTON RINGS ..........................................................................4-23
PISTON PIN................................................................................4-24
CRANKSHAFT ........................................................................... 4-25
PRIMARY DRIVE GEAR ............................................................4-26
CLUTCH ..................................................................................... 4-26
PUSH ROD ................................................................................. 4-27
SHIFT FORK SHIFT CAM ..........................................................4-28
KICK STARTER ..........................................................................4-29
OIL PUMP ................................................................................... 4-30
OIL DELIVERY PASSAGE(CC COVER RH) ............................. 4-31
CRANKCASE ............................................................................. 4-31
BEARINGS AND OIL SEALS ......................................................4-31
ENG
CIRCLIPS AND WASHERS ........................................................ 4-31
ENGINE ASSEMBLY AND ADJUSTMENT ................................ 4-32
CRANKSHAFT ........................................................................... 4-35
TRANSMISSION ........................................................................ 4-37
SHIFTER ..................................................................................... 4-38
CRANKCASE ............................................................................. 4-40
CDI MAGNETO........................................................................... 4-42
SHIFT SHAFT AND KICK STARTER ......................................... 4-44
CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP ................ 4-47
CYLINDER AND PISTON ........................................................... 4-52
CYLINDER HEAD ....................................................................... 4-53
CAM SPROCKET AND TIMING CHAIN .................................... 4-54
ENGINE MOUNTING ................................................................. 4-60
ENGINE REMOVAL
ENG
ENGINE REMOVAL
It is not necessary to remove the Engine
in order to remove the following parts.
•
•
•
•
•
Cylinder Head
Cylinder
Piston
Clutch
CDI Magneto
SIDE COVERS, SEAT AND FUEL TANK
REMOVAL
1. Remove :
• Side covers (LH and RH)
• Seat
• Fuel tank
Refer to the “SIDE COVERS, SEAT AND FUEL
TANK” section in Chapter 3, Page no 3-3
ENGINE OIL
¿
1. Drain :
• Engine oil
Refer to the “ENGINE OIL REPLACEMENT”
section in Chapter 3, Page no 3-14
BATTERY
À
1. Remove :
• Fuse ¿
• Negative terminal (Black) À
• Battery Breather Hose Á
• Battery Â
Á
Â
WARNING
CAUTION:
Disconnect the Battery Negative Terminal
(Black) first and then disconnet the Positive
Terminal (Red)
À
¿
Ã
Á
Â
À
CARBURETOR
1. Loosen
• Air cleaner case mounting bolts ¿ - 4 Nos.
• Hose Clamp assy À
2. Remove
• Throttle Cable Á
• Carburetor Mounting Clamp Â
• Air vent hose
• Carburetor Ã
Refer to the “CARBURETOR” section in Chapter 5, Page no 5-2
NOTE :
Cover the Carburetor with a clean cloth to prevent dirt or foreign material from entering the
Carburetor.
4-1
ENGINE REMOVAL
ENG
CLUTCH CABLE
À
1. Remove :
• Clutch cable
ææææææææææææææææææææææææææææææææææ
Removal steps :
• Loosen the locknut ¿ of the Clutch Lever.
• Turn in the Adjuster À to enough to free the
inner Clutch Cable
• Unhook the Cable End from Push Lever Á on
the Crankcase L.H.
ææææææææææææææææææææææææææææææææææ
¿
3
DRIVE CHAIN
¿
Á
1. Remove :
• Crankcase Cover#1 (L.H.) ¿
• Drive Chain Case upper À and lower Á
2. Slack off the Drive Chain
Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in Chapter 3, Page no 3-20
3. Remove :
• Bolt ¿ (Holder Sprocket)
• Holder Sprocket À
• Sprocket Drive Á
Remove with the Drive Chain
À
Á
EXHAUST MUFFLER
¿
1. Remove :
• Bolt (exhaust pipe)
• Bolt (muffler)
Refer to “EXHAUST SYSTEM” section in
Chapter 3, Page no 3-15
2. Remove :
• Exhaust muffler
À
FOOTREST ASSEMBLY
1. Remove:
• Bolt (footrest) ¿ - 2 Nos. (LH & RH)
• Bolt Axle - Lower rear mounting À
• Footrest Assembly
À
À
¿
4-2
ENGINE REMOVAL
ENG
SHIFT PEDAL
À
1. Remove
• Bolt (Shift Pedal) ¿
• Shift Pedal À
¿
BATTERY BOX
¿
1. Remove
• Bolt (Battery Box) ¿ 3 nos
• Battery Box À
¿
À
LEADS
1. Disconnect:
• Stator Coil Lead Coupler ¿
• Sensor Coil Lead Coupler À
2. Remove :
• Spark Plug Cap
À
¿
ENGINE REMOVAL
1. Remove :
• Engine Mount Bolt (front centre) ¿
• Bolt (Engine Mount stay front upper) À
• Bolt (Engine Mount stay front lower) Á
• Engine Mount Bolt front lower Â
• Engine Mount stay Ã
• Engine Mount Bolt (bottom rear) Ä
• Engine Mount Bolt (upper rear) Å
• Engine mount stay upper Æ
• Bolt AIS Mounting on stay Ç - 2 Nos.
• Engine Mount Stay È
Ç
Æ
È
Å
À
Á
3. Remove :
• Engine Assembly
¿
Â
Ã
Ä
4. Mount
• Engine on Engine Stand
4-3
ENGINE DISASSEMBLY
ENG
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER AND
PISTON
NOTE:
With Engine mounted on Motorcycle, the Cylinder Head, Camshaft and Cylinder can be
maintained by removing the following parts.
• Side Covers
• Spark Plug Lead
• Seat
• Engine Mount Stay
• Chain Tensioner
(upper)
(Retract )
• Timing Check Plug
• Exhaust Pipe
• Center Plug
• Carburetor
• AIS Clamps
À
¿
¿
WARNING
CAUTION:
Before Engine disassembly clean the outer
body of Engine properly
¿
À
è
ç
ê
é
1. Remove :
• Spark Plug
• Bolts (Intake Manifold) ¿ 2 nos
• Intake Manifold À
• Valve Cover with ‘O’ ring
2. Remove
• Timing Check Plug (with ‘O’ ring) ¿
• Centre Plug (with ‘O’ ring) À
3. Align :
• Piston to TDC position
NOTE:
Turn the Crankshaft anticlockwise with a
Socket Spanner 17 mm
ææææææææææææææææææææææææææææææææææ
TDC alignment steps:
• Turn the Crankshaft anticlockwise until the slit
(cut mark on magneto) ç matches the stationary pointer è
• Align the “I” mark é on the Cam Sprocket with
the stationary pointer ê on the Cylinder Head,
the Piston is at the Top Dead Center (TDC)
of compression stroke.
NOTE :
To confrim that the Piston is at TDC of compression stroke, check Rocker Arms for free
movement.
4-4
ENGINE DISASSEMBLY
ENG
5. Remove :
• Tensioner Cap Bolt ¿
• Retract completely the Tensioner Rod by
Screw in (clockwise) direction.
• Bolts (timing chain tensioner ) À 2 Nos
• Timing Chain Tensioner Assembly Á
• Gasket
¿
Á
À
6. Remove :
• Bolt (cam sprocket) ¿
• Plate washer (cam sprocket) À
• Cam sprocket Á
À
¿
Á
NOTE :
Hold the Nut Rotor with socket spanner for
opening Cam Sprocket Bolt. Fasten a safety
wire to the Timing Chain to prevent it from falling in the Crankcase.
Á
Ä
Ã
Â
¿
À
Á
7. Remove :
• Bolts (Cylinder Head) as per sequence.
(6 nos)
• Cylinder Head
NOTE :
• Loosen the Bolts 1/4 turn each and remove
then after all are loosened.
• Reomve the Bolts starting with the lowest
number one.
¿
8. Remove :
• Guide Stopper #1 ¿
• Dowel Pins À
• Gasket (Cylinder Head) Á
• Cylinder Â
À
Â
4-5
MAINTENANCE SPECIFICATIONS
ENG
9. Remove :
• Dowel Pins ¿ - 2 Nos
• Gasket (Cylinder) À
À
¿
Á
À
¿
10. Remove :
• Piston Pin Circlip ¿ 2 nos
• Piston Pin À , using Piston Pin Replacer
• Piston Á
NOTE :
Before removing the Piston Pin Circlip, cover
the Crankcase with a clean cloth to prevent the
Circlip from falling into the Crankcase cavity.
Piston Pin Replacer :
YSST - 607
C. D. I. MAGNETO
NOTE :
The CDI Magneto can be removed while the
Engine is mounted on the Motorcycle by removing the following parts :
• Shift Pedal
• Cover Chain Case (L. H.)
1. Remove :
• Bolts (Crankcase Cover-1 L.H.) ¿ - 7 nos
• Crankcase Cover-1 (L.H.)
• Neutral Light wire from Neutral Switch
NOTE :
Loosen the Bolts in criss cross pattern.
¿
¿
2. Attach
• Magneto holder - ¿
¿
Magneto Holder :
YSST - 627
4-6
ENGINE DISASSEMBLY
ENG
CLUTCH
À
Á
Á
¿
NOTE :
The Clutch Assembly can be removed while the
Engine is mounted on the Motorcycle by removing the following parts and draining the Engine
oil:
• Kick Starter.
1. Remove :
• Nut kick Crank assy ¿.
• Kick Crank Assy À.
• Bolts Crankcase Cover-2 (R.H.) Á - 9 nos
• Crankcase Cover (RH)
¿
À
NOTE :
• Hold Kick Crank Assy. at extreme down position for opening the Nut Kick Crank Assy.
• Loosen the Bolts of Crankcase Cover #2 (RH)
in a crisscross pattern.
2. Remove :
• Gasket ¿
• Dowel pins À - 2 Nos
3. Remove:
• Pressure Plate Bolts ¿ - 4 Nos
• Clutch Springs À - 4 Nos
• Pressure Plate Á with Push rod 1
• Friction Plates  - 5 Nos
• Clutch Plates à - 4 Nos
NOTE :
Loosen the Pressure Plate Bolts in a crisscross
pattern.
4. Remove :
• Ball Ä
¿
À
5. Loosen :
• Straighten the Lock Washer tab.
• Nut (clutch boss) ¿
NOTE :
Loosen the Clutch Boss Nut ¿ while holding the
Clutch Boss À with the Clutch Holder.
Clutch Hub Holder
YSST - 233
4-7
ENGINE DISASSEMBLY
Á
Â
6. Remove :
• Clutch Boss Nut ¿
• Lock Washer À
• Clutch Boss Á
• Thrust Washer Â
• Clutch Housing Ã
• Spacer Ä
Ã
Ä
¿ À
ENG
7. Loosen :
• Nut ¿ (Primary Drive Gear)
¿
NOTE :
• Open the Nut (Primary Drive Gear) by holding
the Magneto with Magneto Holder.
Magneto Holder
YSST - 627 A
8. Remove
• Nut
• Plate Washer
• Primary Drive Gear ¿
• Key À
• Rotary Filter Á
À
¿
Á
OIL PUMP
NOTE :
The oil pump can be removed while the engine
is mounted by removing the following parts
• Clutch
• Primary drive gear
• Rotary filter
1. Remove :
• Gear pump drive ¿
• Screw (oil pump-2 nos) À
• Oil pump assembly Á
• Gasket (oil pump)
• Oil strainer Â
À
¿
Â
Á
4-8
ENGINE DISASSEMBLY
ENG
KICK STARTER
NOTE :
The kick starter can be removed while the engine is mounted by removing the following part.
• Kick Crank Assy
• Crankcase Cover 2 (RH)
• Clutch Drum Assy
Á
1. Remove :
• Circlip ¿
• Plate washer À
• Gear Kick idle Á
• Plate washer
• Circlip
¿
À
2. Remove :
• Torsion spring ¿
• Kick axle assembly À
¿
À
Kick Starter disassembly
Å
Ä Ã
 Á
1. Remove :
• Spacer ¿
• Torsion spring À
• Shim Á
• Ratchet gear Â
• Shim Ã
• Ratchet gear with return spring Ä
• Kick axle Å
À ¿
SHIFT SHAFT
NOTE :
The Shift Shaft can be removed while the Engine
is mounted by removing the following parts.
• Shift Pedal
• Kick Crank Assy.
• Crankcase Cover#2(RH) • Clutch
¿
Â
À
Á
1. Remove :
• Shift Shaft ¿
• Torsion Spring À
• Bolt (stopper lever) Á
• Stopper Lever Â
Â
4-9
ENGINE DISASSEMBLY
ENG
CDI MAGNETO REMOVAL
¿
1. Remove :
• Nut (magneto)
• Plain washer
NOTE :
• Loosen the Nut Magneto while holding the
Magneto À with Magneto Holder ¿
À
Magneto Holder :
YSST - 627
¿
2. Attach
• Bush
• Magneto Puller ¿
NOTE :
• Place the Bush on the Crankshaft threaded
end before using the Magneto Puller to avoid
thread damage.
3. Remove :
• CDI magneto ¿ using magneto puller À
• Key wood-ruff
À
¿
Magneto Puller :
YSST - 628
Á
4. Remove
• Bolt ¿
• Guide Stopper# 2 À
• Bush
• Timing chain Á
À
¿
5. Remove :
• Torx Screw ¿ (Segment) using Torx Bit.
Torx Bit :
YSST - 611
¿
WARNING
Never use Phillips screw driver
4-10
ENGINE DISASSEMBLY
ENG
CRANKCASE
1. Remove :
• Bolts (Crankcase RH-2 nos) ¿
¿
2. Remove :
• Bolts (Crankcase LH-8 nos)
¿
Â
Á
NOTE :
• Loosen the Bolts in a crisscross pattern.
• Loosen each Bolts 1/4 turn at a time and remove them after all are loose.
Ä
Ã
Å
Æ
À
ç
ç
1. Remove :
• Right crankcase half
NOTE :
Open the Engine stand mounting Nuts 2 nos .
Then separate the Crankcase by using the flat
head screw driver in the separating slit ç.
WARNING
CAUTION:
À
¿
• Do not use the flat head screw driver except at the separating slot.
• Separate the Crankcase after first checking that the shift cam segments and the
Drive Axle Circlip can be removed.
• Do not damage the Crankcase mating surfaces.
2. Remove :
• Dowel pins ¿
• Balancer À
¿
4-11
ENGINE DISASSEMBLY:
TRANSMISSION AND SHIFTER
ENG
TRANSMISSION AND SHIFTER
1. Remove :
• Shift Fork Guide Bar ¿ (short)
• Shift Fork Guide Bar À (long)
• Shift Cam Á
• Shift Fork -C
• Shift Fork -R
• Shift Fork - L
¿
Á
À
2. Remove :
• Axle Drive assembly ¿
• Axle Main assembly À
• Push Rod # 2
• Washer
• Push Lever Assembly
• Lock
• Oil Seal
À
¿
3. Remove :
• Neutral switch ¿
• Gasket neutral switch
¿
CRANKSHAFT
À
1. Attach
• Crankshaft Removal Tool À
Crankshaft Removal Tool :
YSST - 265
2. Remove :
• Crankshaft ¿ using Crankshaft removal
tool À
¿
NOTE :
Fully tighten the Crankshaft removal tool holding Bolts, but make sure that the tool body is
parallel with the Crankcase. If necessary, one
holding bolt may be turned out slightly to adjust
the Crankshaft Removal Tool’s position.
4-12
ENGINE DISASSEMBLY
DISASSEMBLY OF CYLINDER HEAD,
ROCKER ARMS, CAMSHAFT AND
VALVES
À
Á
Â
ENG
1. Loosen :
• Valve Adjuster Locknuts ¿
• Valve Adjusters À
2. Remove :
• Stopper Plate Á by opening allen bolt Â
¿
3. Attach
• Rocker arm shaft puller ¿
¿
Rocker Arm Shaft Puller
YSST - 608A
À
4. Remove :
• Rocker Arm Shafts by tightening the Puller
nut À
• Rocker Arms (intake/exhaust)
5. Remove :
• Camshaft Assy with spacer
NOTE :
Before the Valves, Valve Springs, Valve Stem
Seals, etc. are removed from the Cylinder Head,
the Valve sealing should be checked.
6. Check
• Valve sealing
Leakage at the valve seat Ÿ Inspect the
valve face, valve seat and seat width.
Refer to “INSPECTION AND REPAIR
VALVE SEAT”. on Chapter 4 Page no 4-16
ææææææææææææææææææææææææææææææææææ
Checking Steps :
• Pour clean petrol ¿ into the intake and exhaust ports.
• Check the valve sealing. There should be no
leakage at the valve seat À
ææææææææææææææææææææææææææææææææææ
4-13
ENGINE DISASSEMBLY
ENG
7. Attach
Valve Spring compression Tool ¿
¿
À
Valve Spring Compressor :
YSST - 603
8. Remove :
• Valve Cotters À
NOTE :
Valve Spring compressor tool is to be attached
between the Valve Spring retainer and the Valve
face (Inlet and Exhaust) one at a time.
9. Remove :
• Valve Spring Retainer ¿
• Valve Spring À
• Valve Á
• Valve Stem Seal Â
• Valve Spring Seat Ã
NOTE :
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
4-14
INSPECTION AND REPAIR:
CYLINDER HEAD
ENG
INSPECTION AND REPAIR
CYLINDER HEAD
1. Remove :
• Carbon deposits from combustion
chambers using a rounded scraper.
NOTE :
Do not use a sharp instrument to avoid damaging or scratching :
• Spark Plug threads
• Valve seats
2. Inspect :
• Cylinder Head
Scratches/damage Ÿ Replace
3. Measure :
• Cylinder Head warpage
Out of specification Ÿ resurface/ replace.
Cylinder Head warpage :
Less than 0.03 mm
ææææææææææææææææææææææææææææææææææ
Warpage measurement and resurfacement
steps:
• Place a straightedge ¿ and a feeler gauge À
across the Cylinder Head.
• Measure the warpage.
• If the warpage is out of specification, resurface the Cylinder Head/replace if necessary.
• Place a 400 ~ 600 grit wet abrasive paper on
the surface plate, and resurface the Head
using a figure-eight sanding pattern.
NOTE :
Rotate the Cylinder Head several times for an
even resurfacement.
ææææææææææææææææææææææææææææææææææ
4-15
INSPECTION AND REPAIR:VALVE SEATS
ENG
VALVE SEATS
1. Remove :
• Carbon deposits from the Valve Face and
Valve Seat.
2. Inspect :
• Valve Seats
Pitting/wear Ÿ reface the valve seat.
3. Measure :
• Valve Seat width ç
Out of specification Ÿ 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>
ææææææææææææææææææææææææææææææææææ
Measurement steps :
• Apply Mechanic’s blueing dye (Dykem) è to
the valve face.
• Install the Valve in the Cylinder Head
• Press the Valve through the Valve Guide and
onto the valve seat to make a clear pattern.
• Measure the Valve Seat width. Where the
Valve Seat and Valve Face made contact,
blueing will have been removed.
• If the Valve Seat is too wide, too narrow, or
the seat is not centered, the valve seat must
be refaced.
ææææææææææææææææææææææææææææææææææ
4. Lap :
• Valve face
• Valve seat
NOTE :
After refacing the Valve Seat or replacing the
Valve, the Valve Seat and Valve Face should be
lapped.
4-16
INSPECTION AND REPAIRS
ENG
ææææææææææææææææææææææææææææææææææ
Lapping steps :
• Apply coarse lapping compound ç to the Valve
Face
WARNING
CAUTION:
Do not let compound enter the gap between the
Valve Stem and the Guide.
• Apply molybdenum disulfide oil to the Valve
Stem.
• Install the Valve into the Cylinder Head.
• Turn the Valve in one Direction using the Valve
lapping tool until the Valve Face and Valve
Seat are evenly polished, then clean off all
compound.
NOTE :
For best lapping results, lightly tap the Valve
seat while rotating the Valve.
• Apply a fine lapping compound è to the Valve
face and repeat the above steps.
NOTE :
Make sure to clean off all compound from the
Valve face and Valve seat after every lapping
operation.
• Apply Mechanic’s blueing dye (Dykem) è to
the Valve face.
• Install the Valve in the Cylinder Head.
• Press the Valve through the Valve Guide and
onto the Valves Seat to make a clear pattern.
• Measure the Valve Seat width é again. If the
Valve Seat width is out of specification, lap the
Valve and Valve Seat.
ææææææææææææææææææææææææææææææææææ
4-17
INSPECTION AND REPAIR :
VALVE SPRINGS AND VALVES
ENG
VALVE SPRINGS AND VALVES
1. Measure :
• Valve Spring free length ç
Out of specification Ÿ Replace.
Valve spring free length :
39.62 mm
<Limit 38.17 mm>
ç
2. Measure :
• Spring tilt ç
Out of specification Ÿ Replace
Spring Tilt Limit :
1.7 mm
3. Check
• Spring contact face
Wear/pitting/scratches Ÿ Replace
4. Measure :
• Valve guide inside diameter
Valve guide inside diameter :
Intake :
5.000 ~ 5.012 mm
<Limit : 5.042mm>
Exhaust :
5.000 ~ 5.012 mm
<Limit : 5.042mm>
5. Measure :
Valve stem diameter
4-18
ENGINE INSPECTION AND REPAIR
ENG
6. Calculate :
Stem Guide Clearance
Stem-to-guide clearance =
Valve guide inside diameter –
Valve stem diameter
Stem-to-guide clearance limit :
Intake :
0.010 ~ 0.00370 mm
<limit : 0.08 mm>
Exhaust :
0.025 ~ 0.052 mm
<limit : 0.10 mm>
Out of specification Ÿ Replace the Cylinder
Head
7. Measure :
• Runout (valve stem)
Out of specification Ÿ Replace
Runout Limit :
0.01 mm
CAMSHAFT INSPECTION
1. Inspect :
• Cam lobes
Pitting/scratches/blue discoloration Ÿ
Replace
2. Measure :
• Cam lobes dimension ç and è
Out of specification Ÿ Replace.
ç
è
Cam lobes dimension :
Intake :
ç 25.881 ~ 25.981 mm
<limit 25.851 mm>
è 21.195 ~ 21.295 mm
<limit 21.165 mm>
Exhaust :
ç 25.841 ~ 25.941 mm
<limit 21.811 mm>
è 21.05 ~ 21.15 mm
<limit 21.02 mm>
3. Inspect :
• Camshaft oil passage
Chocked Ÿ Blow out oil passage with
compressed air.
4-19
ENGINE INSPECTION AND REPAIR
ENG
ROCKER ARMS AND ROCKER ARM
SHAFTS INSPECTION
¿
À
1. Inspect :
• Cam lobe contact surface ¿
• Adjuster surface À
Wear/pitting/scratches/blue discoloration Ÿ
Replace
ææææææææææææææææææææææææææææææææææ
Inspection steps :
• Inspect the two contact areas on the Rocker
Arms for signs of unusual wear.
• Rocker Arm Shaft hole
• Cam-lobe contact surface
Excessive wear Ÿ Replace
• Inspect the surface condition of the Rocker
Arm Shafts
Pitting/scratches/blue discoloration Ÿ Replace and check lubrication route
• Measure the inside diameter ç of the Rocker
Arm holes
Out of specification Ÿ Replace
Inside diameter (Rocker Arm) :
10.000 ~ 10.015 mm
<Limit>:10.03 mm
ç
• Measure the outside diameter è of the Rocker
Arm Shafts.
Out of specification Ÿ Replace
è
Outside diameter(Rocker
Shaft):
9.981 ~ 9.991 mm
<Limit> : 9.95 mm
Arm
ææææææææææææææææææææææææææææææææææ
4-20
ENGINE INSPECTION AND REPAIR
ENG
TIMING CHAIN, SPROCKETS AND
CHAIN GUIDES
1. Inspect :
• Timing Chain
Wear out/Stiffness/damage Ÿ Replace the
Chain and the Sprockets as a set.
2. Inspect :
• Cam Sprocket
Wear/damage Ÿ Replace the Cam
Sprocket and the timing chain as a set.
3. Inspect :
• Guide Stopper #1 ¿
• Guide Stopper # 2 À and Bush
Wear/damage Ÿ Replace
À
¿
¿
TIMING CHAIN TENSIONER
1. Check :
• One-way Cam operation
If Unsmooth operation Ÿ Replace
ææææææææææææææææææææææææææææææææææ
Checking steps :
• While pressing the Tensioner Rod lightly with
fingers, use a flat screwdriver ¿ and retract
the Tensioner Rod up fully clockwise.
• When releasing the screwdriver by pressing
lightly with fingers, make sure that the
Tensioner Rod will come out smoothly.
• If not, replace the Tensioner Assembly
ææææææææææææææææææææææææææææææææææ
4-21
ENG
ENGINE INSPECTION AND REPAIR
CYLINDER AND PISTONS
1. Inspect :
• Cylinder and Piston walls
Vertical scratches Ÿ Rebore or replace
the Cylinder and the Piston
2. Measure :
• Piston-to-Cylinder clearance
ææææææææææææææææææææææææææææææææææ
Measurement steps :
1st step :
• Measure the Cylinder Bore “C” with a Cylinder Bore Gauge.
NOTE :
Measure the Cylinder Bore “C” in parallel to and
at right angles to the Crankshaft. Then, find the
average of the measurements.
Cylinder Bore “C”
54.000 ~ 54.018 mm
Taper limit “T”
0.005 mm
Out of round “R”
0.01 mm
• If out of specification, rebore or replace the
Cylinder- Piston Kit
2nd step :
• Measure the Piston Skirt diameter “P” with a
Micrometer.
ç 4.5 mm from the Piston bottom edge
Piston size p
“C”=Maximum Diameter D
Standard
“T” =(Maximum D1 or D2) - (Maximum D5 or D6)
“R”=(Maximum D1, D3 or D5)
Oversize
- (Maximum D2, D4 or D6)
P
53.977 ~ 53.996 mm
Ist
II nd
• If out of specification, replace the Piston and
the Piston Rings as a set.
3rd step:
• Calculate the Piston-to Cylinder clearance using the following formula :
Piston-to-Cylinder clearance = Cylinder
Bore “C”– Piston Skirt diameter “P”
ç
Piston-to-Cylinder clearance :
0.020 ~ 0.027 mm
• If out of specification, rebore or replace the
Cylinder, and replace the Piston and Piston
Rings as a set
ææææææææææææææææææææææææææææææææææ
4-22
ENGINE INSPECTION AND REPAIR
ENG
PISTON RING INSPECTION
1. Measure :
• Side clearance
Out of specification Ÿ Replace the Piston
and the Piston Rings as a set
NOTE :
Remove the carbon deposits from the Piston
Ring Grooves and Rings before measuring the
side clearance.
Side clearance :
Top Ring : <Limit>
0.030 ~ 0.07 mm
2nd Ring : <Limit>
0.020 ~ 0.060 mm
5mm
2. Position :
• Piston Ring
(in the Cylinder bore)
1
NOTE :
Push the Ring with the Piston Crown so that
the Ring will be at right angles to the Cylinder
Bore 5 mm from the bottom side.
3. Measure :
• End gap ¿ using a feeler gauge
Out of specification Ÿ Replace
NOTE :
You cannot measure the end gap on the expander spacer of the Oil Ring, If the Oil Ring
Rails show excessive gap, replace all three
Rings.
Eng gap :
Top Ring : 0.10 ~ 0.30 mm
<limit> : <0.40 mm>
2nd Ring : 0.30 ~ 0.45 mm
<Limit> : <0.55 mm>
Oil Ring : 0.2 ~ 0.7 mm
4-23
ENGINE INSPECTION AND REPAIR
ENG
PISTON PIN INSPECTION
ç
1. Inspect :
• Piston Pin
Blue discoloration/grooves Ÿ Replace and
inspect the lubrication system
2. Measure :
• Piston Pin-to-Piston clearance
ææææææææææææææææææææææææææææææææææ
Measurement steps.
• Measure the Piston Pin outside diameter ç
using a micrometer. If out of specification, replace the Piston Pin.
Outside diameter (Piston Pin):
14.995 ~ 15.000 mm
<Limit:> :
14.975 mm
• Measure the Piston Pin hole inside diameter
è using a Internal Micrometer
• Calculate the Piston Pin -to-Piston clearance
using the following formula :
Piston Pin-to-Piston clearance =
Bore size (Piston Pin) è – Outside diameter (Piston Pin) ç
• Out of specification Ÿ replace the Piston
Clearance ( Piston Pin to Piston ) :
0.009 ~ 0.013 mm
ææææææææææææææææææææææææææææææææææ
4-24
ENGINE INSPECTION AND REPAIR
ENG
CRANKSHAFT
1. Measure :
• Crankshaft runout, using a Surface plate
and Dial gauge. Keep the Crankshaft on
V blocks and rotate slowly while
measuring.
Out of spescification Ÿ Replace
Runout : 0.01 mm
<limit> : <0.03 mm>
2. Measure :
• Big end side clearance ç using a Feeler
Gauge
Out of specification Ÿ Replace big end
Bearing , Crank Pin and Connecting Rod
Big end side clearance :
0.15 ~ 0.45 mm
3. Measure :
• Crank width ç
Out of specification Ÿ Replace Crankshaft.
Crank width :
46.95 ~ 47.00 mm
4. Inspect :
• Crankshaft Sprocket ¿
Wear/damage Ÿ Replace Crankshaft
• Bearing À
Wear/crack/damage
Ÿ
Replace
Crankshaft
À
¿
5. Inspect :
• Crankshaft journal oil passage
Clogged Ÿ Blow the oil passage with
compressed air
4-25
ENGINE INSPECTION AND REPAIR
ENG
BALANCER WEIGHT INSPECTION
1. Inspect:
2.
• Balancer drive gear teeth ¿
• Balancer driven gear teeth À
Wear/damage Ÿ Replace as a set
Inspect:
• Balancer Shaft
• Wear/bend/damageŸ Replace
PRIMARY DRIVE GEAR INSPECTION
1. Inspect :
• Primary Drive Gear teeth ¿
• Primary Driven Gear teeth À
Wear/damage Ÿ Replace both Gears as
a set.
NOTE :
Refer the general specification for grading.
À
Excessive noise during operation Ÿ Replace
both Gears as a set.
¿
CLUTCH INSPECTION
1. Inspect :
• Friction Plates
Wear/damage Ÿ Replace the Friction
Plates as a set
2. Measure :
• Friction Plate thickness ç using a Vernier
Calliper at four points.
Out of specification Ÿ Replace the
Friction Plates as a set
Thickness (Friction Plate) :
3.0 ~ 3.1 mm
<Limit>: <2.8 mm>
3. Inspect :
• Clutch Plates for damage
• Clutch Plate Warpage Using a Surface
Plate and a Feeler Gauge ¿
Out of specification Ÿ Replace the Clutch
Plates as a set
¿
Warp limit (Clutch Plate ):
Less than 0.05 mm
4-26
ENGINE INSPECTION AND REPAIR
ENG
4. Inspect :
• Clutch Springs
Damage Ÿ Replace the Clutch springs as
a set.
5. Measure
• Free length (Clutch Spring) ç
Out of specification Ÿ Replace the Clutch
springs as a set.
ç
Free length (Clutch Spring) :
32.0 mm
<Limit> : 30.5 mm
6. Inspect :
• Dogs on the Primary Driven Gear ¿
Scoring/wear/damage Ÿ Deburr or
replace
• Clutch Boss Splines À
Scoring/wear/damage Ÿ Replace
NOTE :
Scoring on the Clutch Housing Dogs and the
Clutch Boss Splines will cause erratic operation
of the clutch.
¿
À
PUSH ROD INSPECTION
1. Inspect :
• Ball ¿
• Push Rod #1 À
Wear/damage/Bend Ÿ Replace
À
¿
2. Inspect :
• Push Rod # 2 ¿
Wear/damage/Bend Ÿ Replace
¿
4-27
ENGINE INSPECTION AND REPAIR
ENG
SHIFT FORK SHIFT CAM INSPECTION
¿
1. Inspect :
• Shift Fork follower ¿
• Shift Fork Pawl À
Scoring/bends/wear/damage Ÿ Replace
À
2. Inspect :
• Shift Cam grooves ¿
Wear/damage/scratches Ÿ Replace
• Shift Cam Segment À
Wear/damage Ÿ Replace
À
¿
3. Check :
• Shift Fork movement
(on the Guide Bar )
Unsmooth operation Ÿ Replace the Shift
Fork and the Guide Bar
Ã
4. Inspect :
The assembly for proper working
• Shift Fork “C” (center) ¿
• Shift Fork “R” (right) À
• Shift Fork “L” (left) Á
• Guide bars (small and big) Â
• Shift Cam Ã
• Shift fork cam follower Ä
Roll the Guide Bar on a flat surface
Bent Ÿ Replace
À
Ä
¿
Á
Â
Ä
Â
WARNING
Do not attempt to straighten a Bend Guide
Bar.
4-28
ENGINE INSPECTION AND REPAIR
ENG
5. Measure :
• Axle runout (Main and Drive)
Use a centering device and a dial gauge ¿
Out of specifications Ÿ Replace the bent
Axle
Runout : 0.01 mm
<limit> : 0.03 mm
6. Inspect :
• Gear teeth
Blue discoloration/pitting/wear Ÿ Replace
• Mated Dogs
Rounded edges/cracks/missing portions Ÿ
Replace
7. Inspect :
• Shift Shaft ¿
Damage/bent/wear Ÿ Replace
• Return spring (shift shaft) À
• Return Spring (stopper lever) Á
Wear/damage Ÿ Replace
À
¿
Á
KICK STARTER INSPECTION
1. Inspect :
• Gear teeth (kick Gear) ¿
• Gear teeth (Idle Gear) À
Wear/damage Ÿ Replace
À
¿
2. Measure :
• Torsion spring ¿ force Using a Spring
Gauge
Out of specification Ÿ Replace
Kick Clip friction force :
0.8 ~ 1.2 kg
4-29
ENGINE INSPECTION AND REPAIR
ENG
OIL PUMP INSPECTION
1. Measure :
• Tip clearance ç
(between the inner rotor ¿ and the outer
rotor À) using feeler gauge.
• Side clearance è
(between the outer rotor À and the Pump
Housing Á) using feeler gauge
Out of specification Ÿ Replace the Oil
Pump Assembly
• Housing and Rotor clearance é
(between the Pump Housing Á and the
Rotors ¿ and À )
Out of specification Ÿ Replace the Oil
• Pump Assembly
Damage Ÿ Replace
Contamination Ÿ Clean with flushing oil.
Tip clearance ç
0.15 mm <Limit:0.20 mm>
Side clearance è:
0.06 ~ 0.10 mm
<Limit: 0.15 mm>
Housing and Rotor clearance é:
0.06 ~ 0.10 mm
<Limit: 0.15 mm>
2. Inspect :
• Rotary Filter ¿
Cracks/damage/choked Ÿ Replace
Contamination Ÿ Clean with flushing oil
¿
3. Inspect :
• Oil strainer ¿
Damage Ÿ Replace
Contamination Ÿ Clean with flushing oil.
¿
4-30
ENGINE INSPECTION AND REPAIR
¿
ENG
DELIVERY PASSAGE INSPECTION
CRANK CASE RH
1. Check :
• Oil delivery passage ¿
Blockage Ÿ Blow the passage with
compressed air.
CRANKCASE
1. Thoroughly wash the crankcase L.H. & R.H.
in mild solvent.
2. Thoroughly clean all the Gasket Mating
surfaces and Crankcase Mating surfaces
using solvent.
3. Inspect :
• Crankcase
Cracks/damage Ÿ Replace
• Oil delivery passages
Blockage Ÿ Blow the passages with
compressed air
¿
À
BEARINGS AND OIL SEALS
1. Inspect :
• Bearings ¿
Clean with solvent and lubricate with
multigrade oil, then rotate the bearing
using finger
Roughness/noise Ÿ Replace
2. Inspect :
• Oil Seals À
Damage/ wear Ÿ Replace
CIRCLIPS AND WASHERS
1. Inspect :
• Circlips ¿
• Washers
Damage/looseness/bends Ÿ Replace
¿
4-31
ENGINE ASSEMBLY AND ADJUSTMENTS
ENGINE ASSEMBLY AND ADJUSTMENTS
VALVES, ROCKER ARM AND CAMSHAFT
¿ Valve Cotters
À Valve Spring Retainer
Á Valve Springs
 Valve Stem Seal
à Valve Spring seat
Ä Valve (intake)
Å Valve (exhaust)
Æ Lock Nut
Ç Adjuster
È Valve Rocker Arm
É Rocker Arm Shaft
Ê Camshaft
Ë Plate
Ì Bearing
Ì
4-32
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
WARNING
¿
¿
For Engine Assembly, replace the following
parts with new ones :
• O-Rings
• Gaskets
• Oil Seals
• Copper Washers
• Lock Washers
• Circlips
VALVES
AND
INSTALLATION
VALVE
SPRINGS
1. Deburr :
• Valve Stem end ¿ Using an Oil Stone for
smoothing.
2. Apply :
• Molybdenum disulfide oil on the Valve
Stem and Oil Seal
Molybdenum Disulfide Oil
3. Install :
• Valve Spring Seat ¿
Ã
À New
• Valve Stem Seal À New
• Valve Á in the valve guide(Cylinder Head)
• Valve Spring Â
• Spring retainer Ã
NOTE :
Install the Valve Spring with the small pitch è
facing downward
ç facing upwards
è facing downward
Â
¿
Á
À
¿
4. Install :
• Valve Cotters ¿
NOTE :
Install the Valve Cotters while compressing the
valve spring with Valve Spring compressor À
Valve Spring Compressor :
YSST - 603
4-33
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
5. Secure the Valve Cotters onto the Valve
Stem by tapping lightly with a mallet
WARNING
CAUTION:
Do not hit so much as to damage the Valve
¿
CAMSHAFT AND ROCKER ARM
INSTALLATION
1. Lubricate :
• Camshaft ¿
Camshaft and Camshaft bearing :
Multigrade engine oil.
2. Apply :
• Molybdenum disulfide oil on the rocker
arm and Rocker Arm Shaft
Molybdenum disulfide oil
3. Install :
• Rocker Arm as shown in figure
• Rocker Arm Shaft by pushing it in
completely
À
4. Install :
• Plate ¿
• Bolt À
¿
Bolt (Plate) :
7 Nm (0.7 m.kg, 5.1 ft.lb)
4-34
ENGINE ASSEMBLY AND ADJUSTMENTS
CRANKSHAFT
¿
À
Á
Â
Ã
Ä
Å
Æ
Ç
Crank Pin
Crank Shaft
Connecting Rod
Big end Bearing
4-35
Crankshaft Bearing
Wood-ruff Key
Gear Balancer
Balancer Assy.
Bearing
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
CRANKSHAFT
1. Insert :
• CrankShaft in the Crankcase (L.H.)
2. Attach :
• Crankshaft Installing Tool on Crankshaft
Crankshaft Installing Tool
YSST - 266
Spacer
YSST - 267
3. Install :
• Crankshaft by tightening the Nut ¿
¿
NOTE :
Hold the Connecting Rod at Top End with one
hand while turning the Nut of the Installing Tool
with the other. Operate the Installing Tool until
the Crankshaft is seated against the Bearing.
CAUTION:
WARNING
To avoid scratching the Crankshaft and to
ease the Installation procedure, apply Engine
Oil onto each Bearing and crankcase LH.
¿
4. Install :
• Balancer shaft ¿
è
ç
NOTE :
When installing the balancer shaft, align the
punched mark ç on the crankshaft drive gear
with the punched mark è on the balancer gear.
5. Install :
• Neutral Switch ¿
¿
4-36
ENGINE ASSEMBLY AND ADJUSTMENTS
TRANSMISSION
¿
À
Á
Â
Ã
Ä
Å
Æ
Ç
È
É
Ê
Ë
Ì
Í
Î
Ï
Drive Sprocket
Oil Seal
Bearing
4th Wheel Gear
Drive Axle
2nd Wheel gear
3rd Wheel Gear
Clutch Dog
4-37
1st Wheel Gear
Bearing
Bearing
4th Pinion Gear
3rd Pinion Gear
2nd Pinion Gear
Main axle
Plate
Bearing
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
SHIFTER
¿
À
Á
Â
Ã
Ä
Å
Æ
Ç
Shift Fork Guide Bar (long)
Shift Fork # R
Shift Fork # L
Shift Cam
Segment
4-38
Shift Fork Guide Bar (short)
Shift fork # C
Torx Screw
Pin Shaft Cam
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
TRANSMISSION, SHIFT CAM AND
SHIFT FORK INSTALLATION
1. Measure :
• Axle Main Assembled length ç
Assembled length (Axle Main):
82.25 ~ 83.45 mm
2. Install :
• Push rod # 2 ¿ in the Axle Main.
Á
Ã
À
¿
Â
3. Install :
The following parts in Crankcase LH in
following sequence.
• Shift Fork “L” (left) ¿
(face the “L” side for the Clutch side.)
• Shift Fork “R” (right) À
(face the “R” side for the Clutch side)
• Shift Fork “C” (center) Á
(face the “C” side for the Clutch side)
• Shift Fork Guide Bar #1 Â (Short)
• Shift Fork Guide Bar #2 Ã (Long)
NOTE :
Install the Shift Forks with the embossed mark
facing upward.
4. Check :
• Shift Cam operation
Improper operation Ÿ Reassemble/Repair
NOTE :
Check the transmission and Shift Forks for
smooth operation by turning the Shift cam with
your hand.
4-39
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
Tightening Sequence
¿
Ç
Â
Á
È
Ä
Ã
Æ
Å
À
CRANKCASE
¿
À
Á
Â
Ã
Crankcase #1 (LH)
Dowel Pins
Crankcase Breather Hose
Crankcase #2 (RH)
Holder Clutch Cable
4-40
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
CRANKCASE LH
1. Apply :
• Sealant on the Crankcase Mating surfaces
Sealant
Yamaha bond No. 1215:
2. Install :
• Dowel Pins ¿
NOTE :
Do not allow any sealant to come in contact with
the Oil Galleries ç and è as shown in the figure.
ç
3. Install:
• Crankcase RH with the Crankcase LH. Tap
lightly on the Case with mallet.
è
NOTE :
Tighten the Engine Mounting Nuts-2 nos for
holding the Engine on the engine stand.
Ç
È
4. Tighten :
• Bolts 2 nos Crankcase RH
• Bolts 8 nos Crankcase LH as per
sequence
Bolts (Crankcase) :
10 Nm (1.0 m.kg, 7.2 ft.lb)
¿
5. Apply :
• 4-Stroke Engine Oil on the Crank Pin,
Bearings and Oil Delivery Hole
Â
Á
Ä
Ã
Æ
Å
À
6. Check :
• Crankshaft and transmission operation for
smooth rotation/ shifting by hand
Unsmooth operation Ÿ Reassemble/Repair
4-41
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
CDI MAGNETO
¿
À
Á
Â
Ã
Ä
Å
Æ
Timing Chain
Guide Stopper # 1 and # 2
CDI Rotor Assy
Wood-Ruff Key
4-42
Stator Assy.
Gasket
Dowel Pin
Cover Crankcase #1
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
TIMING CHAIN AND GUIDE STOPPER#2
À
1. Install
• Timing Chain ¿
2. Install
• Guide stopper#2 À with spacer
• Tighten the bolt Á
¿
Á
C.D.I. MAGNETO INSTALLATION
¿
1. Install :
• Woodruff Key
2. Install :
• C.D.I. Magneto ¿
• Washer À
• Nut Á
NOTE :
When installing the Magneto Rotor, make sure
that the Woodruff Key is properly seated in the
Keyway of the Crankshaft.
À
Á
3. Tighten :
• Nut (CDI Magneto) using the Magneto
Holder ¿ - YSST-627
¿
Nut (CDI Magneto):
70 Nm (7.0 m.kg, 51 ft.lb)
¿
SPROCKET DRIVE
1. Install
• Sprocket Drive ¿
• Drive Sprocket Washer À
2. Tighten
• Bolt Á (Drive Sprocket) using the
sprocket Holder.
Á
Drive sprocket Holder
YSST-605
À
¿
Bolt Sprocket Drive
10 Nm (1.0 m.kg, 7.2 ft.lb)
4-43
ENGINE ASSEMBLY AND ADJUSTMENTS
SHIFT SHAFT AND KICK STARTER
¿
À
Á
Â
Ã
Ä
Shift Shaft
Torsion Spring
Stopper Lever
Return Spring
Segment
Kick Starter Assembly
Å
Æ
Ç
È
É
4-44
Circlip
Washer
Kick Idle Gear
Kick Shaft Assy.
Cover Crankcase # 2
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
SEGMENT AND SHIFT SHAFT
¿
À
1. Install
• Dowel Pins ¿ on the Cam Shifter À
2. Install :
• Segment ¿ using Torx Bit Tool
Torx Bit Tool
YSST - 611
NOTE :
Fit the Dowel Pins on the Cam Shifter to the locating hole on the Cam Shifter and install the
Segment ¿
¿
¿
3. Install :
• Stopper Lever ¿
• Spring À
4. Tighten
• Bolt stopper lever Á
Á
À
Bolt (Stopper Lever) :
10 Nm (1.0 m.kg, 7.2 ft.lb)
NOTE :
Hook the Spring ends on the Stopper Lever ¿
and the Crankcase Pin
Mesh the Stopper Lever ¿ with the Cam Shifter
Stopper.
Â
5. Install :
• Shift Shaft Assembly Â
NOTE :
Apply Oil to the Stopper Pin and hook the Spring
ends on the Stopper pin Ã
Ã
4-45
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
KICK STARTER INSTALLATION
¿
À Á
ç
À
¿
 Ã
1. Install :
• Kick axle ¿
• Ratchet gear with return spring À
• Shim Á
• Ratchet gear Â
• Shim Ã
• Torsion spring Ä
• Spacer Å
Ä Å
2. Install :
• Kick Axle Assembly ¿
• Kick Gear Clip À
• Torsion Spring Á
NOTE :
Turn the Torsion Spring clockwise and hook into
the proper hole ç in the Crankcase.
Á
2. Install :
Following parts on the Axle Drive Ä
• Circlip ¿
• Washer À
• Kick Idle gear Á
• Washer Â
• Circlip Ã
NOTE :
Install Circlips radius side towards the component refer Chapter 1, Page no 1-3
4-46
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP
¿
À
Á
Â
Ã
Ä
Å
Clutch Spring
Pressure Plate
Push Plate
Push Rod #1
Friction Plate
Clutch Plate
Clutch Boss
Æ
Ç
È
É
Ê
Ë
Ì
Thrust Washer
Primary Driven Gear
Ball
Push Rod # 2
Push lever Axle
Primary Drive Gear
Rotary Filter
4-47
Í
Î
Ï
Ð
Ñ
Key
Oil Pump Drive Gear
Oil Pump Driven Gear
Oil Pump
Gasket
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
OIL PUMP INSTALLATION
1. Lubricate :
• Oil delivery passage (Crankcase RH)
• Oil Pump Assembly ¿
¿
Recommended Lubricant:
4- Stroke Engine Oil
2. Install :
• Drive gear (Oil Pump) ¿
• Gasket
• Oil Pump Assy À
3. Tighten
• Screw (2 nos) Á
¿
Á
À
ç
4. Install
• Rotary Filter
NOTE :
Align the Rotary Filter Dog ç with groove of the
Crankshaft è and make sure to keep ‘TOP’
marking facing upside.
è
PRIMARY DRIVE GEAR INSTALLATION
1. Install :
• Primary Drive Gear ¿
• Key
• Washer À
2. Tighten :
• Nut Á
¿
Á
À
Nut (Primary Drive Gear)
70 Nm (7.0 m.kg, 51 ft.lb)
NOTE :
Hold the Rotor with Magneto Holder then tighten
the Primary Drive Gear Nut.
Magneto Holder
YSST - 627
4-48
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
CLUTCH INSTALLATION
1. Install :
• Oil Seal ¿ New
• Circlip New
• Push Lever Axle À
NOTE :
Install longer side ç of the Spring on Push Lever and smaller side è on the Crankcase Notch.
¿
New
À
2. Install :
• Spacer ¿
• Primary Driven Gear À
• Thrust Washer Á
• Clutch Boss Â
• Lock Washer à New
• Clutch Boss Nut Ä
À
Ä
Ã
Â
¿
Á
3. Tighten :
• Nut Clutch Boss ¿ while holding the Clutch
Boss with Clutch Hub Holder À
¿
À
Clutch Hub Holder
YSST - 233
Nut (Clutch Boss ):
60 Nm (6.0 m. kg, 43.5 ft. lb)
4. Bend :
• Lock Washer tab
(along a flat side of the end)
5. Install :
• Friction Plate ¿ 5 Nos
• Clutch Plate À 4 nos
NOTE :
• Install the Clutch Plates and Friction Plates alternately on the Clutch Boss, starting with a
Friction Plate and ending with a Friction Plate.
• Lubricate all Clutch and Friction Plates with
Engine Oil before installation
• Be sure to install a Clutch Plate with “Projection Mark” offset approximately 90 º from previous plates projection continue this procedure
in clockwise direction until all Clutch Plates
are installed
4-49
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
6. Install :
• Ball ¿
¿
¿
 Á
7. Install :
• Push Rod # 1 ¿
• Push Plate À
• Plate Washer Á
• Nut  (Push Rod # 1)
À
8. Install :
• Pressure Plate ¿
• Compression Springs À
• Bolts Á (Clutch Spring)
¿
À
Á
Bolts (Clutch Spring) :
6 Nm (0.6 m.kg, 4.3 ft. lb)
ç
è
NOTE :
Match arrow mark ç on the Pressure Plate with
the Punch mark on Clutch Boss è while installing the Pressure Plate.
Tighten the Clutch Spring Bolts in stage, using
a crisscross pattern.
ç
è
ALIGNED
9. Check :
• Push Lever position
• Push the Push Lever Assembly in the
arrow direction and make sure that the
mach mark are aligned adjust;
ç Match mark on the Push Lever Assembly
è Match mark on the Crankcase
NON ALIGNED
10. Adjust :
• Push Lever position
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
• Loosen the Lock Nut ¿
•Turn the Adjuster À clockwise or anticlockwise
to match alignment marks.
4-50
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
• Hold the Adjuster to prevent it from moving and
tighten the Locknut to specification
À
WARNING
CAUTION:
¿
Take care not to overtighten the Adjuster À and
remove the freeplay between both Push Rods.
• Tighten the Locknut ¿
ææææææææææææææææææææææææææææææææææ
11. Install
• Strainer ¿
NOTE :
Always keep its wider side, outside of Crankcase
12. Install :
• Dowel Pins
• Gasket (Crankcase #2) New
• Crankcase Cover #2 (RH)
¿
¿
Ä
Ã
Bolts (Crankcase Cover):
10 Nm (1.0 m.kg, 7.2 ft.lb)
Å
Â
Æ
Á
NOTE :
Tighten the Bolts in decreasing numerical order
(see number on the illustration)
13. Install :
• Kick Crank ¿
• Nut Kick Crank À
Ç
À
¿
Nut (Kick Arm):
50 Nm (5.0 m.kg, 36 ft. lb)
14. Install :
• Dowel Pins
• Gasket (Crankcase Cover #1) New
• Crankcase Cover #1(L.H.)
NOTE:
Tighten the Bolts in decreasing numerical order.
À
Ã
¿
Ä
Â
Bolts (Crankcase Cover):
10 Nm ( 1.0 m.kg, 7.2 ft.lb)
Å
Á
À
4-51
ENGINE ASSEMBLY AND ADJUSTMENTS
CYLINDER AND PISTON
¿
À
Á
Â
Cylinder
Gasket Cylinder
Dowel Pins
Piston Rings
Ã
Ä
Å
Æ
4-52
Piston Pin Circlips
Piston
Pin Piston
O’ Ring
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
CYLINDER HEAD
¿
À
Á
Â
Ã
Ä
Bolt Flange
Washer
Bolt
Valve Cover (intake)
O-Ring
Valve Cover (exhaust)
Å
Æ
Ç
È
É
Ê
4-53
Cylinder Head
Dowel Pin
Gasket Cylinder Head
O-Ring
Cover Cylinder Head Side # 3
Spark Plug
ENGINE ASSEMBLY AND ADJUSTMENTS
CAM SPROCKET AND TIMING CHAIN
 Cam Sprocket
à Timing Chain
Ä Guide Stopper # 1
¿ Gasket
À Timing Chain Tensioner Assembly
Á Guide Stopper # 2
4-54
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
PISTON RING, PISTON AND CYLINDER
INSTALLATION
1. Install in following sequence
• Expander Spacer (Oil Ring) ¿
• Side Rails (Oil Ring) À
• 2nd Ring Á
• Top Ring Â
NOTE :
• Make sure to install the Piston Rings so that
the RN mark is located on the upper side of
the 2nd Ring.
• Lubricate the Piston and Piston Rings with Engine Oil.
2. Install :
• Piston ¿
• Piston Pin À using Piston Pin Replacer
Tool
Piston Pin replacer tool
YSST - 607
• Piston Pin Circlip Á New
NOTE :
• Apply Engine Oil on the Piston Pin
• The “Ÿ”mark ç on the Piston must be kept
towards the exhaust side of the Cylinder
• Before installing the Piston Pin Circlip, Cover
the Crankcase opening with a clean cloth.
À
ç
¿
Á
3. Install :
• Dowel Pins ¿ - 2 Nos.
• Gasket (Cylinder) À New
¿
À
4-55
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
4. Install :
• Piston Rings ¿
NOTE :
Offset the Piston Rings end gaps as shown.
ç Top Ring End
è Oil Ring end (lower)
é Oil Ring End (upper)
ê 2nd Ring End
5. Lubricate :
• Piston outer surface
• Piston Rings
• Cylinder Inner Surface
6. Install :
• Cylinder ¿
¿
À
NOTE :
• Install the Cylinder with one hand while compressing the Piston Rings with the other hand
• Pass the Timing Chain and Guide stopper # 2
through the Timing Chain Cavity.
• Press the Piston down to rest on Piston
Base À YSST - 604
Piston Base
YSST - 604
New
New À ¿
Cylinder head Installation
1. Install
• Dowel Pins ¿ New
• Gasket ( Cylinder Head) À New
• Guide Stopper#1 Á
Á
4-56
ENGINE ASSEMBLY AND ADJUSTMENTS
2. Install :
• Cylinder Head
• Bolt with Washer (Cylinder Head)
Â
¿
Á
Bolts (Cylinder Head ):
M8 (1-4) :
22 Nm (2.2 m.kg, 17 ft.lb)
M6(5-6) :
10 Nm (1.0 m.kg., 7.2 ft. lb)
À
Ã
ENG
Ä
NOTE :
• Apply Engine Oil onto the Bolt thread
• Tighten the Bolts starting with the lowest numbered one.
ê
¿
é
À
è
ç
3. Install :
• Cam Sprocket À
• Timing Chain ¿
ææææææææææææææææææææææææææææææææææ
Installing steps :
• Turn the Crank Shaft anticlockwise until the
slit ç (3rd Mark) matches the stationary
pointer è
• Align the “I” mark é on the Cam Sprocket with
the stationary pointer ê on the Cylinder Head.
• Fit the Timing Chain ¿ on Cam Sprocket À
and install the Cam Sprocket on the Camshaft.
NOTE :
When installing the Cam Sprocket , keep installation of the Camshaft. Damage or improper
Valve timing will result.
WARNING
CAUTION:
Do not turn the Crankshaft during installation of the Camshaft. Improper Valve Timing will result.
NOTE :
Remove the safety wire from the Timing Chain
before installation of Sprocket Cam.
ææææææææææææææææææææææææææææææææææ
4-57
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
4. Install :
• Plate Washer
5. Tighten
• Bolt Sprocket ¿
¿
Bolt (Timing Chain Sprocket) :
20 Nm (2. 0 m.kg, 14.5 ft. lb)
NOTE :
Install the Bolt while holding the Magneto
Mounting nut with a Wrench.
ê
é
6. Check :
• Magneto Rotor Slit ç Third mark in
Anticlockwise direction.
Align with stationary pointer è in the
Crankcase Cover #1 (LH)
• Cam Sprocket “I” mark é
Align with stationary pointer ê on the
Cylinder head
Out of alignment Ÿ Adjust
è
ç
7. Install :
• Gasket (Timing Chain Tensioner)
• Timing Chain Tensioner
¿
À
Á
Ã
Ä
ææææææææææææææææææææææææææææææææææ
Installation steps :
• Remove the Tensioner Cap Bolt
• While Pressing the Tensioner Rod lightly with
fingers, use a Flat Head Screwdriver ¿ and
retract the Tensioner Rod up fully clockwise
• With the Rod fully retracted, install the Gasket
À and the Chain Tensioner Á and tighten the
Bolt  with Copper Washer to the specified
torque
• Release the Chain Tensioner Rod by Screwdriver, Then install the Gasket à and the Cap
Bolt Ä to the specified torque.
Bolts (Timing Chain Tensioner):
10 Nm (1.0 m.kg, 7.2 ft.lb)
Cap Bolt (Timing Chain Tensioner):
8 Nm (0.8 m.kg, 5.8 ft.lb)
Â
4-58
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
8. Check :
• Valve clearance specifications
Out of specification Ÿ Adjust.
Refer to the “VALVE CLEARANCE ADJUSTMENT” section in Chapter 3, Page no 3-8
9. Lubricate :
• 4 Stroke Engine Oil
Recommended Lubricant :
Engine Oil - YAMALUBE
10.Install :
• Valve Covers (with O-Ring) ¿
• Cylinder Head Side Cover (with O-Ring) À
• Bolts Á
À
¿
Valve Cover :
17.5 Nm (1.75 m.kg, 13 ft.lb)
Bolts (Cylinder Head Side Cover)
10 Nm (1.0 m.kg, 7.2 ft.lb)
Á
11. Install :
• Timing Check Plug (with O-Ring) ¿
• Center Plug (with O-Ring) À
¿
À
12. Install
• O-Ring (intake manifold)
• Intake Manifold ¿
13. Tighten
• Bolts (intake manifold) À 2 Nos.
À
Bolts (intake Manifold) :
10 Nm (1.0 m.kg, 7.2 ft. lb)
¿
4-59
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
14. Install :
• Spark Plug
Spark Plug :
12.5 Nm (1.25 m.kg, 12.6 ft. lb)
15. Install :
• Plug Drain ¿
¿
Plug Drain :
20 Nm (2.0 m.kg, 2.0 ft.lb)
ENGINE MOUNTING
When remounting the Engine, reverse the removal procedure. Note the following points :
1. Install :
• Engine Assembly (from the Left side of
the Motorcycle)
2. Install
• Footrest Assy
3. Install :
• Engine Mount Bolt (front centre) ¿
• Bolt (Engine Mount stay front upper) À
• Bolt (Engine Mount stay front lower) Á
• Engine Mount Bolt front lower Â
• Engine Mount stay Ã
• Engine Mount Bolt (bottom rear) Ä
• Engine Mount Bolt (upper rear) Å
• Engine mount stay upper Æ
• Bolt AIS Mounting on stay Ç - 2 Nos.
• Engine Mount Stay È
4. Tighten :
• Bolts Foot Rest Assembly
Bolts (foot rest) :
17.5 Nm (1.75 m.kg, 13 ft lb)
4-60
ENGINE ASSEMBLY AND ADJUSTMENTS
Engine Mount Bolt (Rear) :
38 Nm (3.8 m.Kg.27.5 ft. lb)
Bolt (Engine mount Stay) :
38 Nm (3.8 m..kg, 27. 5 ft.lt)
Engine mount bolt (upper)
38 Nm (3.8 m..kg, 27. 5 ft.lt)
Bolt (Engine Mount Stay front upper)
55 Nm (5.5 m.kg., 40 ft.lb)
À
ENG
Bolt (Engine Mount stay front lower)
55 Nm (5.5 m.kg., 40 ft.lb)
Engine Mount Bolt (Front lower)
38 Nm (3.8 m.kg., 27.5 ft.lb)
Engine Mount bolt (from upper))
38 Nm (3.8 m.kg., 27.5 ft.lb)
5. Install :
• Gasket
• Exhaust pipe ¿
• Bolts Exhaust Pipe À - 2 nos
• Bolt (Muffler) Á
Á
Bolts (Exhaust Pipe) :
10 Nm (1.0m. kg, 7.2 ft. lb)
Bolt (Muffler) :
15 Nm (1.5 m.kg, 11 ft lb)
¿
¿
6. Install :
• Shift Pedal ¿
7. Tighten :
• Bolt Shift Pedal À
À
Bolt (Shift Pedal):
10 Nm (1.0m. kg, 7.2 ft. lb)
8. Install :
• Stay Clutch Cable ¿
¿
Bolt (cable stay) :
7 Nm (0.7 m.kg, 5.1 ft. lb)
9. Install
• Clutch cable
• Adjust Clutch Cable free play at Lever end
Refer “CLUTCH ADJUSTMENT” in Chapter 3,
Page no 3-17
10. Adjust
Drive Chain Slackness
Refer to “DRIVE CHAIN SLACK
ADJUSTMENT” section in Chapter 3, Page
no 3-20
4-61
ENGINE ASSEMBLY AND ADJUSTMENTS
ENG
11. Install:
• Carburetor
Refer to “CARBURETOR “ section in
Chapter 5 page no 5-7
12. Tighten:
• Air Filter Case Screws
Bolts (Air Filter Case ):
7 Nm (0.7 m.kg, 5.1 ft.lb)
À
13. Install
• Battery Box
• Battery
• Battery Flap
¿
Bolts (Battery Box)
3.8 Nm (0.38 mkg), 3 ft lb
14. Connect
• Battery Leads
• Sensor Coil Lead Coupler ¿
WARNING
CAUTION:
¿
Connect the positive lead ¿ First and then the
negative lead À
15. Install
Spark Plug Cap
16. Fill
• Crankcase
Refer to “ENGINE OIL REPLACEMENT”
section in Chapter 3, Page no 3-14
17. Adjust :
• Idle Speed
Refer to “IDLING CO. MEASUREMENT
AND ADJUSTMENT” in Chapter 3, Page
no 3-8
18. Adjust :
• Throttle cable Free play
Refer
to
“THROTTLE
CABLE
ADJUSTMENT” in Chapter 3, Page no 3-9
4-62
CARBURETION
CARB
CHAPTER 5
CARBURETION
CARBURETOR VIEW ................................................................5-1
REMOVAL ................................................................................... 5-2
DISASSEMBLY ........................................................................... 5-3
INSPECTION ..............................................................................5-4
ASSEMBLY ................................................................................. 5-6
INSTALLATION ........................................................................... 5-7
TUNING ....................................................................................... 5-8
FUEL LEVEL ADJUSTMENT ......................................................5-9
THROTTLE POSITION SENSOR (TPS) ......................................5-10
AIR INDUCTION SYSTEM ........................................................... 5-12
CARBURETOR
CARB
CARBURETOR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
SCREW (TOP COVER)
TOP COVER
PISTON VALVE SPRING
HOLDER (JET NEEDLE)
JET NEEDLE RETAINER SPRING
RING
JET NEEDLE E-RING
JET NEEDLE RING
WASHER
JET NEEDLE
PISTON VALVE ASSY
DIAPHRAGM (PISTON VALVE)
CAP PLUNGER
GUIDE HOLDER
O-RING
PLUNGER SPRING
20
21
22
23
24
25
26
27
28
29
30
31
PLUNGER
AIR VENT HOSE
THROTTLE POSITION SENSOR
(TPS) KIT
PILOT SCREW
SPRING
O-RING
WASHER
PILOT JET ASSY.
HOLDER
IDLE ADJUSTER SPRING
IDLE ADJUSTER SCREW
MAIN JET
NEEDLE VALVE ASSY. KIT
FLOAT ASSEMBLY
FLOAT PIN
32
33
34
35
36
37
38
39
40
FLOAT PIN FIXING SCREW
FCB O-RING
FLOAT CHAMBER BODY
ASSY
DRAIN SCREW
FCB - FIXING SCREW
CLIP FOR DRAIN HOSE
DRAIN HOSE
NEEDLE SET KIT
STARTER SET KIT
BS (BUTTERFLY SLIDE) - TYPE
1
2
13
14
41
3
15
16
17
18
4
5
19
6
39
7
8
21
26
22 23
24
20
28
9
10
27
25
11
29
30
31
32
12
33
35
34
36
37
38
5-1
CARBURETOR
CARB
R E M O VA L
1 . Remove :
• Side Covers (LH /RH)
Refer to the “SIDE COVER, SEAT AND
FUEL TANK” section in Chapter 3, Page
No.- 3-3
2. Close
• Fuel
3. Drain :
• Fuel from Float Chamber
NOTE :
Place a rag under the over flow hose to absorb
the spilt fuel.
WARNING
Petrol is highly flammable. Avoid spilling
fuel on the hot Engine.
4. Disconnect :
• Air Vent Hose ¿
• Fuel Hose À
• Over Flow Hose Á
À
¿
Â
5. Remove :
• Starter wire Nut - Â
Á
6. Remove
• Throttle Cable - ¿
¿
7. Unscrew
• Clamp Front/Rear
• Remove carburettor from Engine.
5-2
DISASSEMBLY
CARB
DISASSEMBLY
NOTE:
The following parts can be cleaned and
inspected without Carburetor Disassembly.
• Throttle Cable
• Starter Plunger Assembly
• Fuel Hose, Air vent Hose, over flow Hose
• Before disassembly of Carburetor clean the
outer surface of Carburettor and Check the
Starter cable operator.
Á
1. Open :
• Screw (Pan Head) 2-Nos- ¿
¿
Â
2. Remove :
• Cover À
• Spring Á
• Diaphragm with Piston Valve Â
À
Á
3. Open :
• Screw (Float chamber) -3 Nos- ¿
¿
À
4. Remove :
• Float Chamber Body À
• Seal Float Chamber Á
5. Remove :
• Screw- ¿
• Float Pin- À
• Float - Á
Á
¿
À
5-3
DISASSEMBLY/INSPECTION
CARB
6. Remove :
• Needle Valve- ¿
Â
Á
7. Open :
• Main jet- À # 127.5
• Main Nozzle- Á
• Pilot Jet- Â
¿
À
8. Remove :
• Pilot screw Assy.¿ (With spring, washer
and O’Ring)
¿
9. Unscrew :
• Throttle Stop Screw with Spring À
À
NOTE:
Don’t Remove/Unscrew the T.P.S. (Throttle
Position Sensor) during normal screw
INSPECTION
Carburetor Body
1. Inspect :
• Cracks/damage Ÿ Replace
• Fuel Passages Blockage Ÿ Clean with
petrol and Compressed air.
• Contamination in jet housings Ÿ Clean
Carburetor Float Chamber Body
1. Inspect
• Cracks/damage Ÿ Replace
• Fuel Starter Passage Blockage Ÿ Clean
with petrol and compressed air
• Contamination in Starter jet Ÿ Clean
ææææææææææææææææææææææææææææææææææ
Cleaning Steps :
ó Wash the Carburetor in petroleum based solvent. (Do not use any caustic cleaning solution )
ó Blow all passages and Jets with compressed
air.
ææææææææææææææææææææææææææææææææææ
5-4
INSPECTION
CARB
Float
1. Inspect :
• Damage/Leakage Ÿ Replace
Jets Screws Diaphragam
Ä
Â
1. Inspect :
• Jet Needle ¿
• Main Nozzle À
• Main Jet Á
• Pilot jet Â
• Throttle Stop Screw Ã
• Pilot screw with ‘O’ Ring, spring and
washer Ä
• Needle Valve Å
• valve seat
• Bends/wear/damage Replace
Blockage Ÿ Blow the Jets with
compressed air
À
Ã
¿
Å
Á
Æ
2. Inspect
Diaphragam damage Æ - Replace
Piston Valve
1. Check :
• Free movement
Insert the Piston Valve with Diaphragm in
Carburetor body, and check for free
movement
Hinderance Ÿ Clean/Replace
Throttle Valve
1. Check :
• Free movement with throttle lever Ÿ Clean
and Lubricate.
Hinderance Ÿ Clean/Replace
Starter Assembly
1. Inspect :
• Starter plunger movement
• Starter spring
• Starter wire
5-5
ASSEMBLY
CARB
ASSEMBLY
Reverse the disassembly procedure.
1. Wash
• All the parts in clean petroleum based
solvent
• Always use new ‘o’ Rings
2. Install :
• Pilot screw assembly ¿
3. Install :
• Main Nozzle ¿
• Main Jet À
• Pilot Jet Á
Á
¿
4. Install :
• Needle valve assembly Â
• Float Ã
• Float Pin Ä
Â
À
5.Tighten :
• Screw float Pin Å
Ã
Å
Ä
¿
6. Install
• Seal Float chamber ¿ New
• Float chamber À
• Screw - 3 Nos. Á
Á
À
7. Install
• Throttle stop screw assembly ¿
5-6
INSTALLATION
CARB
8. Install
• Piston Valve Assy. with Diaphragm ¿
¿
NOTE :
Hold the piston Valve Assy. with diaphragm
open condition and Aligns the diaphragn match
mark with carburetor mark,, Then put the pan
head with spring on Top of diaphragn press the
spring to same holding position of piston Valve
and tighten the screw pan head. After Tighting
the screw, Release the piston Valve Assy.
INSTALLATION
Reverse the “REMOVAL” procedure
1. Carburettor Inlet Manifold and tighten Air
filter Hose.
Screw Front/Rear Clamp
¿
2. Install :
Throttle cable assembly ¿ on carburettor.
3.
4. Connect :
• Over Flow Hose Á
• Air Vent Hose Â
• Fuel Hose Ã
Ã
Â
À
Starter Cable assy À.
Á
5-7
CARBURETOR TUNING
CARB
8. Adjust :
• Idling speed by Throttle Stop Screw ¿
Engine Idling Speed :
1300 - 1500 R.P.M.
9. Adjust :
• Throttle Cable free play
Refer
to
“THROTTLE
CABLE
ADJUSTMENT” in Chapter 3, Page no 3-9
¿
Carburetor Tuning
‘CO MEASUREMENT AND ADJUSTMENT”
1. Start the Engine and let it worm up by
running approximately 4 kms.
2. Attach :
• Tachometer to the Spark Plug lead
3. Check :
• Engine idling speed
If out of sepecification Ÿ adjust
Engine Idling Speed :
1300 - 1500 R.P.M.
ææææææææææææææææææææææææææææææææææ
Adjustment Steps
Turn the Throttle Stop Screw ¿ in or out until
specified idling speed is obtained.
Turning in Ÿ RPM Increases
Turning Out Ÿ RPM Decareses
ææææææææææææææææææææææææææææææææææ
4. Insert :
• Sampling probe À of ‘CO’ tester
(calibrated) to the exhaust pipe Á using
suitable adapter Â
Â
Á
‘CO’ density :
2.5% ± 1.5% v/v
À
If out of specification Ÿ adjust
5. Adjust :
• ‘CO’ density through pilot screw
ææææææææææææææææææææææææææææææææææ
Adjustment Steps
Turn the Pilot Screw à in or out until the specified ’CO’ density is achieved.
Turning Out Ÿ ‘CO’ density Increases
Turning In
Ÿ ‘CO’ density Decareses
Ã
• Reset idling speed as per specifications
æææææææææææææææææææææææææææææææææ
5-8
CARBURETOR TUNING
CARB
CAUTION:
WARNING
Do not disturb settings of the Carburetor if
the Engine performance is O.K.
• If required, must record the existing setting (No. of turns) of the Pilot Screw.
• To counter check the setting of the Pilot
Screw, follow the ‘CO’ adjustement procedure.
• Ensure proper clamping of the blind plug
6. Adjust :
• Idling speed by Throttle Stop Screw ¿
Engine Idling R.P.M.
1300 to 1500 RPM
¿
ææææææææææææææææææææææææææææææææææ
FUEL LEVEL ADJUSTMENT
1. Measure :
• Fuel Level ç
• Out of specification Ÿ Adjust
Fuel level :
6.5 ± 0.5 mm Above the Joint of
Main Chamber Body and Float
Chamber Body
ææææææææææææææææææææææææææææææææææ
Measurement and adjustment steps :
• Place the motorcycle on a level surface on centre stand
• Connect the Fuel Level Gauge ¿ to the Drain
Pipe À
Fuel Level Gauge
• Loosen the Drain Screw Á
• Hold the Gauge vertically next to the Float
Chamber Line
• Measure the Fuel level ç with the Gauge
• If the fuel level is incorrect, adjust the fuel level,
using the following steps
• Remove the Carburetor
• Inspect the Valve Seat and Needle Valve
• If either is worn, replace as a set
5-9
CARBURETOR TUNING
Â
CARB
• Otherwise adjust Float level by bending the
Float Tang  on the Float slightly up or down
as required.
• Install the Carburetor
• Recheck the fuel level
• Adjust Float height through Float Tang Â
By Bending Down Ÿ Float Height increase
By Lifting Up
Ÿ Float Height Decrease
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
• Check/adjust the idle rpm - 1300~1500
• Remove the TPS Coupler from TPS
Unit mounted at carbruettor.
• Check TPS resistance at idling throttle
position without starting the engine.
• Make connection as below
Multimeter
À
¿
+
-
YTPS
Terminal of Blue wire ¿
Terminal of Black wire À
Specification
At Idling
À
3.5 ~ 6.5 K Ohms
• Check TPS resistance at full throttle
position without starting engine
¿
Multimeter
+
-
YTPS
Terminal of Yellow wire ¿
Terminal of Black wire À
Specification
By slowly
opening
the throttle
0 ~ 5 K Ohms
If out of specifi cations, replace YTPS
5-10
CARBURETOR TUNING
CARB
• Check/adjust the idle rpm - 1300~1500
• Remove side covers, seat & fuel tank
• Check TPS input & output voltage at
idling & full throttle position without
starting the engine at CDI unit.
• Check TPS Input voltage
Make connection as below
Multimeter
+
-
YTPS
Terminal of Blue wire
Terminal of Black wire
Input Voltage
5 V ± 0.05 V
• Check TPS output Voltage
Multimeter
+
-
YTPS
Terminal of Yellow wire
Terminal of Black wire
Output Voltage
0.7 V ± 0.05 V
¿
If out of specifications, adjust YTPS Angle
with in specifications by loosening YTPS
screw ¿
5-11
CARB
CARBURETOR TUNING
AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned
exhaust gases by injecting fresh
air(secondary air) into the exhaust port,
reducing the emission of hydrocarbons.
When there is negative pressure at the
exhaust port, the reed valve opens,
allowing secondary air to flow into the
exhaust port. The required temperature for
burning the unburned exhaust gases is
approximately 600 to 700º C.
¿
1.
2.
3.
À
Air Filter Case ¿
AIS Unit À
Exhaust Port Á
Ã
Ä
Á
Â
Ä
Â
CHECKING
SYSTEM
1.
Â
Ä
5-12
THE
AIR
INDUCTION
Check
•
hose Â
Loose connection Ÿ
Connect Properly
Crack/Damage Ÿ Replace
•
Pipes Ã
Crack/damage Ÿ Replace
•
Clamps Ä
for proper clamping
FRONT WHEEL AND FRONT BRAKES
CHAS
CHAPTER 6
CHASSIS
FRONT WHEEL AND FRONT BRAKE ........................................ 6-1
FRONT WHEEL ......................................................................... 6-1
FRONT BRAKE .......................................................................... 6-2
REMOVAL ................................................................................... 6-3
FRONT WHEEL INSPECTION .................................................. 6-4
BRAKE SHOE PLATE DISASSEMBLY ...................................... 6-5
SPEEDOMETER GEAR INSPECTION...................................... 6-5
FRONT BRAKE INSPECTION ................................................... 6-6
BRAKE SHOE PLATE ASSEMBLY ............................................ 6-7
FRONT WHEEL INSTALLATION ................................................. 6-8
REAR WHEEL AND REAR BRAKE ............................................ 6-10
REAR BRAKE ............................................................................. 6-11
REMOVAL ................................................................................... 6-12
REAR WHEEL INSPECTION ...................................................... 6-13
REAR BRAKE INSPECTION ...................................................... 6-13
REAR WHEEL INSTALLATION ................................................... 6-14
DRIVE CHAIN AND SPROCKETS .............................................. 6-15
REMOVAL ................................................................................... 6-16
DRIVE CHAIN INSPECTION ....................................................... 6-17
CLUTCH HUB INSPECTION ....................................................... 6-18
DRIVEN SPROCKET ASSEMBLY .............................................. 6-18
DRIVEN SPROCKET AND DRIVE CHAIN INSTALLATION ......... 6-18
FRONT FORK............................................................................. 6-20
FRONT FORK REMOVAL .......................................................... 6-21
FRONT FORK DISASSEMBLY .................................................. 6-21
FRONT FORK INSPECTION ..................................................... 6-23
FRONT FORK ASSEMBLY ........................................................ 6-24
FRONT FORK INSTALLATION .................................................. 6-26
STEERING HEAD AND HANDLEBAR ...................................... 6-27
REMOVAL ................................................................................... 6-28
HANDLEBAR REMOVAL ........................................................... 6-29
HANDLEBAR INSPECTION ....................................................... 6-29
STEERING INSPECTION .......................................................... 6-30
STEERING INSTALLATION ....................................................... 6-30
HANDLEBAR INSTALLATION ................................................... 6-31
REAR SHOCK ABSORBER AND SWING ARM VIEW ............. 6-32
REMOVAL ................................................................................... 6-33
INSPECTION .............................................................................. 6-33
FRONT WHEEL AND FRONT BRAKES
FRONT WHEEL
¿
À
Á
Â
Ã
Ä
Å
Æ
Cotter Pin
Axle Nut
Speedometer Cable Assy.
Wheel Axle
Spacer
Brake Shoe Plate Assy.
Dust Seal/Collar
Front Wheel
6-1
CHAS
CHAS
FRONT WHEEL AND FRONT BRAKES
FRONT BRAKE
¿
À
Á
Â
Ã
Ä
Å
Æ
Ç
È
Brake Shoe Assy.
Oil Seal
Gear drive
Lever Camshaft
Indicator Plate
Camshaft
Bush
Plate Washer
Gear Meter
O-Ring
¿
È
Å
À
Æ
Á
Ç
Ä
Ã
Â
6-2
FRONT WHEEL AND FRONT BRAKES
CHAS
REMOVAL
WARNING
À
¿
• Securely support the Motorcycle on the
centre stand so that there is no danger of
it falling over.
• Park the Motorcycle on a level surface
1. Loosen :
• Lock nut ¿ and screw in the adjuster À
fully to loosen the Brake Cable
2. Remove :
• Front Brake Cable Á by slacking and
removing it first from the Handlebar end
and then from the Front Wheel end.
• Nut
• Spring
• Take out Brake wire from slot of Brake
Plate
Á
3. Disconnect
• Speedometer Cable ¿ by removing the
clip À
¿
À
¿
4. Remove
• Cotter Pin ¿
• Nut À
5. Lift
• Front Wheel
À
NOTE :
Place suitable stand under the Engine.
5. Remove
• Front Wheel Axle ¿
• Brake Shoe Plate Assembly À
• Dust Seal/Collar Á
• Front Wheel Â
6-3
FRONT WHEEL AND FRONT BRAKES
CHAS
Front Wheel Inspection :
1. Inspect
• Front Wheel Axle
(by rolling it on a flat surface)
Bends Ÿ Replace
Wheel Axle Bending Limit :
0.25 mm
WARNING
Do not attempt to straighten a bent Axle
2. Inspect :
• Front Tyre
Wear/damage Ÿ Replace
Refer to “TYRE INSPECTION” in Chapter 3,
Page no 3-26
• Front Wheel
Refer to “WHEEL INSPECTION” in
Chapter 3, Page no 3-27
3. Check :
• Spokes
Bends/damage Ÿ Replace
Loose Spokes Ÿ Tighten
Turn the Wheel and tap the Spokes with a
Screwdriver
NOTE :
A tight Spoke will emit a clear, ringing tone; a
loose Spoke will sound flat.
4. Tighten :
• Loose Spokes
• Nipple
NOTE :
Check the Front Wheel runout after tighteneing
the Spokes.
Nipple Tightening Tool
YSST - 629
6-4
FRONT WHEEL AND FRONT BRAKES
CHAS
5. Measure :
• Front Wheel runout using a height gauge
Over the specified limits Ÿ Correct/Replace
Front Wheel runout limits :
Radial ç : 1.5 mm (max)
Lateral è : 1.5 mm (max)
6. Inspect :
• Front Wheel Bearings
Bearings allow free play in the Wheel Hub
or the Wheel does not turn smoothly Ÿ
Replace
• Oil Seals
Wear/damage Ÿ Replace
7. Inspect :
• Collar
Grooved Wear Ÿ Replace the Collar and
the Oil Seal as a set
BRAKE SHOE PLATE DIASSEMBLY
1. Remove :
• Bush ¿
• Meter Gear À
Remove the bush using a Meter Gear
Bush Tool Á
À
¿
Á
Nipple Tightening Tool
YSST - 629
SPEEDOMETER GEAR INSPECTION
1. Inspect :
• Meter Drive Gear ¿
• Meter Gear À
¿
À
6-5
FRONT WHEEL AND FRONT BRAKES
CHAS
FRONT BRAKE INSPECTION
1. Inspect :
• Brake Lining surface
Glazed areas Ÿ Replace
Use Coarse Sand Paper for polishing of
Brake Lining
NOTE:
After polishing , wipe the polished particles with
a cloth.
2. Measure :
• Brake Lining thickness ç
Out of specification Ÿ Replace
Brake Lining thickness:
Standard
: 4 mm
Limit
: 2 mm
ç
NOTE :
Replace the Brake Shoes as a set if either is
worn to the limit.
3. Measure :
• Brake Drum inside diameter ç
Out of specification Ÿ Replace the Wheel
Drum
ç
Brake Drum inside diameter:
Standard : 150 mm
Limit
: 151 mm
4. Inspect :
• Brake Drum inner surface
Oil/Scratches Ÿ Repair
• Oil : Use a Rag soaked in solvent
• Scratches : Use an emery cloth and polish
lightly and evenly.
5. Inspect :
• Camshaft Face ¿
Wear Ÿ Replace
¿
WARNING
When inspecting the Brake Lining, do not
spill oil or grease on the Brake Lining.
6-6
FRONT WHEEL AND FRONT BRAKES
CHAS
BRAKE SHOE PLATE ASSEMBLY
1. Install :
• Camshaft ¿
• Indicator Plate À
ææææææææææææææææææææææææææææææææææ
Installation steps :
• Align the projection ç on the Indicator Plate
À with the Camshaft notch è
ææææææææææææææææææææææææææææææææææ
À
ç
¿
è
2. Install :
• Cam Lever ¿
• Bolt Cam Lever À
¿
À
Cam Lever Nut :
10 Nm (1.0m.kg, 7.2 ft.lb)
3. Install
• Brake Shoes ¿
¿
• Tension Springs À New
NOTE :
• When installing the Springs and Brake
Shoes, take care not to damage the Springs
• Replace the Tension Spring as a set when
replacing the Brake Shoes.
¿
À
WARNING
New
After installing the Brake Camshaft, remove
the excess grease
4. Install :
• Meter Gear ¿
• Bush À
Install the Bush using the Spanner -Speedometer Gear Nut
À
Á
Spanner - Speedometer Gear Nut
YSST - 237
¿
¿
è
5. Install :
• Brake Shoe Plate Assembly ¿
NOTE :
Make sure that the Wheel Hub and the Speedometer Gear Unit are installed with the two projections ç meshed into the two solts è
6. Install :
• Hub Dust Cover
• Collar
ç
6-7
FRONT WHEEL AND FRONT BRAKES
CHAS
FRONT WHEEL INSTALLATION
Reverse the “REMOVAL” procedure
Note the following points
1. Lubricate :
• Axle Front Wheel
• Bearings
• Oil Seal (lips)
• Drive/Driven Gear (Speedometer)
Recommended lubricant :
Lithium Soap base grease
ç
è
2. Install :
• Front Wheel
NOTE:
Make sure that the slot ç in the Shoe Plate fits
over the Stopper è on the Front Fork Outer
Tube LH
3. Tighten :
• Front Wheel Axle
• Axle Nut ¿ (Front Wheel)
NOTE :
Do not loosen the Axle Nut after Torque tightening. If Axle Nut groove is not aligned with the
Wheel axle Cotter Pin hole, align groove to hole
by tightening up on the Axle Nut.
¿
WARNING
CAUTION:
Before tightning the Wheel Axle, Stroke the
Front Fork several times to check for proper
fork operation
Axle Nut :
59 Nm(5.9 m.kg. 43 ft.lb)
4. Install :
• Cotter Pin ¿ New and bend its ends.
New
WARNING
¿
Always use a new Cotter Pin
6-8
FRONT WHEEL AND FRONT BRAKES
CHAS
5 Install :
• Meter Cable ¿
• Clip À
• Brake Cable Á thru nozzle
• Bush Â
• Nut
¿
À
Á
Â
WARNING
Make sure that the Brake Cable and Meter
Cable is routed properly.
¿
6. Check :
• Front Brake for proper operation
Improper operation Ÿ Recheck or
disassemble.
7. Adjust
• Brake Lever free play
Refer to “FRONT BRAKE ADJUSTMENT”
section in Chapter 3, Page no 3-18
À
6-9
REAR WHEEL AND REAR BRAKE
CHAS
REAR WHEEL
¿
À
Á
Â
Ã
Ä
Å
Æ Spacer
Ç Rear Wheel Assembly
È Brake Shoe Plate Assembly
É Damper
Ê Bearing
Ë Spacer/Collar
Ì Bearing
Adjuster
Pin
CompressionSpring
Cotter Pin
Tension Bar
Axle Nut
Chain Puller
6-10
REAR WHEEL AND REAR BRAKE
CHAS
REAR BRAKE
¿ Brake Shoe Kit
À Cam Lever
Á Indicator Plate
 Camshaft
à Spring
Ã
6-11
REAR WHEEL AND REAR BRAKE
¿
CHAS
REMOVAL
WARNING
Á
• Securely support the Motorcycle on centre
stand so that there is no danger of it falling over
• Stand the Motorcycle on a level surface
À
Ã
¿
Ä À
1. Remove :
• Chain Cover (upper ¿ and lower À)
2. Loosen
• Chain Adjuster Á
3. Remove :
• Nut (Rear Brake) ¿
• Cotter Pin À
• Nut Á with Bolt
• Tension Rod Â
• Compression Spring Ã
• Brake Rod Ä
Â
Á
4. Remove :
• Cotter Pin ¿
• Nut (Wheel Axle) À
• Wheel Axle Á
• Collar Â
Â
¿
À
Á
NOTE :
When removing the Wheel Axle, the Collar will
fall off. Take care not to lose it.
5. Remove :
• Axle Wheel ¿
• Rear Wheel À
• Rear Brake Shoe Plate
Remove the Rear Wheel Hub. with chain
and spacer
¿
À
6-12
REAR WHEEL AND REAR BRAKE
CHAS
REAR WHEEL INSPECTION
1. Inspect :
• Axle Rear Wheel
• Rear Wheel
• Bearings Rear Wheel
• Oil Seals
Refer to “FRONT WHEEL INSPECTION”
Page no 6-4
¿
2. Measure :
• Rear Wheel runout
Refer to “FRONT WHEEL INSPECTION ”
Page no 6-4
3. Inspect :
• Clutch Hub Damper
Wear/damage Ÿ Replace
REAR BRAKE INSPECTION
1. Inspect :
• Brake Lining surface
2. Measure :
• Brake Lining thickness
3. Inspect :
• Brake Drum inner surface for Oiliness and
Scratches
Refer to “FRONT WHEEL BRAKE
INSPECTION” page no 6-6
4. Measure :
• Brake Drum inside diameter ç
Out of specification Ÿ Replace
Brake Drum inside diameter :
Standard
: 130 mm
Limit
: 131 mm
ç
6-13
REAR WHEEL AND REAR BRAKE
CHAS
REAR WHEEL INSTALLATION
Reverse the “REMOVAL” procedure
1. Install :
• Chain Adjuster in Rear Swinging fork
• Rear Wheel Assembly in Sprocket Hub
with spacer
• Brake Shoe Plate Assembly
• Spacer between Chain Sprocket and
Frame
• Spacer (RH) between brake plate and
frame.
• Axle Rear Wheel
NOTE :
Make sure that the slots in the Rear Wheel Hub
Damper fits over the tabs on the Clutch Hub assembly
2. Adjust :
• Drive Chain Slack
Refer to “DRIVE CHAIN ADJUSTMENT”
section in Chapter 3, Page no 3-20
3. Tighten :
• Nut Rear Wheel Axle
NOTE :
Do not loosen the Axle Nut after torque tightening. If Axle Nut Groove is not aligned with the
Wheel Axle Cotter Pin Hole, align Groove to hole
by tightening up on the Axle Nut.
Nut (Rear Wheel Axle) :
91 Nm (9.1 m.kg., 66 ft.lb)
4. Install :
¿
New
• Cotter Pin ¿ New
NOTE :
Bend the ends of the Cottor Pin
WARNING
Always use a new Cottor Pin
5. Check :
• Rear Brake Pedal free play
Refer to “REAR BRAKE ADJUSTMENT”
section in Chapter 3, Page no 3-18
6-14
DRIVE CHAIN AND SPROCKETS
CHAS
DRIVE CHAIN AND SPROCKETS
¿
À
Á
Â
Ã
Ä
Chain Case
Crankcase Cover 3
Drive Sprocket
Clip Chain Joint
Link Plate
Chain Joint
Å Drive Chain
Æ Spacer
Ç Driven Sprocket Assembly
È Chain Tensioner Adjuster
É Circlip
Ê Oil Seal
6-15
DRIVE CHAIN AND SPROCKETS
CHAS
REMOVAL
1. Stand the Motorcycle on a level surface.
WARNING
Securely support the Motorcycle on Centre
stand so that there is no danger of it falling
over.
2. Remove :
• Chain Case (upper and lower) ¿
• Shift pedal À
• Crankcase Cover 3 Á
• Drive Sprocket
Refer to “ENGINE REMOVAL” Section in
Chapter 4, Page No 4-1
Á
À
¿
3. Remove
• Rear Wheel
Refer to “REAR WHEEL” Section Page no
6-12
4. Remove :
• Chain Joint Clip ¿
• Link Plate À
• Chain Joint Á
• Drive Chain Â
Á
Â
À
¿
5. Remove :
• Rear wheel Assy. removal
Refer to Rear Wheel removal on page 6-12
• Rear wheel Sprocket Assy.
6-16
DRIVE CHAIN AND SPROCKETS
CHAS
DRIVE CHAIN INSPECTION
1. Inspect :
• Drive Chain stiffness
Stiffness Ÿ Clean and Lubricate or replace
2. Inspect :
• Drive Chain ¿
• Driven Sprocket À
More than 1/2 tooth wear ç Ÿ Replace
the Drive Chain and both the Sprockets as
a set.
3. Measure :
• 10 link length è (Drive Chain)
Out of specification Ÿ Replace the Drive
Chain
10 link length limit :
127 mm
NOTE :
• Tighten the Drive Chain with a fingers before
measuring
• 10 link length is the distance è between the
inside edge of Roller ¿ and É as shown.
• 10 link length measurement should be done
at two or three different places.
4. Clean :
• Drive Chain
Put it in Kerosene and brush off as much
dirt as possible. Then remove the Drive
Chain from the ketosene and dry it.
Drive Chain Lubricant :
Engine Oil
6-17
DRIVE CHAIN AND SPROCKETS
CHAS
CLUTCH HUB INSPECTION
1. Inspect :
Clutch Hub
Wear/damage/cracks Ÿ Replace
DRIVEN SPROCKET ASSEMBLY
Á
1. Install
• Driven Sprocket ¿ on Clutch Hub
¿
• Lock Washer À New
• Nut Á
• Bolt Â
À
Â
Nut (Driven Sprocket ):
26 Nm (2.6 m.kg, 19 ft.lb)
NOTE :
Tighten the Nuts in a crisscross pattern
2. Bend :
Lock Washer Tab ¿
(along a flat side of the end)
¿
DRIVEN SPROCKET AND DRIVE CHAIN
INSTALLATION
1. Install :
• Chain Tensioner in Rear Swinging fork
• Driven Sprocket Spacer ¿ with Drive
Sprocket Assembly
• Axle Rear Wheel À with Washer.
2. • Install Brake Shoe plate with Spacer
(RH Side).
À
6-18
DRIVE CHAIN AND SPROCKETS
CHAS
3. Install :
• Drive Chain ¿
• Chain Joint À
• Plate Á
• Chain Joint Clip Â
À
¿
Á
Â
4. Install :
Clip ¿ New
WARNING
CAUTION:
Be sure to install the Chain Joint Clip to the direction as shown
5. Install :
• Chain Case (upper)
• Chain Case (lower)
• Crank Case Cover - 3
Refer to “ENGINE REMOVAL” section in
Chapter 4 Page no 4-1
6. Adjust :
• Drive Chain Slack
Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in Chapter 3, Page no 3-20
6-19
FRONT FORK
CHAS
FRONT FORK
¿
À
Á
Â
Ã
Ä
Front Fender
Cap Bolt with Gromet
Holder Cable
O Ring
Collar
Spring Seat
Å
Æ
Ç
È
É
Ê
Fork Spring
Seal Dust
Ring Snap
Washer
Bolt
Gasket
À
Á
6-20
Ë
Ì
Í
Î
Ï
Ð
Spindle Taper
Cylinder Comp Front Fork
Inner Tube
Sub Spring
Oil seal
Outer Tube
FRONT FORK
CHAS
FRONT FORK REMOVAL
WARNING
¿
Securely support the Motorcycle so there is
no danger of it falling over
1. Stand the Motorcycle on a level surface
2. Elevate the Front Wheel by placing a suitable stand under the Engine
3. Remove :
• Front Wheel
• Front Fender
Refer to “FRONT WHEEL REMOVAL”
Section Page no 6-3
• Handlebar
Refer to “HANDLEBAR REMOVAL”
Section Page no 6-30
4. Remove
• Rubber Cap LH/RH
• Pinch Bolt (Inner Tube) - 2 Nos ¿
• Cap Bolt Under Bracket - 2 Nos À
À
Á
FRONT FORK DISASSEMBLY
1. Remove
• Bolt Upper -TFF Á
2. Drain :
• Fork Oil
3. Remove :
• Spacer ¿
• Seat Upper À
• Spring Front Fork Á
Á
À
¿
6-21
FRONT FORK
CHAS
4. Loosen :
• Bolt Allen (Damper Rod) ¿
Loosen the Bolt (Damper Rod) ¿ while
holding the Damper Rod with T-Handle À
T-Handle
YSST - 213
¿
À
5. Remove :
• Bolt (Damper Rod) ¿
• Washer À
• Cylinder complete Fornt Fork Á
• Spindle Taper Â
• Spring Sub Ã
À
¿
Ã
Á
Â
6. Remove :
• Ring snap
• Washer
• Oil Seal ¿ using Oil Seal Remover À
À
¿
Oil Seal Remover
YSST - 275
WARNING
CAUTION:
Never reuse the Oil Seal
6-22
FRONT FORK
CHAS
FRONT FORK INSPECTION
1. Inspect :
• Inner Tube bending
Inner Tube bending limit :
0.2 mm
Scratches/bends/damage Ÿ Replace
WARNING
Do not attempt to straighten a bent Inner
Tube as this may dangerously weaken the
Tube
ç
2. Measure :
• Fork Spring length ç
Front Fork Spring free length :
316.9 mm
<Wear limit>
311.9
À
Over the specified limit Ÿ Replace
3. Inspect :
• Cylinder Complete Front Fork ¿
• Piston Ring À
Wear/cracks/damage Ÿ Replace
• Spring Sub Á
• Spindle Taper Â
Bends/damage Ÿ Replace
Contamination Ÿ Blow out all Oil
Passages with Compressed Air
Á
¿
Â
WARNING
CAUTION:
• When disassembling and assembling the
Front Fork do not allow any foreign material to enter the Oil
6-23
FRONT FORK
CHAS
FRONT FORK ASSEMBLY
Reverse the “DISASSEMBLY” procedure
Note the following points
NOTE :
• When assembling the Front Fork be sure to
replace the following parts
• Oil Seal
• Seal Dust
• Snap Ring
• Before assembling the Fork, make sure that
all the components are clean.
¿
À
1. Install :
• Spring Sub ¿
• Cylinder Complete À
WARNING
Allow the Cylinder Complete to slide slowly
down the Inner Fork Tube until it protrudes
from the bottom, being careful not to damage the Inner Fork Tube
2. Lubricate :
• Inner Tube (outer surface)
Recommended lubricant :
Fork Oil 10 W or equivalent
3. Install :
• Cylinder Complete ¿
• Spindle Taper À
• Inner Tube Á
• Outer Tube Â
Â
À
¿
Á
4. Install :
• Washer ¿ New
• Bolt (Damper Rod) À
¿
New
À
6-24
FRONT FORK
CHAS
5. Tighten :
• Bolt (Cylinder Complete) ¿ holding the
Cylinder Complete with a T-Handle À
Bolt (Cylinder Complete) :
23 Nm (2.3 m.kg, 17 ft.lb)
¿
T-Handle
YSST - 213
À
6. Install :
• Oil Seal ¿ New Using TFF Oil Seal
Installation Tool À
À
¿
New
TFF Oil Seal Installation Tool
YSST - 275
NOTE :
• Before installing the Oil Seal ¿ apply lithium
soap base grease onto the Oil Seal lips.
• Adjust the Ring Snap so that it fits into the
Outer Tube Groove
WARNING
CAUTION:
Make sure that the Oil Seal numbered side
faces upward
¿
À
7. Install :
• Washer ¿
• Ring Snap À
• Dust Seal Á
Á
8. Inspect :
• Inner Tube operation
Unsmooth operation Ÿ Disassembly and
recheck
6-25
FRONT FORK
CHAS
9. Fill :
• Fork Oil ¿
Oil Quantity :
Overhauling - 151 ± 3 ml
Refilling - 139 ± 3 ml
Recommended Oil :
Teleshocab Oil
10. After filling up, slowly Pump the Fork up
and down to distribute the Fork Oil
11. Install :
• Front Fork Spring ¿
• Seat Upper
• Spacer
¿
12. Install :
• Cap Bolt Temporarily to avoid oil drain.
NOTE :
• Install the Fork Spring with its smaller Pitch
upward.
• Before installing the Cap Bolt, apply grease to
the O-Ring.
FRONT FORK INSTALLATION
¿
Reverse the “REMOVAL PROCEDURE”
Note the following points
1. Install
• Front Fork
• Temporarily
tighten
Pinch
Bolt
(Underbracket) ¿
NOTE:
Pull up the inner to until its end flushes with the
top of the Handle Crown then temporarily tighten
the bolts (underbracket)
2. Tighten
• Pinch Bolts (underbracket) ¿
• Cap Bolts À
À
Pinch Bolt (Underbracket) :
28Nm (2.8 m.kg, 20 ft.lb)
Bolt (Cap Bolt) :
23Nm (2.3 m.kg, 17 ft.lb)
6-26
STEERING HEAD AND HANDLEBAR
CHAS
STEERING HEAD AND HANDLEBAR
¿
À
Á
Â
Ã
Ä
Å
Æ
Ç
È
É
Ê
Ë
Ì
Í
Î
Bolt Steering
Holder Handle bar Upper
Handlebar
Grip Assembly (right)
Handle Crown
Lock Washer
Ring Nut (upper)
Damper Rubber
Ring Nut (lower)
Ball Race Cover
Under Bracket
Ball Race (upper)
Ball (upper)
Ball (lower)
Ball Race (center)
Ball Race (lower)
¿
Ã
Tightening Steps
• Tighten the ring nut Lower
33 Nm (3.3 m.kg, 25 ft.lb)
• Loosen One turn
• Retighten The ring nut Lower
23 Nm (2.3 m.kg, 17 ft.lb)
6-27
STEERING HEAD AND HANDLEBAR
CHAS
REMOVAL
WARNING
À
¿ Á
Securely support the motorcycle so that
there is no danger of it falling over
Stand the motorcycle on a level surface
1. Remove :
• Band ¿
• Brake Cable (front) À
• Clutch Cable Á
• Speedometer Cable
2. Remove :
• Starter wire ¿
• Switch Handle À
À
¿
3. Remove :
• Bolts (4 Nos) ¿
• Handlebar Upper Holder À
• Handlebar Á
• Throttle Grip
• Lever Holder (Front Brake)
Á
À
4. Remove :
• Front Wheel
Refer to “FRONT WHEEL” Section, Page
No 6-4
• Front Fender
• Front Fork
Refer to “FRONT FORK” Section, Page no
6-21
¿
5. Remove :
• Fuel Tank
Refer to “SIDE COVERS, SEAT, FUEL
TANK” section in Chapter 3, page no 3-3
¿
6. Remove :
• Headlight Assembly ¿
• Bolt Steering
• Bolt Cap (Upper Bracket) - 2 Nos.
• Upper Bracket
6-28
STEERING HEAD AND HANDLEBAR
CHAS
7. Remove :
Lock Washer ¿
Ring Nut (upper) À
Damper Rubber Á
¿
À
Á
8. Remove :
• Ring Nut (lower) ¿
Use a Ring Nut Wrench À
À
Ring Nut Wrench :
YSST - 621
WARNING
¿
Securely support the Steering Shaft so that
there is no danger of it falling down
9. Remove :
• Bearing Cover ¿
• Bearing Race À
• Rack Balls (upper) Á
• Lower Bracket Â
• Rack Balls (lower) Ã
HANDLEBAR REMOVAL
1. Remove :
• Grip (left)
ææææææææææææææææææææææææææææææææææ
Removal Steps :
• Blow with compressed air between the Handlebar and Adhesive side of the Grip to remove
ææææææææææææææææææææææææææææææææææ
HANDLEBAR INSPECTION
1. Inspect :
• Handlebar ¿
Bends/Cracks/damage Ÿ Replace
¿
WARNING
Do not attempt to straighten a bent Handlebar as this may dangerously weaken the
Handlebar
6-29
STEERING HEAD AND HANDLEBAR
CHAS
STEERING INSPECTION
2
1
1. Wash the Bearing and Ball Races with a solvent
2. Inspect :
• Bearing Races ¿
• Ball Cage Bearing À
Pitting/Damage Ÿ Replace
ææææææææææææææææææææææææææææææææææ
Bearing Race replacement steps :
• Remove the Ball Races on the Head Pipe using Long Rod ¿ and the hammer as shown
• Remove the Ball Race on the Under Bracket
using the floor chisel À and the hammer as
shown
• Install the new Dust Seal and Races
ææææææææææææææææææææææææææææææææææ
NOTE :
Always replace Bearing races as a set.
WARNING
CAUTION:
If Bearing Race is not fitted squarely, the
Head Pipe could be damaged.
STEERING INSTALLATION
Reverse the “REMOVAL”procedure
Note the following points
1. Lubricate
• Balls (upper and lower)
• Ball Races
Recommended lubricant
Lithium - soap base grease
2. Install :
• Ring Nut (lower) ¿
• Damper Rubber À
• Ring Nut (upper) Á
• Lock Washer Â
Refer
to
“STEERING
HEAD
INSPECTION” section in Chapter 3, Page
no 3-22
3. Install :
• Bush
• Meter Assembly with Handle Crown
Ring Nut:
23 Nm (2.3 m.kg, 17 ft.lb)
6-30
STEERING HEAD AND HANDLEBAR
CHAS
4. Install :
• Front Fork
Refer to “FRONT FORK” Section, Page no
6-27
• Front Fender
• Front Wheel
Refer to “FRONT WHEEL” Section, Page
no 6-8
HANDLEBAR INSTALLATION
1. Install :
• Holder Handelbar Lower ¿
• Handlebar ¿
• Upper Handlebar Holder À
Bolt (Handlebar Upper Holder):
7.5 ~ 12 Nm (2.3 m.kg, 17 ft.lb)
NOTE :
• Apply a light coat of lithium soap base grease
onto the Handlebar right end
• The Upper Handlebar Holders should be installed with the longer side ç to the forward,
then tighten the Front Bolt as shown
2. Install :
• Front Brake Lever Assembly ¿
• Handlebar Switch (left)
• Grip Assembly
• Throttle Cable
• Housing (Throttle Grip)
¿
NOTE :
Align the projection ç on the Handlebar Switch
with the Hole è in the Handlebar.
WARNING
Check the throttle grip for smooth operation
ç
3. Adjust :
• Throttle Cable free play
• Brake operation
Refer to “THROTTLE CABLE ADJUSTMENT
/ BRAKE LEVER ADJUSTMENT” section in
Chapter 3, Page no 3-9 and 3-18
è
6-31
REAR SHOCK ABSORBER AND SWING ARM
REAR SHOCK ABSORBER AND SWINGARM
¿
À
Á
Â
Ã
Rear Shock Absorber
Axle Nut
Swing arm
Tension Bar
Seal Guard
6-32
CHAS
REAR SHOCK ABSORBER AND SWING ARM
CHAS
REMOVAL
1. Stand the Motorcycle on a level surface.
WARNING
Securely support the Motorcycle on a level surface
2. Remove :
• Side Covers (left and right)
• Seat
• Cover Chaincase
• Chain Case (upper and lower)
Refer to “SIDE COVERS, SEAT, AND
FUEL TANK ” section in Chapter 3, Page
no 3-3
3. Remove :
• Rear Wheel
• Driven Sprocket Assembly
Refer to “DRIVE CHAIN AND
SPROCKETS” section, Page no 6-16
4. Remove :
• Nut Rear Shocker (upper and lower)
• Rear Shock Absorber (left and right)
5. Remove :
• Nut Footrest L.H./R.H.
• Axle Nut (Swing Arm) ¿
• Washer À
• Axle Shaft Á
• Foot Rest LH/RH
• Swing Arm Â
¿ À
Â
Á
6-33
REAR SHOCK ABSORBER AND SWING ARM
CHAS
INSPECTION
1. Inspect :
• Swingarm looseness
Looseness exists Ÿ Tighten the Pivot
Shaft nut or replace Bushes
• Swingarm up and down movement
Unsmooth movement/bending/rough spots
Ÿ Replace Bushes
2. Inspect :
• Rear Shock Absorber
Oil leaks/damage Ÿ Replace the Rear
Shock Absorber Element
6-34
ELEC
CHAPTER 7
ELECTRICAL
CIRCUIT DIAGRAM ................................................................... 7-1
LOCATION OF ELECTRICAL COMPONENTS ......................... 7-2
CHECKING OF CONNECTIONS ............................................... 7-3
IGNITION SYSTEM/CHARGING SYSTEM
CIRCUIT DIAGRAM ............................................................. 7-4
TROUBLESHOOTING ......................................................... 7-4
CHARGING SYSTEM
TROUBLESHOOTING ......................................................... 7-9
LIGHTING SYSTEM
CIRCUIT DIAGRAM ............................................................. 7-10
TROUBLESHOOTING ......................................................... 7-10
LIGHTING SYSTEM CHECK ............................................... 7-12
SIGNAL SYSTEM
CIRCUIT DIAGRAM ............................................................. 7-14
TROUBLESHOOTING ......................................................... 7-14
SIGNAL SYSTEM CHECK ................................................... 7-16
CIRCUIT DIAGRAM
7-1
ELEC
ELECTRICAL COMPONENTS
ELEC
LOCATION OF ELECTRICAL COMPONENTS
¿
À
Á
Â
Ã
Ä
Main Switch
Flasher Relay Assy
C.D.I. Unit Assy
Battery
Fuse
Stop Switch Rear
Å
Æ
Ç
È
É
Ê
Neutral Switch Assy
Rectifier / Regulator Assy
Ignition Coil Assy
Spark Plug Cap
Horn
Throttle Position Sensor (TPS)
Ê
7-2
CHECKING OF CONNECTIONS
ELEC
CHECKING OF CONNECTIONS
Dealing with wire pressed stains, rust,
moisture etc. on the connector.
1. Disconnect
• Connector ¿
2. Dry each terminal with an air blower
3. Connect and disconnect the Connector two
or three times.
4. Pull the lead to check that it will not come
off.
5. If the terminal comes off, bend up the pin
¿ and reinsert the terminal in to the connector.
6. Check for continuity with a tester.
NOTE:
• If there is no Continuity, Check/Clean the terminals
• Be sure to check the steps 1 to 6 listed above
when checking the wire harness.
• Use the tester on the connector as shown.
7-3
IGNITION SYSTEM/ CHARGING SYSTEM
ELEC
IGNITION SYSTEM, CHARGING SYSTEM AND TACHOMETER SYSTEM
CIRCUIT DIAGRAM
TROUBLE SHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE.
(NO SPARK OR INTERMITTENT SPARK)
PROCEDURE
CHECK
1. Spark Plug
2. Spark Plug Cap resistance
3. Ignition coil
4. Main switch
5. Sensor coil resistance
6. Charging Coil resistance
7. Rectifier cum Regulator Unit
8. Wiring connections (entire ignition system)
9. CDI
10.Tachometer Circuit
Note :
Remove the required parts before trouble shooting.
1) Side covers (LH and RH)
2) Seat
3) Fuel Tank
• Use Service Instrument as specified.
Digital Multimeter
NOTE :
For Checking Coil resistance, set Multimeter a
step higher than specified range.
7-4
IGNITION SYSTEM / CHARGING SYSTEM
ELEC
PROCEDURE STEPS
•
•
•
•
1. SPARK PLUG
Check the spark plug condition
Check the Spark Plug type
Check the Spark Plug gap
Refer to “SPARK PLUG INSPECTION“
section in Chapter 3, Page 3-10
Standard Spark Plug
CR7HSA - NGK
Spark Plug Gap : 0.6~0.7 mm
OUT OF SPECIFICATION
Adjust or replace the Spark Plug
2. SPARK PLUG CAP RESISTANCE
• Remove the Spark Plug Cap
• Connect the Multimeter (ΩX1k) to the Spark
Plug Cap.
NOTE:
• When removing the Spark Plug Cap, turn
out the Spark Plug Cap from high tension
Cord.
Multimeter (+) lead Ÿ Spark Plug side ¿
Multimeter (-) lead Ÿ High tension Cord
side À
Remove Ÿ Turn anticlockwise
Connect Ÿ Turn clockwise
• When connecting the Spark Plug Cap, cut
the High Tension Cord about 5 mm.
Spark Plug Cap resistance :
Ω (at 20°C)
5 KΩ
æ
À
¿
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Replace the Spark Plug Cap
7-5
IGNITION SYSTEM / CHARGING SYSTEM
æ
ELEC
Multimeter (+) lead Ÿ Black/Blue Terminal ¿
Multimeter (-) lead Ÿ Green Terminal À
3A. IGNITION COIL RESISTANCE (Primary)
• Disconnect the Ignition Coil Connector
From the Wire harness
• Connect the Multimeter to the Ignition Coil.
• Check the primary Coil resistance
¿
Primary coil resistance :
0.22 Ω ± 15 %
À
3B. IGNITION COIL RESISTANCE (Secondary)
• Connect the Multimeter to the Ignition Coil
• Check the secondary coil resistance
Multimeter (+) lead Ÿ High Tension lead ¿
Multimeter (-) lead Ÿ Green Terminal À
À
Secondary coil resistance :
Ω ± 20% (at 20 º C)
3.0 kΩ
¿
OUT OF SPECIFICATION
BOTH MEET
SPECIFICATIONS
Ignition Coil OK
Replace the Ignition Coil
4. MAIN SWITCH
• Check for Continuity of Switch ON position
Multimeter (+)
Multimeter (-)
R
BR/L
NO CONTINUITY
• Check for ignition “ON” “OFF” position
Replace the Main Switch
CONTINUITY
Main Switch OK
7-6
ELEC
IGNITION SYSTEM/ CHARGING SYSTEM
Mutimeter (+) lead ŸWhite/Blue terminal ¿
Multimeter (-) lead Ÿ Earth À
5. SENSOR COIL RESISTANCE
• Disconnect the sensor Coil Coupler from
the Wiring Harness
• Connect the Multimeter (Ω X 100) to the
sensor coil coupler
• Check the sensor coil resistance
Sensor coil resistance :
240 Ω ± 20 % (at 20ºC)
À
¿
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Sensor coil is OK
Replace the Sensor Coil Assembly
6. CHARGING COIL RESISTANCE
Multimeter (+) lead Ÿ White Terminal ¿
Multimeter (-) lead Ÿ Black Terminal À
• Remove the Charging Coil coupler from the
Wire Harness
• Connect the Multimeter to the charging coil
• Measure the charging coil resistance
À
¿
Charging coil resistance
0.75 Ω ± 20 % (at 20ºC)
OUT OF SPECIFICATION
MEETS
SPECIFICATIONS
Replace the Charging CoiL
Charging coil is OK
æ
7-7
IGNITION SYSTEM / CHARGING SYSTEM
ELEC
æ
Multimeter (+) lead Ÿ Battery (+) terminal ¿
Multimeter (-) lead Ÿ Battery (-) terminal À
7. RECTIFIER CUM REGULATOR UNIT
• Check the Charging Voltage
Procedure Steps
• Connect the Tachometer to Spark plug lead
• Connect the Multimeter ( DC 20V) to Battery Red Wire.
Measure the Battery Voltage : 12V
If less than specifications, charge the
Battery
• Start the engine and accelearte the Engine
up to 5000 RPM .
• Check the Charging voltage :
Charging voltage :
14 ~ 15 V at 5000RPM
À
¿
MEETS SPECIFICATIONS
OUT OF
SPECIFICATION
Rectifier cum Regulator unit is faulty.
• Replace RR unit
Charging Circuit and Rectifier cum Regulator are OK
8. WIRING CONNECTIONS
• Check the connection for entire Ignition and
Charging System “REFER TO CIRCUIT
DIAGRAM” Page 7-4
POOR CONNECTIONS
IF CORRECT
Repair/ Replace the Harness
9. CDI Unit
• Check CDI unit “REFER IGNITION
TIMING PROCEDURE Chapter 3,
Page 3.11
IF NOT WORKING
10. TACHOMETER
• Check Tachometer Operation and entire
connection
Replace Tachometer
7-8
CHARGING SYSTEM
ELEC
TROUBLE SHOOTING
IF THE BATTERY IS NOT CHARGED
PROCEDURE
CHECK
1. Fuse
2. Battery
3. Charging voltage
4. Charging coil resistance
5. Wiring system (entire charging system)
1. FUSE
Refer to “FUSE INSPECTION SECTION” in
Chapter 3, Page no 3-30
Note :
Remove the following parts before trouble shooting.
1) Side covers (LH )
• Use Service Instruments as specified.
Engine Tachometer.
Digital Multimeter
NO CONTINUITY
CONTINUITY
Replace the Fuse
2. BATTERY
• Check the Battery condition.
Refer to “BATTERY INSPECTION” section
in Chapter 3, Page no 3-28
Specific Gravity : 1.230 ± 0.005 at 20ºC
INCORRECT
CORRECT
3. CHARGING VOLTAGE
• Refer to Rectifier cum Regulator unit inspection method in the Ignition System
section in this Chapter, Page no 7-8
• Top up with distilled water
• Clean the Battery terminals
• Recharge or Replace the Battery
MEETS SPECIFICATIONS
OUT OF
SPECIFICATION
4. CHARGING COIL RESISTANCE.
• Refer to Charging coil resistance checking
method in the Ignition System section in
this Chapter, Page no 7-7
The Charging circuit is OK
OUT OF SPECIFICATION
MEETS
SPECIFICATION
5. WIRING CONNECTION
• Check entire Charging system for poor
connections.
Refer to circuit diagram Section Page no 7-4
Replace the Charging Coil
POOR CONNECTIONS
Repair or Replace the Wiring Harness
7-9
LIGHTING SYSTEM
ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM : AC
TROUBLE SHOOTING
IF THE HEAD LIGHT, HI BEAM INDICATOR LIGHT, TAILLIGHT AND METER LIGHT
DO NOT WORK
PROCEDURE
CHECK
1. Lighting Coil resistance
2. Light Switch
3. Dimmer Switch
4. Lighting Voltage
5. Wiring connections (entire lighting system)
6. Check individual lighting circuits
Note :
Remove the following parts before trouble
shooting.
1) Side covers (LH and RH)
2) Seat
3) Headlight Assembly
4) Battery
5) Battery Box
Engine Tachometer.
Digital Multimeter
7-10
LIGHTING SYSTEM
1. LIGHTING COIL RESISTANCE
ELEC
Multimeter (+) lead Ÿ Yellow terminal ¿
Multimeter (-) lead Ÿ Black terminal À
• Remove the C.D.I. Magento Coupler from
the wiring Harness
• Connect the Multimeter (Ω X 1) to the Lighting Coil
• Measure the Lighting Coil resistance
À
¿
Lighting Coil resistance
0.62 Ω ± 20 % at 20ºC
OUT OF SPECIFICATION
MEETS
SPECIFICATIONS
2. LIGHT SWITCH
Replace the Lighting Coil
• Disconnect the Handlebar Switch (LH)
Coupler from Wireharness
• Connect the Multimeter (Ω X 1) to Handlebar Switch (LH) Terminals
• Check the switch connections for continuity between “Blue” and “Yellow/Red”
NO CONTINUITY
CONTINUITY
Repair or Replace the Handlebar Switch LH
3. DIMMER SWITCH
• Disconnect the Handlebar Switch (LH)
Coupler from wireharness.
• Connect the Multimeter (Ω X 1) to Handlebar Switch (LH) Terminals
• Check the Switch connections for continuity between “Yellow/Red and Green”, “Yellow/Red and Yellow”
æ
NO CONTINUITY
Repair or Replace the Handlebar Switch LH
CONTINUITY
7-11
LIGHTING SYSTEM
ELEC
æ
4. LIGHTING VOLTAGE
Multimeter (+) lead Ÿ Blue terminal ¿
Multimeter (-) lead Ÿ Black terminal À
• Connect the Tachometer to Spark Plug
lead.
• Disconnect the Taillight coupler from wire
harness
• Connect the Multimeter (AC 20 V) to taillight wire
• Start the Engine and accelerate the engine
up to 5000 RPM
• Measure the lighting Voltage with (full load
by switching on the Headlight)
¿
À
Lighting Voltage :
(With Full Load) :
14V ±0.5 at 5000 RPM
OUT OF SPECIFICATION
MEETS
SPECIFICATION
5. WIRING CONNECTIONS
• Check entire lighting system for poor Connections refer to “WIRING DIAGRAM”
Page
Check the Lighting Coil resistance
POOR CONNECTIONS
CONTINUITY
• Check the condition of individual Lighting
System Circuits
• Repair or Replace wireharness
æ
7-12
LIGHTING SYSTEM
ELEC
æ
6. INDIVIDUAL LIGHTING CIRCUITS
A. If the Headlight and Highbeam Indicator
Light do not work
1. BULBS AND BULB SOCKETS
• Check the Bulbs and Bulb sockets for
continuity.
NO CONTINUITY
CONTINUITY
2. LIGHTING VOLTAGE
Replace Bulb and/or Bulb Socket.
• Refer the lighting Voltage section Page no
7-12
B. If the meter light does not work
1. BULB AND BULB SOCKET
• Check the Bulb and Bulb Socket for
continuity.
NO CONTINUITY
Continuity
2. LIGHTING VOLTAGE
Replace Bulb and/or Bulb socket.
• Refer the lighting Voltage section Page no
7-12
C. If the Tail Light does not work
1. BULB AND BULB SOCKET
• Check the Bulb and Bulb Socket for
continuity.
NO CONTINUITY
CONTINUITY
Replace Bulb and/or Bulb socket.
2. LIGHTING VOLTAGE
• Refer the lighting Voltage section Page no
7-12
7-13
SIGNAL SYSTEM
ELEC
SIGNAL SYSTEM
CIRCUIT DIAGRAM : DC
TROUBLE SHOOTING
IF THE FLASHER LIGHT, BRAKE LIGHT AND INDICATOR LIGHTS DO NOT WORK
IF THE HORN DOES NOT WORK
PROCEDURE
CHECK
1. Fuse
2. Battery
3. Main Switch
4. Wiring connections (entire lighting system)
5. Check individual lighting circuits
Note :
Remove the following parts before trouble shooting.
1) Side covers (LH/RH)
2) Seat
3) Fuel Tank
Digital Multimeter
4) Headlight
7-14
SIGNAL SYSTEM
ELEC
1. FUSE
Refer to “FUSE INSPECTION SECTION “ in
Chapter 3, Page 3-30
NO CONTINUITY
CONTINUITY
2. BATTERY
Replace fuse
• Check the Battery condition
Refer to “BATTERY INSPECTION SECTION” in Chapter 3, Page 3-28
INCORRECT
CORRECT
• Top up the Battery fluid
• Clean Battery terminal
• Recharge or replace the Battery
3. MAIN SWITCH
• Disconnect the main switch coupler from
wireharness
• Check the continuity between ”Brown” and
Red” wires
NO CONTINUITY
CONTINUITY
4. WIRE HARNESS
Repair/Replace the Main Switch
• Check the entire signal system for poor
connections
Refer to “SIGNAL SYSTEM CIRCUIT DIAGRAM” Page 7-14
POOR CONNECTIONS
CORRECT
• Check the condition of each of the signal
system circuits
Repair/Replace the Wireharness
æ
7-15
SIGNAL SYSTEM
ELEC
5. INDIVIDUAL SIGNAL SYSTEMS
A. If the Horn does not work.
1. HORN SWITCH
• Disconnect the Handlebar Switch Coupler
from Wireharness.
• Check the continuity between the “Pink” and
“Black” with switch in Pressed Position.
NO CONTINUITY
Replace the Switch Handle (LH)
CONTINUITY
Multimeter (+) lead Ÿ Brown ¿ Terminal
Multimeter (-) lead Ÿ Body earth À
2. VOLTAGE
• Connect the Multimeter (DC20 V) to the
Horn lead
• Turn the Main Switch to “ON”
• Check the Voltage (12V) between the
“Brown” wire and Body Earth.
À
¿
OUT OF SPECIFICATION
MEETS
SPECIFICATION
The wiring circuit from the Main Switch to the
Horn is faulty. Repair/Replace wireharness.
3. HORN
• Disconnect the “Pink” terminal from the
horn.
• Connect the multimeter (5 A) to the open
terminal ¿ at “Horn”
• Turn the main switch “ON”
• Check current (Amperage) drawn by Horn
by connecting to body earth.
Multimeter (+) lead Ÿ Horn Terminal ¿
Multimeter (-) lead Ÿ Body earth À
À
¿
Specified current 1.5 A
OUT OF SPECIFICATION / NO SOUND
MEETS
SPECIFICATION
Horn is OK
Adjust / Replace the Horn
7-16
SIGNAL SYSTEM
ELEC
B. If the Brake Light does not work.
1. BULB AND BULB SOCKETS
• Check the Bulb and Bulb sockets for continuity.
NO CONTINUITY
CONTINUITY
Replace Bulb and/or Bulb socket.
2. BRAKE SWITCH FRONT / REAR
• Disconnect the Brake switch Coupler from
wire Harness.
• Check the switch front and rear for continuity between “Brown and Yellow” for front
and “Brown and Green/Yellow” for Rear
NO CONTINUITY
CONTINUITY
Replace the Brake Switch
Multimeter (+) lead Ÿ Yellow terminal ¿
Multimeter (-) lead Ÿ Black terminal À
3. VOLTAGE
• Connect the Multimeter “DC20V” to bulb
socket connector
• Turn the Main Switch to “ON”
• Apply the Front/Rear Brake
• Check The voltage (12V) between the “Yellow and Black terminal”
MEETS SPECIFICATIONS
OUT OF
SPECIFICATION
Brake Light circuit is OK
4. WIRING CONNECTION
Wiring circuit from Main Switch to the Bulb
Sockets connector is faulty. Repair
Refer to “SIGNAL SYSTEM” wiring diagram
Page no 7-14
7-17
SIGNAL SYSTEM
ELEC
C. If the flasher light and/or turn
indicator light fails to blink.
1. BULB AND BULB SOCKET
• Check the Bulb and Bulb Socket continuity
NO CONTINUITY
CONTINUITY
2. TURN SWITCH
Replace the Bulb and/or Bulb socket
• Disconnect the Handlebar Switch (left) coupler from Wireharness.
• Check the switch component for the continuity between “Brown/White and Darkgreen”
and “Brown/White and Chocolate”.
NO CONTINUITY
CONTINUITY
Replace the left Handlebar Switch.
3. VOLTAGE
Multimeter (+) lead Ÿ Brown Terminal ¿
Multimeter (-) lead Ÿ Black Terminal À
• Connect the Multimeter (DC20 V) to the
Flasher Relay coupler.
• Turn the Main Switch to ‘ON’ .
• Check or voltage (12V) of the “Brown” ¿
lead at the Flasher Relay terminal and (-)
terminal body earth (Black Wire).
¿
À
OUT OF SPECIFICATION
æ
MEETS
SPECIFICATION
The wiring circuit from Main Switch to
Flasher Relay connector is faulty. Repair/
Replace
7-18
SIGNAL SYSTEM
ELEC
æ
Multimeter (+) lead Ÿ Brown/White Terminal ¿
Multimeter (-) lead Ÿ Black Terminal À
4. FLASHER RELAY
• Connect the Multimeter (DC20V) to the
flasher relay coupler
• Turn Main switch to ‘ON’
• Check for voltage (12V) on “Brown/White”
lead at Flasher Relay and (-) terminal body
earth
¿
À
OUT OF SPECIFICATION
MEETS
SPECIFICATION
The Flasher Relay is faulty. Replace.
At flasher light (LH)
Multimeter (+) lead Ÿ Chocolate Terminal ¿
Multimeter (-) lead Ÿ Body earth Á
At flasher light (RH)
Multimeter (+) lead Ÿ Dark Green Terminal À
Multimeter (-) lead Ÿ Body earth Á
5. VOLTAGE
• Connect the Multimeter (DC20V) to the
Bulb 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
terminal.
MEETS
SPECIFICATIONS
This circuit is O.K.
OUT OF SPECIFICATION
Wiring connection
Wiring circuit from the Turn Switch to Bulb
Socket connector is faulty. Repair/Replace
Refer to “CIRCUIT DIAGRAM”.
7-19
SIGNAL SYSTEM
ELEC
D. If the neutral indicator lights fails to
operate.
1. BULB AND BULB SOCKET
• Check the bulb and bulb socket for continuity.
NO CONTINUITY
CONTINUITY
Replace the Bulb and/or Bulb Socket
2. NEUTRAL SWITCH
• Disconnect the neutral switch lead.
• Check the continuity between the switch
terminal and ground.
NO CONTINUITY
CONTINUITY
Replace the Neutral switch.
Multimeter (+) lead Ÿ Sky Blue Terminal ¿
Multimeter (-) lead Ÿ Body Earth À
3. VOLTAGE
• Connect the Multimeter (DC20 V) to the
neutral switch lead
• Turn the main switch to on position.
• Select the gear position in neutral.
• Check for voltage (12 V) on the “Brown” terminal on the “Neutral Bulb” and body earth
(“Sky Blue” wire)
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Check the connection of the entire signal
system.
Refer to “CIRCUIT DIAGRAM” Page no 7-14.
This circuit is O.K.
7-20
TRBL
SHTG
CHAPTER 8
TROUBLE SHOOTING
STARTING FAILURE/ HARD STARTING .................................. 8-1
POOR IDLE SPEED PERFORMANCE ...................................... 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE ............ 8-2
POOR SPEED PERFORMANCE ............................................... 8-3
CLUTCH SLIPPING / DRAGGING ............................................. 8-3
FAULTY GEAR SHIFTING ......................................................... 8-4
OVER HEATING ......................................................................... 8-4
FAULTY BRAKE ......................................................................... 8-4
FRONT FORK MALFUNCTION ................................................. 8-5
UNSTABLE HANDLING ............................................................. 8-5
FAULTY SIGNAL AND LIGHTING SYSTEM ............................. 8-6
STARTING FAILURE / HARD STARTING
TRBL
SHTG
NOTE:
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 related procedure in this manual for inspection,
adjustment and replacement of parts.
STARTING FAILURE / HARD STARTING
FUEL SYSTEM
COMPRESSION SYSTEM
Fuel Tank
• Empty
• Clogged Fuel Tank Cap Breather Hole
• Deteriorated fuel or fuel containing water or
foreign material
Cylinder and Cylinder Head
• Loose Spark Plug
• Loose Cylinder Head
• Broken Cylinder Head Gasket
• Broken Cylinder Gasket
• Worn, damaged or seized Cylinder
Fuel Cock
• Clogged Fuel Hose
• Clogged Fuel Cock
Piston and Piston ring
• Worn Piston
• Worn, Fatigued or broken Piston Rings
• Seized Piston Rings
• Seized or damaged Piston
Carburetor
• Deteriorated fuel or fuel containing water or
foreign material
• Clogged Pilot Jet
• Clogged air passage
• Improperly set Pilot Screw
• Clogged Pilot air passage/air jet
• Improperly sealed Valve Seat
• Improperly adjusted Fuel level
• Clogged Starter Jet
• Damaged Carburetor Joint
• Improperly tightened Carburetor Joint Clamp
Hose
• Starter Plunger malfunction
• Sucked -in air
Valve System
• Improperly adjusted Valve clearance
• Improperly sealed Valve
• Improperly contacted Valve and Valve seat
• Improper Valve timing
• Broken Valve Spring
• Seized Valve
Air Filter
• Clogged Air Filter element
• Improper Air Filter fitment
8-1
POOR IDLE SPEED PERFORMANCE
IGNITION SYSTEM
TRBL
SHTG
Ignition system
• Faulty C.D.I Unit
• Faulty Sensor Coil
• Broken Magneto Woodruff Key
Spark Plug
• Improper Plug gap
• Worn Electrodes
• Wire between Terminals broken
• Improper heat range
• Faulty Spark Plug Cap
Switch
• Faulty Main Switch
Wiring
• Loose Coupler connection
• Improperly grounded
• Broken Wireharness
R. R. Unit
• Faulty R. R. Unit
Ignition Coil
• Broken or shorted Primary /Secondary Coil
• Faulty High Tension Cord
• Broken Ignition Coil body
POOR IDLE SPEED PERFORMANCE
Carburetor
• Improperly returned Starter Plunger
• Loose or clogged Pilot jet
• Damaged Carburetor Joint
• Improperly tightened Carburetor Joint Clamp
hose
• Improperly adjusted idle speed (Pilot Screw)
, (Throttle stop Screw)
• Improperly adjusted Throttle Cable
• Flooded Carburetor
Air Filter
• Clogged air filter element
Ignition system
• Faulty Spark Plug
• Faulty High tension Cord
• Faulty C. D. I. Unit
• Faulty Sensor Coil
• Faulty Ignition Coil
Valve system
• Improperly adjusted Valve clearance
POOR MEDIUM AND HIGH SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING’’ section. (Fuel system, electrical system,
compression system and valve system Page no 8-1)
Carburetor
Air Filter
• Clogged Air Filter Element
• Improperly adjusted Fuel Level
• Clogged main Nozzle
• Clogged or loose Pilot jet
8-2
POOR SPEED PERFORMANCE
TRBL
SHTG
POOR SPEED PERFORMANCE
Ignition System
Compression System
• Dirty Spark Plug
• Improper heat range
• Faulty C.D.I. Unit
• Faulty Sensor Coil
• Worn Cylinder
• Worn of Seized Piston Rings
• Cylinder Head Gasket Broken
• Cylinder Gasket Broken
• Carbon deposit build-up
• Improperly adjusted Valve clearance
• Improperly contacted Valve and Valve seat
• Faulty Valve timing
Fuel System
• Partially Clogged Fuel Tank Cap Breather
Hole
• Clogged Air Cleaner element
• Clogged Jet
• Improperly adjusted Fuel Level
Clutch
• Refer to “CLUTCH SLIPPING/DRAGGING’’
section Page no 8-3
Engine Oil
• Improper oil level (low or over oil level)
• Improper quality (low oil viscosity)
• Deterioration
• Clogged oil passage
Brakes
• Dragging brake
CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING
CLUTCH DRAGGING
Clutch
• Improperly adjusted clutch cable
• Loose clutch spring
• Fatigued clutch spring
• Worn friction plate/clutch plate
• Incorrectly assembled clutch
Clutch
• Warped pressure plate
• Unevenly tensioned clutch spring
• Bent push rod
• Broken clutch boss
• Burnt primary driven gear bushing
• Bent clutch plate
• Swollen friction plate
Engine oil
• Improper oil level
• Improper quality (low viscosity)
• Deterioration
Engine oil
• Improper oil level
• Improper quality/(high viscosity)
• Deterioration
8-3
FAULTY GEAR SHIFTING / OVERHEATING
TRBL
SHTG
FAULTY GEAR SHIFTING
HARD SHIFTING
JUMPING -OUT OF GEAR
Refer to “CLUTCH DRAGGING’’ Page no 8-3
SHIFT PEDAL DOES NOT MOVE
Shift Shaft
• Improperly returned Stopper Lever
Shift Shaft
• Bent Shift Shaft
Shift Fork
• Improper thrust play
• Worn Shift Cam groove
Shift Cam Shift Fork
• Groove jammed with impurities
• Seized Shift Fork
• Bent Shift Fork Guide Bar
Transmission
• Worn gear dog
Transmission
• Seized Transmission Gear
• Clogged impurities
• Incorrectly assembled transmission
OVER HEATING
Ignition system
• Improper Spark Plug gap
• Improper Spark Plug heat range
• Faulty C.D.I. unit
Compression System
• Heavy carbon deposit built-up
• Improperly adjusted Valve timing
• Improperly adjusted Valve clearance
Fuel system
• Improper Carburetor setting
• Improper fuel level adjustment
• Clogged air Filter element
Engine oil
• Incorrect Engine oil level
• Improper Engine oil quality (high viscosity)
• Low Engine oil quality
Brakes
• Dragging brake
FAULTY BRAKE
FRONT / REAR BRAKE
• Faulty Brake cable
• Mud or water in to the Brake Drum Inside
• Broken or fatigued Tension Spring
• Faulty Camshaft/ Cam lever
• Improper Brake adjustment
• Worn Brake Shoe
• Worn Cam Shaft
• Worn Brake drum
• Oily and greasy Brake lining
8-4
FRONT FORK MALFUNCTION /
UNSTABLE HANDLING
TRBL
SHTG
FRONT FORK MALFUNCTION
OIL LEAKAGE
MALFUNCTION
• Bent damaged or rusty Inner Tube
• Damaged or cracked Outer Tube
• Damaged oil seal lip.
• Loose hexagon Bolt
• Damaged Cap Bolt O-ring
• Improperly installed Oil seal
• Bent Inner Tube
• Deformed Outer Tube
• Damaged Fork Spring
• Bent Cylinder Complete
• Improper oil viscosity / Level
UNSTABLE HANDLING
Wheels
• Incorrect Wheel balance
• Loose Spokes
• Deformed Wheel Rim
• Unevenly worn Tyres
• Incorrect Tyre pressure
• Loose Bearing
• Bent or loose Wheel Axle
• Excessive Wheel Runout
Frame
• Twisted
• Improperly installed Bearing Race
• Faulty Bushing
• Bent Rear Arm
Rear arm
• Worn or damaged Bush
• Bent rear arm
Rear shock absorber
• Fatigued spring
• Improperly adjusted Spring preload
• Oil leakage
Drive chain
• Improperly adjusted Chain line
Handlebars
• Improperly installed or bent
• Loose Handlebar Tightening Bolt
Steering
• Improperly installed Handlebar Crown
• Loose or overtightened Steering Nut
• Loose or overtightened Steering Nut
• Bent Under Bracket
• Improperly installed Steering Shaft (improperly tightened Ring Nut)
• Damaged Bearing or Ball Race
Front forks
• Uneven oil levels on both sides
• Uneven spring tension
• Broken Front Fork Spring
• Fatigued Front Fork Spring
• Twisted Front Forks
8-5
FAULTY SIGNAL AND LIGHTING SYSTEM
TRBL
SHTG
FAULTY SIGNAL AND LIGHTING SYSTEM
HEADLIGHT DIM
FLASHER BLINKS SLOWER
• Improper Bulb
• Too many electric accessories
• Hard charging
• Faulty rectifier/regulator
• Faulty Battery
• Improperly connected coupler, connector wire
harness
• Improperly grounded
• Faulty main switch or lights (dimmer) switch
• Faulty Flasher Relay
• Insufficient Battery capacity (nearly discharged)
• Improper Bulb
• Faulty Main and/or Turn Switch
FLASHER BLINKS QUICKER
• Improper Bulb
• Faulty Flasher Relay
HORN DOES NOT SOUND
BULB BURNT OUT
• Faulty Battery
• Faulty Fuse
• Faulty Main and/or Horn Switch
• Improper Horn adjustment
• Faulty Horn (burnt Coil, Connector)
• Broken Wireharness
• Improper Bulb
• Faulty Battery
• Faulty R. R. Unit
• Improperly grounded
• Improperly mounted Light Unit
FLASHER DOES NOT BLINK
• Improperly grounded
• Insufficient battery capacity
• Faulty Fuse
• Faulty Turn Switch
• Faulty Flasher Relay
• Broken wireharness, incorrect coupler connection
• Bulb burnt out
FLASHER KEEPS ON
• Faulty Flasher Relay
• Insufficient Battery capacity (nearly discharged)
• Bulb burnt out (front or rear)
8-6
YAMAHA MOTOR INDIA PVT. LIMITED
19/6, Mathura Road, Faridabad - 121 006 INDIA
PRINTED IN INDIA
5YY (FAZER)
1Y16(WM-01)-204-10-04-E