Yamaha SR125 Service manual

Yamaha SR125 Service manual
EB000000
SR125
SERVICE MANUAL
1996 by Yamaha Motor Co., Ltd.
1st Edition, September 1996
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycle has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.
Yamaha Motor Company, Ltd., is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future aditions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or
death to the motorcycle operator, a bystander or a person inspecting or
repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid
damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
YP002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
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 upper left corner of the page.
3rd title 3 : This title indicates a sub-section 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 disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6 . The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to
the exploded diagram and the job instruction chart.
2
4
1
3
8
6
6
7
EB003000
1
ILLUSTRATED SYMBOLS
2
GEN
INFO
SPEC
3
4
INSP
ADJ
ENG
5
6
CARB
CHAS
7
8
ELEC
TRBL
SHTG
10
9
Illustrated symbols 1 to 9 are designed as
thumb tabs to indicate the chapter’s number
and content.
1 General information
2 Specifications
3 Periodic inspection and adjustment
4 Engine
5 Carburation
6 Chassis
7 Electrical
8 Troubleshooting
Illustrated symbols 9 to 16 are used to identify
the specifications appearing in the text.
9 Possible to maintain with engine mounted
10 Filling fluid
11 Lubricant
11
12
12 Special tool
13 Tightening
14 Wear limit, clearance
15 Engine speed
13
14
15
16
16 Ω , V, A
Illustrated symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication points.
17 Apply engine oil
17
18
19
18 Apply gear oil
19 Apply molybodenum disulfide oil
20 Apply wheel bearing grease
21 Apply lightweight lithium-soap baes grease
20
21
22
22 Apply molybdenum disulfide grease
Illustrated symbols 23 to 24 in the exploded diagrams indicate the where to apply locking agent
23 and when to install new parts 24 .
23
24
23 Apply locking agent (LOCTITE)
24 Use new one
INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE OVERHAUL
CARBURATION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
INSP
ADJ
3
ENG
4
CARB
5
CHAS
6
ELEC
7
TRBL
SHTG
8
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL PROCEDURES . . . . . . . . . . . . . . .
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-2
1-2
1-3
1-3
1-3
CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
MOTORCYCLE IDENTIFICATION
GEN
INFO
YP100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
SR100020
FRAME SERIAL NUMBER
The frame serial number 1 is stamped into the
right side of the frame.
EB100030
ENGINE SERIAL NUMBER
The engine serial number 1 is stamped into the
crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
MODEL LABEL
The model label 1 is affixed under the seat.
This information will be needed to order spare
parts.
1-1
IMPORTANT INFORMATION
GEN
INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES
1. Remove all dirt, mud, dust and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the “SPECIAL TOOLS” section.
4. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or replaced as an assembly.
5. During machine disassembly, clean all parts
and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.
6. Keep all parts away from any source of fire.
NB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
1-2
IMPORTANT INFORMATION
GEN
INFO
EB101030
LOCK WASHERS/PLATES AND COTTER
PINS
1. Replace all lock washers/plates and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.
OR
EB101040
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating of
lightweight lithium base grease to the seal lips.
Oil bearings liberally when installing, if appropriate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassembly. Always replace piston pin clips after one
use. Replace distorted circlips. When installing a circlp 1 , make sure that the sharpedged corner 2 is positioned opposite the
thrust 3 it receives. See sectional view.
4 Shaft
1-3
CHECKING OF CONNECTIONS
GEN
INFO
EB801000
CHECKING OF CONNECTIONS
Dealing with 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.
4. Pull the lead to check that it will not come off.
5. If the terminal comes off, bend up the pin 1
and reinsert the terminal into the connector.
6. Connect:
Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
If there is no continuity, clean the terminals.
Be sure to perform the steps 1 to 7 listed above
when checking the wireharness.
For a field remedy, use a contact revitalizer
available on the market.
Use the tester on the connector as shown.
1-4
GEN
INFO
HOW TO USE THE CONVERSION TABLE
EB201000
HOW TO USE THE CONVERSION TABLE
All specification data in this manual are listed in Sl and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC MULTIPLIER
IMP
** mm 0.03937
=
** in
2 mm 0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMP
Known
Multiplier
Result
Torque
m:kg
m:kg
cm:kg
cm:kg
7.233
86.794
0.0723
0.8679
ft:lb
in:lb
ft:lb
in:lb
Weight
kg
g
2.205
0.03527
lb
oz
Distance
km/hr
km
m
m
cm
mm
0.6214
0.6214
3.281
1.094
0.3937
0.03937
mph
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lit (liter)
lit (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu:in
qt (IMP liq.)
gal (IMP liq.)
Miscellaneous
kg/mm
kg/cm2
Centigrade
55.997
14.2234
9/5 (_C) + 32
lb/in
psi (lb/in2)
Fahrenheit (_F)
1-5
SPECIAL TOOLS
GEN
INFO
EB102000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
90890-01080
90890-04052
Tool name/Usage
Rotor puller
Attachment
This tool is used when removing or installing
the meter gear bush.
90890-01083
90890-01084
Rocker arm shaft puller bolt
Weight
These tools are used when removing or
installing the rocker arm shafts.
90890-01268
Ringnut wrench
This tool is used to loosen and tighten the
exhaust and steering ringnut.
90890-01311
Valve adjusting tool
This tool is necessary for adjusting valve
clearance.
90890-01312
Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
90890-01367
90890-01400
Fork seal driver weight
Fork seal driver attachment (ø30 mm)
This tool is used when installing the fork seal.
90890-01403
Ring nut wrench
This tool is used to loosen and tighten the
steering ring nut.
90890-01701
Sheave holder
This tool is used for holding the secondary
sheave.
90890-01996
Cylinder cup installer set
This tool is used for installing the cylinder
cup to the master cylinder piston.
1-6
Illustration
SPECIAL TOOLS
Tool No.
90890-03079
Tool name/Usage
Thickness gauge
This tool is used to measure the valve
clearance.
90890-03081
90890-04082
Compression gauge
Adaptor
These tools are used to measure the engine
compression.
90890-03112
Pocket tester
These instruments are invaluable for
checking the electrical system.
90890-03113
Engine tachometer
This tool is needed for detecting engine rpm.
90890-03141
Timing light
This tool is necessary for checking ignition
timing.
90890-04019
90890-04108
Valve spring compressor
Attachment
These tools are used when removing or
installing the valve and the valve spring.
90890-04064
Valve guide remover 6 mm
This tool is used to remove the valve guide.
90890-04065
Valve guide reamer 6 mm
This tool is used to rebore the valve guide.
90890-04066
Valve guide installer 6 mm
This tool is needed to install the valve guides
properly.
90890-04086
Clutch holding tool
This tool is used for holding the Clutch Boss.
1-7
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
90890-04101
Tool name/Usage
Valve lapper
This tool is used for removing and installing
the lifter and for lapping the valve.
90890-06754
Ignition checker
This instrument is necessary for checking the
ignition system components.
90890-85505
Yamaha bond No.1215
This sealant (bond) is used for crankcase
mating surface, etc.
1-8
GEN
INFO
Illustration
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
2-4
2-10
2-13
GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
LUBRICATION POINT AND GRADE OF LUBRICANT . . . . . . . . . . . . . 2-16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
SR125
Model code:
3MW6
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
1,915 mm
775 mm
1,080 mm
745 mm
1,280 mm
155 mm
2,100 mm
Basic weight:
With oil and full fuel tank
113 kg
Engine:
Engine type
Cylinder arrangement
Displacement
Bore stroke
Compression ratio
Compression pressure (STD)
Starting system
Lubrication system:
Air-cooled 4-stroke, SOHC
Forward-inclined single cylinder
0.124 L (124 cm3)
57.0 48.8 mm
10.0 : 1
1,200 kPa (12.0 kg/cm2, 12.0 bar) at 1,000 r/min
Electric starter
Wet sump
Oil type or grade:
Engine oil
API “SE” or higher grade
Periodic oil change
With oil filter replacement
Total amount
1.0 L
1.1 L
1.3 L
Air filter:
Wet type element
Fuel:
Type
Fuel tank capacity
Fuel reserve capacity
Regular unleaded gasoline
10.0 L
1.6 L
2-1
GENERAL SPECIFICATIONS
Model
SR125
Carburetor:
Type/quantity
Manufacturer
Y24P/1
TEIKEI
Spark plug:
Type
Manufacturer
Spark plug gap
DR8EA
NGK
0.6 X 0.7 mm
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio 1st
2nd
3rd
4th
5th
Spur gear
73/22 (3.318)
Chain drive
49/14 (3.500)
Constant mesh 5 speed
Left foot operation
36/16 (2.250)
31/21 (1.476)
27/24 (1.125)
25/27 (0.926)
23/29 (0.793)
Chassis:
Frame type
Caster angle
Trail
Diamond
26.75
90 mm
Tire:
Type
Size
Manufacture
Type
front
rear
front
rear
front
rear
Tire pressure (cold tire):
Maximum load-except motorcycle
Loading condition A *
front
rear
Loading condition B *
front
rear
Tube type
3.00-17 45P
3.50-16 52P
INOUE
INOUE
8F
8RA
164 kg
0 X 90 kg
175 kPa (1.75 kg/cm2, 1.75 bar)
200 kPa (2.0 kg/cm2, 2.0 bar)
90 X 205 kg
175 kPa (1.75 kg/cm2, 1.75 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
*Load is the total weight of cargo, rider, passenger, and accessories.
2-2
SPEC
GENERAL SPECIFICATIONS
Model
Brake:
Front brake
Rear brake
type
operation
type
operation
SR125
Single disc brake
Right hand operation
Drum brake
Right foot operation
Suspension:
Front suspension
Rear suspension
Telescopic fork
Swingarm
Shock absorber:
Front shock absorber
Rear shock absorber
Coil spring/Oil damper
Coil spring/Oil damper
Wheel travel:
Front wheel travel
Rear wheel travel
120 mm
78 mm
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
C.D.I.
C.D.I. magneto
12N 7-3B
12 V 7 AH
Headlight type:
Bulb type
Bulb wattage quantity:
Headlight
Auxiliary light
Tail/brake light
Flasher light
Meter light
High beam indicator
Neutral indicator
TURN indicator
12 V 36 W/36 W 1
12 V 4 W 1
12 V 5 W/21 W 1
12 V 21 W 4
12 V 3.4 W 1
12 V 3.4 W 1
12 V 3.4 W 1
12 V 3.4 W 2
2-3
SPEC
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Standard
Limit
Cylinder head:
Warp limit
SSS
0.03 mm
Cylinder:
Bore size
Taper limit
Out of round limit
57.00 X 57.02 mm
SSS
SSS
57.1 mm
0.05 mm
0.01 mm
Camshaft:
Cam dimensions
Intake
“A”
“B”
“C”
Exhaust “A”
“B”
“C”
Camshaft runout limit
36.537 X 36.637 mm
30.131 X 30.231 mm
6.59 mm
36.577 X 36.677 mm
30.214 X 30.314 mm
6.63 mm
SSS
36.45 mm
30.05 mm
SSS
36.49 mm
30.13 mm
SSS
0.03 mm
Cam chain:
Cam chain type/No. of links
Cam chain adjustment
DID 25SH/104 ENDLESS
Manual
SSS
SSS
12.000 X 12.018 mm
11.985 X 11.991 mm
12.036 mm
11.950 mm
0.009 X 0.033 mm
SSS
Rocker arm/rocker armshaft:
Rocker arm inside diameter
Rocker shaft outside diameter
Rocker arm-to-rocker armshaft
clearance
Valve, valve seat, valve guide:
Valve clearance (cold)
IN 0.05 X 0.09 mm
EX 0.11 X 0.15 mm
SSS
SSS
Valve dimensions
Head Dia.
“A” head diameter
“B” face width
“C” seat width
“D” margin thickness
Stem outside diameter
Face Width
Seat Width
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
28.9 X 29.1 mm
23.9 X 24.1 mm
2.4 X 2.8 mm
2.4 X 2.8 mm
0.9 X 1.1 mm
0.9 X 1.1 mm
0.8 X 1.2 mm
0.8 X 1.2 mm
5.975 X 5.990 mm
5.960 X 5.975 mm
2-4
Margin Thickness
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
5.955 mm
5.940 mm
MAINTENANCE SPECIFICATIONS
Item
Guide inside diameter
Stem-to-guide clearance
Stem runout limit
Valve seat width
Valve spring:
Free length
(inner)
(outer)
Set length (valve closed)
(inner)
(outer)
Compressed pressure
(inner)
(outer)
Tilt limit
(inner)
Tilt limit
(outer)
Direction of winding (inner)
Direction of winding (outer)
Piston:
Piston to cylinder
clearance
Piston size “D”
Piston over size (1st)
Piston over size (2nd)
Measuring point “H”
Piston off-set
Piston off-set direction
Piston pin bore
inside diameter
Piston pin outside diameter
Piston rings:
Top ring:
Type
Dimensions (B
T)
End gap (installed)
Side clearance (installed)
2nd ring:
Type
Dimensions (B
T)
End gap (installed)
Side clearance
Oil ring:
Dimensions (B
T)
End gap (installed)
IN
EX
IN
EX
IN
EX
SPEC
Standard
Limit
6.000 X 6.012 mm
6.000 X 6.012 mm
0.010 X 0.037 mm
0.025 X 0.052 mm
SSS
0.9 X 1.1 mm
0.9 X 1.1 mm
6.042 mm
6.042 mm
0.08 mm
0.10 mm
0.03 mm
1.6 mm
1.6 mm
IN/EX 35.5 mm
IN/EX 37.2 mm
33.5 mm
35.2 mm
IN/EX 22.5 mm
IN/EX 24.0 mm
SSS
SSS
IN/EX
IN/EX
IN/EX
IN/EX
IN/EX
IN/EX
26.7 X 30.7 kg
52.4 X 40.2 kg
SSS
SSS
Clockwise
Counterclockwise
SSS
SSS
2.5_/1.5 mm
2.5_/1.5 mm
SSS
SSS
0.025 X 0.045 mm
SSS
56.960 X 56.975 mm
57.25 mm
57.50 mm
7.0 mm
0.5 mm
IN side
15.002 X 15.013 mm
SSS
SSS
SSS
SSS
SSS
SSS
15.045 mm
14.978 X 14.992 mm
14.975 mm
Plane
2.3
2.5 mm
0.15 X 0.35 mm
0.03 X 0.07 mm
SSS
SSS
0.60 mm
0.15 mm
Plane
2.3
2.5 mm
0.15 X 0.35 mm
0.02 X 0.06 mm
SSS
SSS
0.60 mm
0.15 mm
2.5
2.8 mm
0.3 X 0.9 mm
SSS
SSS
2-5
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
55.95 X 56.00 mm
SSS
0.35 X 0.65 mm
0.010 X 0.025 mm
0.8 X 1.0 mm
SSS
0.03 mm
1.0 mm
SSS
SSS
Clutch:
Friction plate thickness
Quantity
Clutch plate thickness
Quantity
Clutch spring free length
Quantity
Push rod bending limit
2.9 X 3.1 mm
4 pcs.
1.6 mm
3 pcs.
34.9 mm
4 pcs.
SSS
2.7 mm
SSS
0.05 mm
SSS
32.9 mm
SSS
0.2 mm
Transmission:
Main axle runout limit
Drive axle runout limit
SSS
SSS
0.08 mm
0.08 mm
Carburetor:
Type
I.D. mark
Main jet
Main air jet
Jet needle
Needle jet
Cut away
Pilot outlet
Pilot jet
Bypass 1
Pilot screw
Valve seat size
Starter jet 1
Starter jet 2
Float height
Engine idle speed
Intake vacuum
CO
Oil temperature
Y24P
4WP-10
#102
ø1.3
4C9A-3/5
2.600
2.25
0.8
#38
1.0
2
ø2.0
#60
#64
28.5 mm
1,250 X 1,350 r/min
180 X 200 mmHg
4.5 X 5.5%
60 X 70_C
Crankshaft:
Crank width “A”
Runout limit “C”
Big end side clearance “D”
Big end radial clearance
Small end free play “F”
Oil pump;
Type
Tip clearance
Side clearance
Bypass valve setting pressure
(M.J)
(M.A.J)
(J.N)
(N.J)
(C.A)
(P.O)
(P.J)
(B.P.1)
(P.S)
(V.S)
(G.S.1)
(G.S.2)
(F.H)
Trochoid type
0.03 X 0.09 mm
0.10 X 0.15 mm
80 X 120 kPa
(0.8 X 1.2 kg/cm2, 0.8 X 1.2 bar)
2-6
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.14 mm
0.35 mm
SSS
MAINTENANCE SPECIFICATIONS
SPEC
TIGHTENING TORQUES
ENGINE
Part to be tightened
g
Cylinder head blind plug
Cylinder head and cylinder
Cylinder head
(Timing chain side)
Cam sprocket cover
Valve cover
Plate
Spark plug
Cylinder
Buffer boss
C.D.I. magneto
Valve adjuster locknut
Cam sprocket
Timing chain tensioner
(Body)
(Cap)
Timing chain guide (intake)
Oil pump
Oil pump and crankcase
Drain plug
Oil filter cover
Drain bolt (oil filter)
Carburetor joint and carburetor
Carburetor joint and cylinder
Carburetor joint and air filter
Air filter case
Air filter case and frame
Muffler and frame
Exhaust pipe and cylinder
Crankcase (left and right)
Crankcase cover (left)
Crankcase cover (left)
Crankcase cover (right)
Drive sprocket cover
Starter clutch
Kick crank
Primary drive gear
Clutch spring
Clutch boss
Push lever axle
Push lever adjuster
Thread
Th
d
size
Q’ty
y
Screw
Bolt
Bolt
M6
M8
M8
Screw
Bolt
Bolt
—
Bolt
Nut
Bolt
Nut
Bolt
Part name
Tightening
g
g
torque
Nm
mSkg
2
4
2
7
22
20
0.7
2.2
2.0
M6
M6
M6
M12
M6
M14
M10
M6
M10
2
5
2
1
2
1
1
2
1
7
10
8
18
10
50
50
14
60
0.7
1.0
0.8
1.8
1.0
5.0
5.0
1.4
6.0
Nut
Nut
Bolt
Screw
Screw
Bolt
Screw
Bolt
Screw
Screw
Screw
Screw
Screw
M14
M14
M6
M6
M6
M35
M6
M6
M6
M5
M5
1
1
2
1
3
1
2
1
2
1
1
30
5
8
7
7
43
7
10
12
2
4
3.0
0.5
0.8
0.7
0.7
4.3
0.7
1.0
1.2
0.2
0.4
M5
2
4
0.4
M6
2
7
0.7
Bolt
M8
2
20
2.0
Bolt
Screw
Screw
Screw
Screw
Screw
Bolt
Bolt
Nut
Screw
Nut
Screw
Nut
M6
2
13
M6
M4
M6
M6
M8
M32
M14
M5
M14
M8
M6
9
1
9
2
3
1
1
4
1
1
1
12
7
7
2
7
7
30
1.2
M6
50
6
70
12
8
5.0
0.6
7.0
1.2
0.8
2-7
Remarks
0.7
0.7
0.2
0.7
0.7
3.0
Stake
MAINTENANCE SPECIFICATIONS
Part to be tightened
g
Drive sprocket
Shift cam (Segment)
Shift pedal
Pick up coil
Neutral switch
Stator coil
Starter motor
Thread
Part name
size
Bolt
Screw
Bolt
Screw
Screw
Screw
Screw
2-8
M6
M6
M6
M6
M10
M4
M6
Q’ty
y
2
1
1
4
1
6
1
SPEC
Tightening
torque
Nm
mSkg
10
12
8
7
20
3
7
1.0
1.2
0.8
0.7
2.0
0.3
0.7
Remarks
MAINTENANCE SPECIFICATIONS
Item
Standard
Tightening sequence
Cylinder head
Crankcase
2-9
SPEC
Limit
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Item
Standard
Limit
Steering system:
Steering bearing type
No./size of steel balls (upper)
(lower)
Ball bearing
22 pcs. 0.1875 in
19 pcs. 0.251 in
SSS
SSS
SSS
Front suspension:
Front fork travel
Fork spring free length
Fitting length
Spring rate
(K1)
(K2)
Stroke
(K1)
(K2)
Oil capacity
Oil level
Oil grade
Inner tube vend limit
120 mm
326.1 mm
311.1 mm
3.6 N /mm (0.36 kg/mm)
5.1 N/mm (0.51 kg/mm)
0 X 85 mm
85 X 120 mm
0.177 L (177 cm3)
135 mm
Fork oil 15 WT or equivalent
SSS
SSS
321 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.2 mm
Rear suspension:
Shock absorber stroke
Spring free length
Fitting length
Spring rate
(K1)
(K2)
Stroke
(K1)
(K2)
65 mm
178.5 mm
198 mm
18.3 N/mm (1.83 kg/mm)
21.6 N/mm (2.16 kg/mm)
0 X 30 mm
30 X 65 mm
SSS
173 mm
SSS
SSS
SSS
SSS
SSS
Front wheel:
Type
Rim size
Rim material
Rim runout limit radial
lateral
Spoke wheel
17
1.60
Steel
SSS
SSS
SSS
SSS
SSS
2 mm
2 mm
Rear wheel:
Type
Rim size
Rim material
Rim runout limit radial
lateral
Spoke wheel
16
1.85
Steel
SSS
SSS
SSS
SSS
SSS
2 mm
2 mm
Drive chain:
Type/manufacturer
No. of links
Chain free play
428HG/DAIDO
120
25 X 35 mm
SSS
SSS
SSS
2-10
MAINTENANCE SPECIFICATIONS
SPEC
Item
Standard
Limit
Front brake:
Type
Disc outside diameter
Disc thickness
Pad thickness (inner)
(outer)
Master cylinder inside diameter
Caliper cylinder 1 inside diameter
Caliper cylinder 2 inside diameter
Brake fluid type
Single disc
267 mm
4 mm
6.2 mm
6.2 mm
12.7 mm
30.16 mm
25.4 mm
DOT#4 or DOT#3
SSS
SSS
3.5 mm
0.8 mm
0.8 mm
SSS
SSS
SSS
SSS
Rear brake:
Type
Drum inside diameter
Shoe thickness
Shoe spring free length
Leading, trailing
110 mm
4 mm
50.5 mm
SSS
111 mm
2 mm
SSS
Brake lever:
Brake lever free play (at lever end)
2 X 5 mm
SSS
Brake pedal:
Brake pedal free play
Brake pedal position
20 X 30 mm
0 mm
SSS
SSS
Clutch lever:
Clutch lever free play (at lever end)
10 X 15 mm
SSS
Throttle cable free play
3 X 5 mm
SSS
2-11
MAINTENANCE SPECIFICATIONS
SPEC
TIGHTENING TORQUES
CHASSIS
Part to be tightened
g
Thread size
Handle crown and front fork
Handle crown and steering shaft
Handlebar holder (under and upper)
Steering ring nut
Master cylinder and cap (front brake)
Handlebar under holder and nut
Master cylinder (front brake)
Brake hose union bolt (front brake)
Front flasher and stay
Steering shaft and front fork
Engine and front engine stay
Front engine stay and frame
Engine and top engine stay
Top engine stay and frame
Engine and engine bracket (frame)
Swingarm pivot shaft
Rear shock absorber and frame
Rear shock absorber and swingarm
Swingarm and tension bar
Tension bar and rear brake shoe plate
Grab bar and frame
Fuel tank an fuel cock
Rear flasher and stay
Sidestand (bolt)
Sidestand (nut)
Rear footrest (left)
Front wheel axle
Rear wheel axle and nut
Brake caliper and front fork
Brake disc and front wheel
Driven sprocket and clutch hub
Brake caliper bleed screw
Meter gear and meter cable
Brake cam lever
Front wheel axle pinch bolt
M10
M10
M8
M25
M4
M10
M6
M10
M12
M10
M8
M8
M8
M8
M8
M12
M10
M10
M8
M8
M8
M6
M12
M8
M8
M10
M14
M14
M10
M8
M10
M7
M12
M6
M8
Tightening
torque
Nm
mSkg
45
40
20
7
2
40
9
30
4
30
33
33
33
33
33
45
40
30
20
20
16
7
4
19
16
45
59
65
40
23
40
6
3
9
20
4.5
4.0
2.0
0.7
0.2
4.0
0.9
3.0
0.4
3.0
3.3
3.3
3.3
3.3
3.3
4.5
4.0
3.0
2.0
2.0
1.6
0.7
0.4
1.9
1.6
1.5
5.9
6.5
4.0
2.3
4.0
0.6
0.3
0.9
2.0
Remarks
Refer to NOTE
NOTE:
1. When tighten the ring nut, should be steady the ball bearings and the steering shaft moving smoothly.
2. First, tighten the ring nut approximately 38 Nm (3.8 mSkg) by using the torque wrench, then loosen
the ring nut one turn and retighten the ring nut to specification.
2-12
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Item
Standard
Limit
Ignition timing:
Ignition timing (B.T.D.C.)
Advanced timing
Advanced type
9_ at 1,300 r/min
29_ at 5,500 r/min
Electrical type
SSS
SSS
SSS
656 X 984 Ω at 20_C/
Red – White
624 X 936 Ω at 20_C/
Brown – Green
4WP/YAMAHA
SSS
Ignition coil:
Model/ manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
2JN/YAMAHA
6 mm
0.32 X 0.48 Ω at 20_C
5.68 X 8.52 kΩ at 20_C
SSS
SSS
SSS
SSS
Spark plug cap:
Type
Resistance
Resin type
10 kΩ
SSS
SSS
C.D.I. magneto
4WP/YAMAHA
14 V 9 A/5,000 r/min
0.48 X 0.72 Ω at 20_C/
White – White
SSS
SSS
SSS
SSS
SSS
Rectifier/regulator:
Model/manufacturer
Type (regulator)
No load regulated voltage
Capacity (rectifier)
Withstand voltage
SH553D/SHINDENGEN
Semi conductor-short circuit type
14.5 V
25 A
200 V
SSS
SSS
SSS
SSS
SSS
Battery:
Specific gravity
1.280
SSS
C.D.I.:
Pickup coil resistance/color
Source coil resistance/color
C.D.I. unit model/manufacturer
Charging system:
Type
Model/manufacturer
Standard output
Stator coil resistance/color
Electric starter system:
Type
Starter motor:
Model/ manufacturer
Output
Armature coil resistance
Brush overall length
Brash spring pressure
Commutator diameter
Mica undercut (depth)
SSS
SSS
Constant mesh type
SM-14/MITUBA
0.6 kW
0.0207 X 0.0253 Ω at 20_C
10 mm
5.30 X 6.47 N
28 mm
0.7 mm
2-13
SSS
SSS
SSS
3.5 mm
SSS
27 mm
SSS
MAINTENANCE SPECIFICATIONS
SPEC
Item
Standard
Limit
Starter relay:
Model/manufacturer
Amperage rating
Coil winding resistance
MS5D-191/JIDECO
100 A
3.9 X 4.7 Ω at 20_C
SSS
SSS
SSS
Horn:
Model/manufacturer
Maximum amperage
YF-12/NIKKO
2.5 A
SSS
SSS
Flasher relay:
Type
Model/manufacturer
Flasher frequency
Condenser type
FR2204/MITUBA
85 cycle/min
SSS
SSS
SSS
Circuit breaker:
Type
Main
Reserve
Fuse
20 A
20 A
SSS
SSS
SSS
2-14
1 pcs.
1 pcs.
GENERAL TORQUE SPECIFICATIONS
SPEC
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque
specifications for special components or assemblies are included in the applicable sections
of this book. To avoid warpage, tighten multifastener assemblies in a crisscross 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: Distance across flats
B: Outside thread diameter
2-15
A
(Nut)
B
(Bolt)
10 mm
General torque
specifications
Nm
mSkg
6 mm
6
0.6
12 mm
8 mm
15
1.5
14 mm
10 mm
30
3.0
17 mm
12 mm
55
5.5
19 mm
14 mm
85
8.5
22 mm
16 mm
130
13.0
LUBRICATION POINT AND GRADE OF LUBRICANT
SPEC
LUBRICATION POINT AND GRADE OF LUBRICANT
ENGINE
Lubrication Point
Symbol
Oil seal lips (all)
Bearing retainer (all)
Bolt (cylinder head)
Crank pin
Connecting rod (big end)
Piston pin
Piston/piston ring
Buffer boss
Valve stem/valve guide (IN, EX)
Valve stem end (IN, EX)
Rocker arm shaft
Cam and bearing (camshaft)
Rocker arm inner surface
Crankcase mating surfaces
Yamaha bond No.1215
O-ring (all)
Starter idle gear thrust surfaces
Starter clutch (outer/roller)
Starter wheel gear inner surface
Push rod
Primary driven gear inner surface
Push lever axle
Transmission gear inner surface
Shift fork/guide bar
2-16
LUBRICATION POINT AND GRADE OF LUBRICANT
SPEC
CHASSIS
Lubrication Point
Symbol
Steering head pipe bearing (upper/lower)
Front wheel oil seal lips (left/right)
Rear wheel oil seal lips (left/right)
Rear wheel hub
Rear brake shoe plate, camshaft and pivoting pin
Pivoting points (brake pedal shaft and frame)
Sidestand sliding surface/mounting bolt
Pivoting point (centerstand)
Tube guide (throttle grip) inner surface
Brake lever bolt/master cylinder sliding surface
Clutch lever bolt/cable sliding surface
Steering lock sliding surface
Gear unit (speedometer)
Chain guard inner surface/swigarm insert surface
2-17
LUBRICATION DIAGRAM
LUBRICATION DIAGRAM
1
2
3
4
5
6
Rocker arm (IN)
Rocker shaft
Rocker arm (EX)
Camshaft
Oil pump
Push lever
2-18
SPEC
LUBRICATION DIAGRAM
1
2
3
4
5
6
Oil pump
Oil filter
Crankshaft
Main axle
Drive axle
Oil strainer
2-19
SPEC
CABLE ROUTING
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
Front brake switch lead
Brake hose
Handlebar switch lead (right)
Throttle cable
Clutch cable
Clutch switch lead
Handlebar switch lead (left)
Speedometer cable
Clamp
10 Main switch coupler
11 Front flasher (left)
12
13
14
15
16
17
18
19
20
21
22
Clutch switch coupler
Handlebar switch lead (left)
Front flasher lead (left)
Horn lead
Flasher relay
Handlebar switch lead (right)
Front brake switch lead
Front flasher (right)
Meter lead
Front flasher lead (right)
Wireharness
2-20
A Clamp the handlebar switch
lead, (left and right), front brake
switch lead, clutch switch lead to
the handlebar.
B Do not contact the horn and wireharness.
CABLE ROUTING
1
2
3
4
5
6
7
8
9
Clamp
Wireharness
High tension cord
Collar
Ignition coil
Ground lead
Ignition coil lead
Brake hose
Clutch cable
10 Rear brake switch
11 Starting circuit cut-off relay
12 Battery breather hose
A Align the clamp to the white tape
on the wireharness
B Pass the clutch cable through
the outside of the throttle cable.
C Pass the brake hose and throttle
cable through the slit of the
headlight body. And pass them
the right inside of the front fork.
D Pass the brake hose to the holder.
E Clamp the clutch cable to the
down tube of the frame.
2-21
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
Neutral switch lead
Pickup coil lead
C.D.I. unit
Rear flasher lead (right)
Rear flasher lead (left)
Tail/ Brake light lead
C.D.I. magneto lead
Thermostatic switch lead
Clamp
Sidestand switch lead
Starter relay lead
Fuse
Starter relay
14
15
16
17
18
19
20
21
22
23
24
25
26
Rectifier/ Regulator
Thermostatic switch
Throttle cable
Clutch cable
Wireharness
Speedometer cable
Cable holder
Brake hose holder
Cable holder
Brake hose
Starter motor lead
Sidestand switch
Rectifier/ Regulator lead
2-22
SPEC
A Clamp the speedometer cable to
the steering bracket and pass
the cable to the cable holder.
B Pass the brake hose through the
brake hose holder.
CABLE ROUTING
1
2
3
4
5
6
A
Air filter case
Battery
Swingarm
Battery breather pipe
Lid
Air filter case drain pipe
Pass the air filter case drain pipe
inside the swingarm.
2-23
SPEC
SPEC
CHAPTER 3.
PERIODIC INSPECTIONS
AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 3-1
SIDE COVER, SEAT AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
IDLING SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . .
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING CHINE TENSIONER ADJUSTMENT . . . . . . . . . . . . . . . . . . .
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-13
3-13
3-14
3-15
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE SHOE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE LIGHT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . .
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CHAIN SLACK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . .
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPOKE INSPECTION AND TIGHTENING . . . . . . . . . . . . . . . . . . . . .
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17
3-17
3-17
3-19
3-20
3-20
3-20
3-21
3-22
3-24
3-25
3-25
3-26
3-28
3-28
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-29
3-29
3-31
3-32
INTRODUCTION/
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INSP
ADJ
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All
service technicians should be familiar with this entire chapter.
YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
EVERY
NO.
ITEM
ROUTINE
BRAKE-IN 6,000 km 12,000 km
1,000 KM
or
or
6 months 12 months
1 * Valve(s)
Check valve clearance. Adjust if necessary.
2 * Cam chain
Check chain tension. Adjust if necessary.
3
Spark plug
Check condition.
Clean or replace if necessary.
4
Air filter
Clean. Replace if necessary.
5 * Carburetor
Check idle speed / starter operation.
Adjust if necessary.
6 * Fuel line
Check fuel hose for cracks or damage.
Replace if necessary.
7
Replace (Warm engine before draining.)
8 * Engine oil filter
Replace
9 * Front brake
Check operation / fluid leakage. / see NOTE.
Correct if necessary.
Engine oil
10
Rear brake
Check operation. Adjust if necessary.
11
Clutch
Check operation. Adjust if necessary.
12 * Rear arm pivot
Check rear arm assembly for looseness.
Correct if necessary. Moderately repack
every 24,000 km or 24 months.***
13 * Wheels
Check balance / damage / runout / spoke tightness.
Replace if necessary.
14 * Wheel bearings
Check bearing assembly for looseness / damage.
Replace if damaged.
15 * Steering
bearing
Check bearing assembly for looseness.
Correct if necessary.
Moderately repack every 24,000 km or
24 months.**
16 * Front forks
Check operation / oil leakage.
Repair if necessary.
17 *
Rear shock
absorber
Check operation / oil leakage.
Repair if necessary.
*:
**:
***:
It is recommended that these items be serviced by a Yamaha dealer.
Medium weight wheel bearing grease. (bearing type)
Lithium soap base grease. (bush type)
3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INSP
ADJ
EVERY
NO.
ITEM
ROUTINE
BRAKE-IN 6,000 km 12,000 km
1,000 KM
or
or
6 months 12 months
18
Drive chain
Check chain slack / alignment. Adjust if necessary.
Clean and lube.
19 *
Chassis fasteners
Check all chassis fittings and fasteners.
Correct if necessary.
20 *
Sidestand
Check operation.
Repair if necessary.
21 *
Battery
Check specific gravity.
Check breather pipe for proper operation.
Correct if necessary.
EVERY 500 km
*: It is recommended that these items be serviced by a Yamaha dealer.
**: Medium weight wheel bearing grease. (bearing type)
***: Lithium soap base grease. (bush type)
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid.
Normally check the brake fluid level and fill the fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
3-2
SIDE COVER, SEAT AND FUEL TANK
INSP
ADJ
SIDE COVER, SEAT AND FUEL TANK
Order
Job name/Part name
Q’ty
1
2
3
4
Side cover, seat and fuel tank
removal
Side cover (left)
Side cover (right)
Seat
Fuel pipe
1
1
1
1
5
Fuel tank
1
Remarks
Remove the parts in order.
NOTE:
Disconnect the fuel pipe, set the fuel cock
lever “OFF” position.
Reverse the removal procedure for installation.
3-3
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
SR03004
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
Valve clearance adjustment should be made
with the engine cool, 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.
1. Remove:
S Seat
S Side cover (left and right)
S Fuel tank
Refer to “SIDE COVER, SEAT AND FUEL
TANK” section.
2. Remove:
S Spark plug cap 1
S Spark plug
S Valve cover (intake side) 2
S Valve cover (exhaust side) 3
3. Remove:
S Timing check plug (with O-ring) 1
S Center plug (with O-ring) 2
4. Measure:
S Valve clearance
Out of specification Adjust.
Valve clearance (cold):
Intake valve 0.05 0.09 mm
Exhaust valve 0.11 0.15 mm
***************************************
Measurement steps:
S Rotate the crankshaft counterclockwise to
align the slit a on the rotor with the stationary pointer b on the crankcase cover (left)
when the piston is Top Dead Center (TDC).
S Measure the valve clearance by using a feeler gauge.
Out of specification Adjust clearance.
***************************************
3-4
VALVE CLEARANCE ADJUSTMENT/
IDLING SPEED ADJUSTMENT
INSP
ADJ
5. Adjust:
Valve clearance
***************************************
Adjustment steps:
Loosen the locknut 1 .
Turn the adjuster 3 in or out with the valve adjusting tool 2 until specified clearance is obtained.
Turning in Valve clearance is decreased.
Turning out Valve clearance is increased.
Valve adjusting tool:
90890-01311
Hold the adjuster to prevent it from moving and
tighten the locknut.
14 Nm (1.4 mkg)
Measure the valve clearance.
If the clearance is incorrect, repeat above
steps until specified clearance is obtained.
A
***************************************
B
6. Install:
Valve cover (intake side) 1
10 Nm (1.0 mkg)
O-ring 2 New
Valve cover (exhaust side) 3
10 Nm (1.0 mkg)
O-ring 4 New
A Intake side
B Exhaust side
7. Install:
18 Nm (1.8 mkg)
Spark plug
Timing check window screw 1
(with O-ring)
Center plug 2
(with O-ring)
YP303022
IDLING SPEED ADJUSTMENT
1. Start the engine and let it warm up for several
minutes.
2. Attach:
Inductive tachometer to the spark plug lead.
Inductive tachometer:
90890-03113
3-5
IDLING SPEED ADJUSTMENT/
THROTTLE CABLE ADJUSTMENT
INSP
ADJ
3. Check:
Engine idling speed
Out of specification Adjust.
Engine idling speed:
1,250 1,350 r/min
4. Adjust:
Engine idle speed
***************************************
Adjustment steps:
Turn the pilot screw 1 until it is lightly seated.
Turn the pilot screw out by the specified number of turns.
Pilot screw:
2 turns out
Turn the throttle stop screw 2 in or out until the
specified idling speed is obtained.
Turning in Idling speed is increased.
Turning out Idling speed is decreased.
***************************************
5. Adjust:
Throttle cable free play
Refer to “THROTTLE CABLE ADJUSTMENT” section.
YP303032
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 a
Out of specification Adjust.
Free play (throttle cable):
3 5 mm at throttle grip flange
2. Adjust:
Throttle cable free play
***************************************
Adjustment steps:
NOTE:
Never accelerate the throttle when stopping the
engine.
3-6
THROTTLE CABLE ADJUSTMENT/
SPARK PLUG INSPECTION
INSP
ADJ
Loosen the locknut 1 on the throttle cable.
Turn the adjuster 2 in or out until specified
free play is obtained.
Turning in Free play is increased.
Turning out 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.
***************************************
EB303040
SPARK PLUG INSPECTION
1. Remove:
Spark plug cap
Spark plug
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.
1. Check:
Spark plug type
Incorrect Replace.
Standard spark plug:
DR8EA (NGK)
2. Inspect:
Electrode 1
Wear/damage Replace.
Insulator 2
Abnormal color Replace.
Normal color is a medium-to-light tan color.
3. Clean:
Spark plug
(with spark plug cleaner or wire brush)
4. Measure:
Spark plug gap a
(with a wire gauge)
Out of specification Adjust gap.
Spark plug gap:
0.6 0.7 mm
3-7
SPARK PLUG INSPECTION/
IGNITION TIMING CHECK
INSP
ADJ
5. Install:
Spark plug
18 Nm (1.8 mkg)
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
YP303052
IGNITION TIMING CHECK
NOTE:
Prior to checking the ignition timing, check all
electrical connections related to the ignition
system. Make sure all connections are tight and
free of corrosion and that all ground connections are tight.
1. Remove:
Timing check plug
2. Attach:
Timing light 1
Engine tachometer 2
(to the spark plug lead)
Timing light:
90890-03141
Engine tachometer:
90890-03113
3. Check:
Ignition timing
***************************************
Checking steps:
Start the engine and let it warm up for several
minutes. Let the engine run at the specified
speed.
Engine idling speed:
1,250 1,350 r/min
Visually check the stationary pointer a to
verify it is within the required firing range b indicated on the flywheel.
Incorrect firing range Check the ignition
system.
***************************************
NOTE:
Ignition timing is not adjustable.
3. Install:
Timing check plug
3-8
INSP
ADJ
COMPRESSION PRESSURE MEASUREMENT
SR303060
COMPRESSION PRESSURE MEASUREMENT
NOTE:
Insufficient compression pressure will result in
performance loss.
1. Check:
Valve clearance
Out of specification Adjust.
Refer to “VALVE CLEARANCE ADJUSTMENT” section.
2. Start the engine and let it warm up for several
minutes.
3. Turn off the engine.
4. Remove:
Spark plug
CAUTION:
Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from
falling into the cylinder.
5. Attach:
Compression gauge 1
Compression gauge:
90890-03081
Adaptor:
90890-04082
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 below.
Compression
pressure
p
p
(With oil applied into cylinder)
Reading
Diagnosis
Higher than
Worn or damaged pistons
without oil
Same as
without oil
3-9
Possible defective ring(s),
valves, cylinder head gasket or piston Repair.
COMPRESSION PRESSURE MEASUREMENT/
ENGINE OIL LEVEL INSPECTION
INSP
ADJ
Compression pressure (at sea level):
Standard:
1,200 kPa (12.0 Kg/cm2, 12 bar)
Minimum:
1,100 kPa (11.0 Kg/cm2, 11 bar)
***************************************
Measurement steps:
Crank the engine with the throttle wideopen
until the reading on the compression gauge
stabilizes.
WARNING
Before cranking the engine, ground all
spark plug leads to prevent sparking.
7. Install:
Spark plug
18 Nm (1.8 mkg)
YP303070
ENGINE OIL LEVEL INSPECTION
1. Stand the motorcycle on a level surface.
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. Inspect:
Engine oil level
Oil level should be between maximum 1
and minimum 2 marks.
Oil level is below the minimum mark
Add oil up to the proper level.
RECOMMENDED ENGINE OIL
Refer to the chart for selection of the oils suited
to the atomosperic temperature.
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classification:
API STANDARD:
API “SE” or higher grade
3-10
ENGINE OIL LEVEL INSPECTION/
ENGINE OIL REPLACEMENT
INSP
ADJ
CAUTION:
Do not put in any chemicals additives or
use oils with a grade of CD a or higher.
Be sure not to use oils labeled “ENERGY
CONSERVING II” b or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
Be sure no foreign material enters the
crankcase.
5. Start the engine and let it warm up for a few
minutes.
6. Turn off the engine and inspect the oil level
once again.
NOTE:
Wait a few minutes until the oil settles before inspecting the oil level.
SR303082
ENGINE OIL REPLACEMENT
1. Start the engine and let it warm up for several
minutes.
2. Turn off the engine and place a container under the engine.
3. Remove:
Oil filler plug 1
Drain plug 2
Drain the crankcase of its oil.
4. Loosen:
Bolt 1 (oil filter cover-lower)
5. Drain the crankcase of its oil.
If the oil filter is to be replaced during this procedure, remove the following parts and reinstall them afterwards.
***************************************
Replacement steps:
Remove the oil filter cover 1 and oil filter element 2 .
Check the O-ring 3 . If it is cracked or damaged, replace it.
Install the oil filter element and oil filter cover.
Screw:
7 Nm (0.7 mkg)
Bolt:
10 Nm (1.0 mkg)
***************************************
3-11
ENGINE OIL REPLACEMENT
INSP
ADJ
6. Install:
S Drain plug
43 Nm (4.3 mSkg)
NOTE:
Inspect the O-ring. If it is damaged, replace it
with a new one.
CAUTION:
Before reinstalling the drain plug, do not forget to fit the O-ring, compression spring and
oil strainer. Be sure you fit each item in the
correct position and order.
7. Fill:
S Crankcase
Oil quantity:
With oil filter change
1.1 L
Without oil filter change
1.0 L
Refer to “ENGINE OIL LEVEL INSPECTION”
section.
8. Inspect:
S Oil flow
***************************************
Inspection steps:
S Slightly loosen the oil check bolt 1 .
S Start the engine and keep it idling until the oil
begins to seep from the oil check bolt.
If no oil comes out after one minute, turn the
engine off so it will not seize.
S Check oil passages and oil pump for damage
or leakage.
S Start the engine after solving the problem(s),
and recheck the oil pressure.
S Tighten the oil check bolt to specification.
Oil check bolt:
7 Nm (0.7 mSkg)
***************************************
3-12
TIMING CHAINE TENSIONER ADJUSTMENT/
CLUTCH ADJUSTMENT
INSP
ADJ
SR*******
TIMING CHAINE TENSIONER ADJUSTMENT
1. Remove:
S Cap 1
2. Check:
S Rod
Check the rod end 1 is flush with the adjuster end 2 .
Not flush Adjust.
3. Adjust:
S Timing chine tension
***************************************
Adjustment steps:
S Loosen the locknut 1 .
S Turn the adjuster 2 in or out until the rod end
3 is flush with the adjuster end.
S Tighten the locknut 1 .
Locknut:
30 Nm (3.0 mSkg)
***************************************
4. Install:
S Cap
5 Nm (0.5 mSkg)
EB303093
CLUTCH ADJUSTMENT
1. Check:
S Clutch cable free play a
Out of specification Adjust.
Free play (clutch lever):
10 15 mm at clutch lever end
3-13
CLUTCH ADJUSTMENT/
AIR FILTER CLEANING
INSP
ADJ
2. Adjust:
S Clutch cable free play
***************************************
Adjustment steps:
Crankcase side
S Make sure that the adjuster 1 and locknut 2
are fully tightened.
S Loosen the locknut 2 .
S Turn the adjuster 1 in or out until the specified
free play is obtained.
Turning in Free play is decreased.
Turning out Free play is increased.
S Tighten the locknut 2 .
NOTE:
If the amount of free play is still incorrect, adjust
the clutch cable free play with the other adjuster
(on the clutch lever holder).
Lever side
S Loosen the locknut 3 .
S Turn the adjuster 4 in or out until the specified
free play is obtained.
Turning in Free play is increased.
Turning out Free play is decreased.
S Tighten the locknut 3 .
***************************************
SR303123
AIR FILTER CLEANING
1. Remove:
S Side cover (right)
S Air filter element holder
S Air filter element 1
S Plate 2
CAUTION:
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 filter element will also affect the
carburetor tuning, leading to poor engine
performance and possible overheating.
3-14
AIR FILTER CLEANING/
EXHAUST SYSTEM INSPECTION
INSP
ADJ
2. Inspect:
S Air filter element 1
Damage Replace.
3. Clean:
S Air filter element
Use solvent to clean the element.
NOTE:
After cleaning, remove the remaining solvent by
squeezing the element.
CAUTION:
Do not twist the filter element when squeezing it.
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.
4. Apply the recommended oil to the entire surface of the filter and squeeze out the excess
oil. The element should be wet but not dripping.
Recommended oil:
Engine oil
5. Install:
S Plate 1
S Air filter element 2
S Air filter element holder
S Side cover (right)
T******
EXHAUST SYSTEM INSPECTION
1. Inspect:
S Exhaust pipe 1
S Muffler 2
Crack/Damage Replace.
S Gasket 3
Exhaust gas leaks Replace.
3-15
EXHAUST SYSTEM INSPECTION
INSP
ADJ
2. Check:
S Tightening torque
Bolt 1 :
12 Nm (1.2 mSkg)
Nut 2 :
20 Nm (2.0 mSkg)
3-16
FRONT BRAKE ADJUST MENT/
REAR BRAKE ADJUSTMENT
INSP
ADJ
EB304002
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:
Brake lever free play a
Out of specification Adjust.
Free play (Brake lever):
2 5 mm at brake lever end
2. Adjust:
Brake lever free play
***************************************
Adjustment steps:
Loosen the locknut 1 .
Turn the adjuster 2 in or out until the specified
free play is obtained.
Turning in Free play is decreased.
Turning out Free play is increased.
Tighten the locknut.
CAUTION:
Make sure that there is no brake drag after
adjusting the front brake lever free play.
WARNING
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. This air must be removed by bleeding the brake system before the motorcycle
is operated. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Inspect and bleed the brake
system if necessary.
***************************************
NB304012
REAR BRAKE ADJUSTMENT
1. Check:
Brake pedal height a
Out of specification Adjust.
Brake pedal height:
0 mm
below the top of the footrest
3-17
REAR BRAKE ADJUSTMENT
INSP
ADJ
2. Adjust:
S Brake pedal height
***************************************
Adjustment steps:
S Loosen the locknut 1 .
S Turn the adjuster 2 in or out until the specified
pedal height is obtained.
Turning in Pedal height is decreased.
Turning out Pedal height is increased.
S Tighten the locknut.
***************************************
3. Check:
S Brake pedal free play a
Out of specification Adjust
Free play (Brake pedal):
20 30 mm at brake lever end
4. Adjust:
S Brake pedal free play
***************************************
Adjustment steps:
S Turn the adjuster 1 in or out until the specified
free play is obtained.
Turning in Free play is decreased.
Turning out Free play is increased.
CAUTION:
Make sure that there is no brake drag after
adjusting the brake pedal height and the
free play.
***************************************
5. Adjust:
S Brake light switch
Refer to “BRAKE LIGHT SWITCH ADJUSTMENT”.
3-18
BRAKE FLUID LEVEL INSPECTION
INSP
ADJ
EB304020
BRAKE FLUID LEVEL INSPECTION
1. Stand the motorcycle on a level surface.
NOTE:
S Make sure the motorcycle is upright when inspecting the brake fluid level.
S Stand the motorcycle on its centerstand if it
has one. If not, place a suitable stand under
the motorcycle.
2. Inspect:
S Brake fluid level
Brae fluid level is below the “LOWER” level
line a Fill to proper level.
Recommended brake fluid:
DOT #4 or DOT #3
NOTE:
For a correct reading of the brake fluid level,
make sure the top of the handlebar brake fluid
reservoir is horizontal.
CAUTION:
Brake fluid may corrode painted surfaces or
plastic parts. Always clean up any spilt fluid
immediately.
WARNING
S Use only the designated brake fluid. Other
fluids may deteriorate the rubber seals,
causing leakage and poor brake performance.
S Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical
reaction leading to poor brake performance.
S Be careful that water does not enter the
brake fluid reservoir during refilling. Water
will significantly lower the boiling point of
the fluid and may cause vapour lock.
3-19
BRAKE PAD INSPECTION/BRAKE SHOE INSPECTION/
BRAKE LIGHT SWITCH ADJUSTMENT
INSP
ADJ
EB304030
BRAKE PAD INSPECTION
1. Operate the brake lever.
2. Inspect:
Brake pad (front)
Wear indicators 1 almost touch the brake
disc Replace the brake pads as a set.
Refer to “FRONT BRAKE” in CHAPTER 6.
EB304040
BRAKE SHOE INSPECTION
1. Operate the brake pedal.
2. Inspect:
Brake shoes
Wear indicator 1 reaches the wear limit line
2 Replace the brake shoes as a set.
Refer to “REAR WHEEL” in CHAPTER 6.
EB304050
BRAKE LIGHT SWITCH ADJUSTMENT
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.
1. Check:
Brake light operation timing
Incorrect Adjust.
2. Adjust:
Brake light operating timing
***************************************
Adjustment steps:
Hold the main body 1 of the switch with your
hand so that it does not rotate, and turn the adjuster 2 in or out until the proper operation
timing is obtained.
Turning in Brake light comes on fast.
Turning out Brake light comes on slows.
***************************************
3-20
AIR BLEEDING
INSP
ADJ
EB304070
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
WARNING
Bleed the brake system whenever:
S The system is disassembled.
S A brake hose is loosened or removed.
S The brake fluid level is very low.
S Brake operation is faulty.
Loss of braking performance may occur if
the brake system is not properly bled.
1. Bleed:
S Brake system
***************************************
Air bleeding steps:
a. Fill the reservoir with the proper brake fluid.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2 .
d. Place the other end of the hose into a container.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.
i. Repeat steps (e) to (h) until all air bubbles
have disappeared from the brake fluid.
NOTE:
When bleeding the brake system, make sure
that there is always enough brake fluid in the
brake fluid reservoir before applying the brake
lever. Ignoring this precaution could allow air to
enter the brake system, considerably lengthening the bleeding procedure.
3-21
AIR BLEEDING/
DRIVE CHAIN SLACK ADJUSTMENT
INSP
ADJ
j. Tighten the bleed screw.
Bleed screw:
6 Nm (0.6 mSkg)
NOTE:
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the brake system have disappeared.
k. Fill the brake fluid reservoir to the proper level.
Refer to “BRAKE FLUID LEVEL INSPECTION”.
WARNING
Check brake operation after bleeding the
brake system.
***************************************
SR304093
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.
CAUTION:
Too little chain slack will overload the engine and other vital parts; keep the slack
within the specified limits.
WARNING
S Securely support the motorcycle so that
there is no danger of it falling over.
S Stand the motorcycle on its centerstand.
3-22
DRIVE CHAIN SLACK ADJUSTMENT
INSP
ADJ
1. Check:
S Drive chain slack
Out of specification ! Adjust.
Drive chain slack:
25 35 mm
a Check window
b Adjustable limit
c Usable limit
A
d Usable range
2. Adjust:
S Drive chain slack
B
A Standard
B Useful limit
***************************************
Adjustment steps:
S Loosen the axle nut 1 .
S Turn the chain adjusters 2 clockwise or counterclockwise until the specified drive chain
slack is obtained.
Clockwise ! Chain slack is decreased.
Counter! Chain slack is increased.
clockwise
NOTE:
Turn each chain adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks e on each chain adjuster.
Use them when adjusting the slack for proper
alignment.)
S Before tightening the axle nut to specification,
make sure that there is no clearance at the adjuster (or the swingarm end) on both sides by
pushing the wheel forward.
Rear wheel axle:
65 Nm (6.5 mSkg)
***************************************
CAUTION:
Do not adjust the drive chain slack above
the usable range b of check window a .
3-23
STEERING HEAD INSPECTION
INSP
ADJ
SR304130
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 centerstand.
2. Elevate the front wheel by placing a suitable
stand under the engine.
3. Check:
Steering assembly bearings
Grasp the bottom of the lower front fork tubes
and gently rock the fork assembly.
Looseness Adjust the steering head.
4. Adjust:
Steering head
***************************************
Adjustment steps:
Tighten the ring nut 1 using the ring nut
wrench 2 .
Loosen the ring nut completely, then tighten it.
NOTE:
When tighten the ring nut, should be steady the
ball bearings and steering shaft moving
smoothly.
Ring nut wrench:
90890-01403
Steering ring nut:
1st step:
38 Nm (3.8 mkg)
2nd step:
7 Nm (0.7 mkg)
Check the steering head for looseness or binding by turning it all the way in both directions.
***************************************
3-24
FRONT FORK INSPECTION/
REAR SHOCK ABSORBER ADJUSTMENT
INSP
ADJ
EB304140
FRONT FORK INSPECTION
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
1. Stand the motorcycle on a level surface.
2. Check:
S Inner tube
Scratches/damage Replace.
S Oil seal
Excessive oil leakage Replace.
Hold the motorcycle upright and apply the
front brake.
3. Check:
S Operation
Push down hard on the handlebars several
times.
Unsmooth operation Repair.
Refer to “FRONT FORK” in CHAPTER 6.
YP304160
REAR SHOCK ABSORBER ADJUSTMENT
WARNING
S Always adjust each rear shock absorber
preload to the same setting. Uneven adjustment can cause poor handling and loss
of stability.
S Securely support the scooter so there is no
danger of it falling over.
1. Adjust:
S Spring preload
Turn the adjuster ring 1 to direction a or b .
***************************************
Adjustment steps:
S Turn the adjuster ring in or out.
Turning toward a Spring preload is
increased.
Turning toward b Spring preload is
decreased.
3-25
REAR SHOCK ABSORBER ADJUSTMENT/
TIRE INSPECTION
INSP
ADJ
Adjustment numbers:
Standard
1
Minimum
1
Maximum
5
CAUTION:
S Never turn the adjuster beyond the maximum or minimum setting.
S Always adjust each shock absorber to the
same setting.
***************************************
EB304171
TIRE INSPECTION
1. Measure:
S Tire inflation pressure
Out of specification Adjust.
WARNING
S Tire inflation pressure should only be
checked and adjusted when the tire temperature equals the ambient air temperature. Tire inflation pressure and suspension must be adjusted according to the
total weight of the cargo, rider, passenger
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.
S Operation of an overloaded motorcycle
could cause tire damage, accident or injury.
Basic weight:
With oil and
full fuel tank
113 kg
Maximum load*
164 kg
Cold tire pressure
Front
Rear
175 kPa
200 kPa
Up to 90 kg
(1.75 kg/cm2, (2.0 kg/cm2,
load*
1.75 bar)
2.0 bar)
175 kPa
25 kPa
90 kg (1.75 kg/cm2, (2.25 kg/cm2,
maximum. load*
1.75 bar)
2.25 bar)
* Load is the total weight of the cargo, rider, passenger and accessories.
3-26
TIRE INSPECTION
INSP
ADJ
2. Inspect:
Tire surfaces
Wear/damage Replace.
Minimum tire tread depth
(front and rear): 1.6 mm
1 Tread depth
2 Side wall
3 Wear indicator
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread begins to show signs of
wear, replace the tire immediately.
Patching a punctured tube is not recommended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality replacement tube.
Do not use tubeless tires on a wheel designed for tube type tires only. Tire failure
and personal injury may result from sudden deflation.
Tube type wheel Tube type tire only
T beless type wheel Tubeless
Tube type
yp or
tubeless tire.
Be sure to install the correct tube when using tube type tires.
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. No guarantee concerning handling characteristics can be given if
a tire combination other than one approved by Yamaha is used on this motorcycle. The front and rear tires should always be by the same manufacturer and of
the same design.
WARNING
After mounting a tire, ride conservatively for
a while to give the tire 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 tire repair or replacement, be sure to
tighten the valve stem locknut 1 to specification.
Locknut:
1.5 Nm (0.15 mkg)
3-27
SPOKE INSPECTION AND TIGHTENING/
WHEEL INSPECTION
INSP
ADJ
EB304190
SPOKE INSPECTION AND TIGHTENING
1. Inspect:
S Spokes 1
Bending/damage Replace.
Loose spoke Retighten.
2. Tighten:
S Spokes
NOTE:
Be sure to tighten the spokes before and after
break-in.
Nipple:
2 Nm (0.2 mSkg)
EB304180
WHEEL INSPECTION
1. Inspect:
S Wheels
Damage/Bends Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
WARNING
Never attempt to make any repairs to the
wheel.
3-28
BATTERY INSPECTION
INSP
ADJ
EB305001
ELECTRICAL
BATTERY INSPECTION
1. Remove:
S Side covers (left and right)
Refer to “SIDE COVER, SEAT AND FUEL
TANK” section.
2. Inspect:
S Electrolyte level
Electrolyte level should be between the upper 1 and lower 2 level marks.
Electrolyte level is too low Add electrolyte
to proper level.
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.
3. Inspect:
S Battery terminals
Dirt Clean with a wire brush.
Poor connection Correct.
NOTE:
After cleaning the terminals, apply a light coat of
grease to the terminals.
4. Inspect:
S Breather hose
Obstruction Remove.
Damage Replace.
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 electrolyte or gas to come
into contact with the frame, this could damage the motorcycle and ruin its finish.
5. Connect:
S Breather hose 1
Make sure that the hose is properly attached
and routed.
6. Check:
S Specific gravity
Less than 1.280 Recharge the battery.
Charging Current:
0.7 amps/10 hrs
Specific Gravity:
1.280 at 20_C
3-29
BATTERY INSPECTION
INSP
ADJ
***************************************
Replace the battery if:
S Battery voltage will not rise to a specific value
or bubbles fail to rise during charging.
S Sulphation of one or more cells occurs, (as indicated by the plates turning white, or material
accumulating in the bottom of the cell).
S Specific gravity readings after a long, slow
charge indicate that one cell is charged lower
than the rest.
S Warpage or buckling of plates or insulators is
evident.
***************************************
CAUTION:
Always charge a new battery before using 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:
S Avoid bodily contact with electrolyte as it
can cause severe burns and permanent
eye injury.
S Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
S SKIN – Flush with water.
S EYES – Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
S Drink large quantities of water or milk followed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical
attention.
S Batteries generate explosive hydrogen
gas.
S Always follow these preventive measures:
S Charge batteries in a well – ventilated area.
S Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
S DO NOT SMOKE when charging or handling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
3-30
BATTERY INSPECTION/FUSE INSPECTION
INSP
ADJ
7. Install:
Battery
8. Connect:
Battery leads
CAUTION:
Connect the positive lead 1 first and then
connect the negative lead 2 .
9. Connect:
Breather hose
Be sure the hose is properly attached and
routed.
Refer to “CABLE ROUTING” section.
10. Install:
Side covers (left and right)
Refer to “SIDE COVER, SEAT AND FUEL
TANK” section.
T305010
FUSE INSPECTION
CAUTION:
Always turn off the main switch when
checking or replacing the fuse. Otherwise, a
short circuit may occur.
1. Remove:
Side covers (left and right)
Refer to “SIDE COVER, SEAT AND FUEL
TANK” section.
Fuse holder 1
2. Inspect:
Fuse
***************************************
Inspection steps:
Connect the pocket tester to the fuse and
check it for continuity.
NOTE:
Set the tester selector to “Ω 1” position.
Pocket tester:
90890-03112
If the tester is indicated at ∞. Replace the
fuse.
***************************************
3-31
FUSE INSPECTION/
HEADLIGHT BEAM ADJUSTMENT
INSP
ADJ
3. Replace:
S Blown fuse
***************************************
Replacement steps:
S Turn off the main switch.
S Install a new fuse with the proper current rating.
S Turn on switches to verify operation of related
electrical devices.
S If the fuse blows again immediately, check the
electrical circuit.
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 systems
and could possibly cause a fire.
***************************************
4. Install:
S Fuse holder
S Side cover (left and right)
Refer to “SIDE COVER, SEAT AND FUEL
TANK” section.
EB305022
HEADLIGHT BEAM ADJUSTMENT
1. Adjust:
S Headlight beam (vertical)
Loosen the bolt 1 and adjust the headlight
unit.
3-32
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE, STARTING MOTOR AND WIRE READ . . . . . . . . .
CARBURETOR, CLUTCH CABLE AND DRIVE CHAIN . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-2
4-3
CYLILNDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAM SPROCKET COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
4-4
4-5
4-6
4-7
4-8
CAM SHAFT AND ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARM AND ROCKER ARM SHAFT REMOVAL . . . . . . . . .
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION . . . .
CAMSHAFT AND ROCKER ARM INSTALLATION . . . . . . . . . . . . . .
4-10
4-11
4-11
4-12
4-12
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVES AND VALVE SPRINGS REMOVAL . . . . . . . . . . . . . . . . . . . .
VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SEATS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVES AND VALVE SPRINGS INSTALLATION . . . . . . . . . . . . . . . .
4-14
4-15
4-15
4-17
4-18
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON AND PISTON RINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . .
CYLINDER AND PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
PISTON RING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON RINGS, PISTON AND CYLINDER INSTALLATION . . . . . .
4-20
4-21
4-21
4-23
4-24
4-24
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE COVER (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUSH ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26
4-26
4-27
4-29
4-29
4-30
4-30
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMARY DRIVE GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL DELIVERY PASSAGE INSPECTION
(CRANK CASE COVER (right)) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMARY DRIVE GEAER INSTALLATION . . . . . . . . . . . . . . . . . . . . .
4-33
4-35
4-35
4-35
4-36
4-36
BALANCER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BALANCER DRIVEN GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . .
DRIVE GEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BALANCER DRIVE GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .
BALANCER GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-37
4-38
4-38
4-38
4-39
SHIFT SHAFT AND SEGMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEGMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIFT SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-40
4-42
4-42
4-42
4-43
CDI MAGNETO AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE COVER (LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PICKUP COIL AND STATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CDI MAGNETO AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . .
CDI MAGNETO REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
CDI MAGNETO INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-44
4-44
4-45
4-46
4-47
4-47
4-48
4-48
CRANK CASE AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT AND BALANCER WEIGHT . . . . . . . . . . . . . . . . . . . . .
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUNGER SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUNGER SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BALANCER WEIGHT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-50
4-50
4-52
4-53
4-53
4-54
4-55
4-55
4-55
TRANSMISSION, SHIFT CAM AND SHIFT FORK . . . . . . . . . . . . . . . . .
DRIVE AXLE AND MAIN AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL . . . .
SHIFT FORK SHIFT CAM INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT CAM AND SHIFT FORK INSTALLATION
4-56
4-57
4-58
4-58
4-59
ENGINE REMOVAL
ENG
EB400000
ENGINE OVERHAUL
ENGINE RE MOVAL
EXHAUST PIPE, STARTING MOTOR AND WIRE READ
12 Nm (1.2 mkg)
20 Nm (2.0 mkg)
Order
Job name/Part name
Q’ty
Exhaust pipe, starting motor and
wire read removal
Side cover, seat and fuel tank
1
2
3
4
5
6
7
Remarks
Remove the parts in order.
Refer to “SIDE COVER, SEAT AND
FUEL TANK” section in CHAPTER 3.
1
1
1
1
1
1
1
Rear foot rest (right)
Exhaust pipe Ass’y
Exhaust pipe gasket
Ground lead
Starting motor read
CDI magneto read
Plug cap
Reverse the removal procedure for
installation.
4-1
ENGINE REMOVAL
ENG
CARBURETOR, CLUTCH CABLE AND DRIVE CHAIN
65 Nm (6.5 mkg)
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)
8 Nm (0.8 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Carburetor, clutch cable and drive
chain removal
Carburetor
1
2
3
4
5
Clutch cable
Crankcase breather hose
Shift pedal
Drive sprocket cover
Rear wheel axle nut
1
1
1
1
1
6
7
Sprocket holder
Drive sprocket/drive chain
1
1/1
4-2
Refer to “CARBURETOR” section in
CHAPTER 5.
NOTE:
Loosen the axle nut and slacken the
drive chain.
Reverse the removal procedure for
installation.
ENGINE REMOVAL
ENG
ENGINE
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in order.
Securely support the motorcycle so
there is no danger of it falling over.
Engine removal
1
2
3
4
5
Remarks
Engine stay (top)
Front engine stay
Engine mount bolt (rear upper)
Engine mount bolt (rear under)
Engine
1
1
1
1
1
Reverse the removal procedure for
installation.
4-3
CYLINDER HEAD
ENG
CYLINDER HEAD
CAM SPROCKET COVER
10 Nm (1.0 mkg)
18 Nm (1.8 mkg)
2 Nm (0.2 mkg)
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Cam sprocket cover removal
Side cover, seat and fuel tank
Remove the parts in order.
Exhaust pipe assembly
Carburetor assembly
Engine stay (top)
1
2
3
4
5
6
7
Remarks
Spark plug
Cam sprocket cover/O-ring
Valve cover (intake side)/O-ring
Valve cover (exhaust side)/O-ring
Carburetor joint/O-ring
Timing mark cap/O-ring
Center cap/O-ring
1
1/1
1/1
1/1
1/1
1/1
1/1
Refer to “SIDE COVER SEAT AND
FUEL TANK REMOVAL” section in
CHAPTER 3.
Refer to “ENGINE REMOVAL” section in
CHAPTER 4.
Refer to “CARBURETOR” section in
CHAPTER 5.
Refer to “ENGINE REMOVAL” section in
CHAPTER 4.
Reverse the removal procedure for
installation.
4-4
CYLINDER HEAD
ENG
CYLINDER HEAD
22 Nm (2.2 mkg)
20 Nm (2.0 mkg)
5 Nm (0.5 mkg)
60 Nm (6.0 mkg)
30 Nm (3.0 mkg)
Order
1
2
3
4
5
6
7
8
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Cylinder head removal
Timing chain tensioner cap/O-ring
Timing chain tensioner assembly
Cam sprocket/Timing chain
Ignition coil
Cylinder head
Dowel pins
Gasket
Cylinder head gasket
1/1
1
1/1
1
1
3
1
1
Refer to “CYLINDER HEAD REMOVAL/
INSTALLATION” section.
Refer to “CYLINDER HEAD
INSTALLATION” section.
Reverse the removal procedure for
installation.
4-5
CYLINDER HEAD
ENG
T401030
CYLINDER HEAD REMOVAL
1. Align:
Slit a on the magneto
(with stationary pointer b on the crank case
cover)
NOTE:
Turn the crank shaft counterclockwise with
a wrench and align the “I” mark c with the
cylinder head match mark d when the piston is
at TDC on the compression stroke.
2. Loosen:
Cam sprocket bolt 1
3. Remove:
Timing chain tensioner assembly 1
4. Remove:
Cam sprocket bolt
Cam sprocket 1
Timing chain 2
NOTE:
Fasten a safety wire to the timing chain to
prevent it from falling into the crankcase.
4-6
CYLINDER HEAD
ENG
5. Remove:
Cylinder head
NOTE:
Loosen the nuts in their proper loosening
sequence.
Start by loosening each nut 1/2 turn until all
are loose.
YP402000
CYLINDER HEAD INSPECTION
1. Eliminate:
Carbon deposits
(from combustion chambers)
Use 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 Replace.
3. Measure:
Cylinder head warpage
Out of specification Resurface.
Cylinder head warpage:
Less than 0.03 mm
***************************************
Warpage measurement and resurfacement
steps:
Place a straightedge and a feeler gauge
across the cylinder head.
Measure the warpage.
If the warpage is out of specification, resurface
the cylinder head.
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.
***************************************
4-7
CYLINDER HEAD
ENG
SR********
CYLINDER HEAD INSTALLATION
1. Install:
Dowel pins 1 New
Gasket 2
Gasket (cylinder head) 3 New
2. Install:
Cylinder head
M8 (1 4)
22 Nm (2.2 mkg)
M8 (5 6
20 Nm (2.2 mkg)
NOTE:
apply engine oil onto the nut threads.
Tighten the bolts starting with the lowest
numbered one.
3. Install:
Calm sprocket
Timing chain
***************************************
Installing steps:
Turn the crank shaft counterclockwise until the
slit 1 matches the stationary pointer 2 .
Align the dowel pin 3 on the camshaft with the
stationary pointer 4 on the cylinder head.
Align the “I” mark 5 on the cam sprocket with
the stationary pointer 6 on the cylinder head.
Fit the timing chain 7 onto cam sprocket 8
and install the cam sprocket on the camshaft.
NOTE:
When installing the cam sprocket, keep the timing chain as tight as possible on the exhaust
side.
CAUTION:
Do not turn the crankshaft during installation of the camshaft. Damage or improper
valve timing will result.
Remove the safety wire from the timing chain.
***************************************
4-8
CYLINDER HEAD
ENG
4. Install:
Plate washer
Bolt (timing chain)
Timing chain tensioner assembly
5. Tighten:
60 Nm (6.0 mkg)
Bolt (timing chain)
NOTE:
Install the bolt while holding the magneto
mounting bolt with a wrench.
6. Check:
Magneto rotor slit
Align the stationary pointer with the crankcase cover (left).
Cam sprocket “I” mark
Align the stationary pointer with the cylinder
head.
Out of alignment Adjust.
7. Check:
Timing chain tension
Refer to “TIMING CHAIN ADJUSTMENT”
section in CHAPTER 3.
Valve clearance
Refer to “VALVE CLEARANCE ADJUSTMENT” section in CHAPTER 3.
4-9
CAM SHAFT AND ROCKER ARMS
ENG
CAM SHAFT AND ROCKER ARMS
14 Nm (1.4 mkg)
14 Nm (1.4 mkg)
8 Nm (0.8 mkg)
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Cam shaft and rocker arm removal
Cylinder head
Lock washer
Plate
Collar
Cam shaft
Rocker arm shaft (intake side)
Rocker arm shaft (exhaust side)
Rocker arm
O-ring
Nut/Adjuster
Q’ty
1
1
1
1
1
1
2
1
2/2
Remarks
Remove the parts in order.
Refer to the “CYLINDER HEAD” section.
Refer to the “CAMSHAFT AND ROCKER
ARM INSTALLATION” section.
Refer to the “ROCKER ARM AND
ROCKER ARM SHAFT REMOVAL/
CAMSHAFT AND ROCKER ARM
INSTALLATION” section.
Reverse the removal procedure for
installation.
4-10
CAM SHAFT AND ROCKER ARMS
ENG
SR******
ROCKER ARM AND ROCKER ARM SHAFT
REMOVAL
1. Remove:
Camshaft 1
Collar (camshaft) 2
NOTE:
Use 10 mm bolt 3 to remove the camshaft.
2. Remove:
Rocker arm shaft (intake)
Rocker arm shaft (exhaust)
NOTE:
Attach a rocker arm shaft puller bolt 1 and
weight 2 to the rocker arm shaft and slide out
the shaft.
Rocker arm shaft puller bolt:
90890-01083
Weight:
90890-01084
YP402052
CAMSHAFT INSPECTION
1. Inspect:
Cam lobes
Pitting/Scratches/Blue discoloration Replace.
2. Measure:
Cam lobes length A and B .
Out of specification Replace.
Cam lobes length:
Intake:
A 36.537 36.637 mm
<Limit: 36.45 mm>
B 30.13 30.231 mm
<Limit: 30.05 mm>
Exhaust:
A 36.577 36.677 mm
<Limit: 36.49 mm>
B 30.214 30.314 mm
<Limit: 30.13 mm>
3. Inspect:
Camshaft oil passage
Stuffed Blow out oil passage with compressed the air.
4-11
CAM SHAFT AND ROCKER ARMS
ENG
YP402060
ROCKER ARMS AND ROCKER ARM
SHAFTS INSPECTION
1. Inspect:
Rocker arm shafts
Rocker arms
Wear/Pitting/Scratches/Blue discoloration
Replace.
***************************************
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 Replace.
Inspect the surface condition of the rocker arm
shafts.
Pitting/scratches/blue discoloration Replace or check lubrication.
Measure the inside diameter a of the rocker
arm holes.
Out of specification Replace.
Inside diameter (rocker arm):
12.000 12.018 mm
<Limit: 12.036 mm>
Measure the outside diameter of the rocker
arm shafts.
Out of specification Replace.
Outside diameter (rocker
arm shaft):
11.985 11.991 mm
<Limit: 11.950 mm>
***************************************
SR******
CAMSHAFT AND ROCKER ARM
INSTALLATION
1. Lubricate:
Camshaft
Camshaft:
Molybdenum disulfide oil
Camshaft bearing:
Engine oil
4-12
CAM SHAFT AND ROCKER ARMS
ENG
2. Apply:
Molybdenum disulfide oil
(onto the rocker arm and rocker arm shaft)
Molybdenum disulfide oil
3. Install:
Rocker arm
Rocker arm shaft 1
NOTE:
Apply engine oil onto the outside of the rocker
arm shaft and apply molybdenum disulfide oil
onto the inside of the rocker arm.
Install the rocker arm shaft (intake), mach the
cut away a and bolt hole b .
CAUTION:
Make sure that the rocker shaft install
direction.
Install the rocker arm shaft into the thread
side for the out.
4. Install:
Camshaft 1
Collar 2
NOTE:
Apply engine oil onto the cam profile face and
journal face.
Install the camshaft, mach the dowel pin a
and cylinder head mark b .
5. Install:
Plate 1
Lock washer 2 New
Bolt 3
8 Nm (0.8 mkg)
NOTE:
After tighten the bolt, bend the end of the rock
washer.
4-13
VALVES AND VALVE SPRINGS
ENG
VALVES AND VALVE SPRINGS
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Refer to “CYLINDER HEAD” section.
Refer to “CAMSHAFT AND ROCKER
ARMS” section.
Valves and valve springs removal
Cylinder head
Rocker arm, Camshaft
1
Valve cotters
4
2
3
4
5
6
7
8
Spring retainer
Valve spring (inner)
Valve spring (outer)
Valve (intake)
Valve (exhaust)
Valve guide (stem seal)
Spring seat
2
2
2
1
1
2
2
Refer to “VALVES AND VALVE
SPRINGS REMOVAL/INSTALLATION”
section.
Refer to “VALVES AND VALVE
SPRINGS INSTALLATION” section.
Reverse the removal procedure for
installation.
4-14
VALVES AND VALVE SPRINGS
ENG
YP401150
VALVES AND VALVE SPRINGS REMOVAL
1. Remove:
Valve cotters 1
NOTE:
Attach a valve spring compressor and attachment 2 between the valve spring retainer and
cylinder head to remove the valve cotters.
CAUTION:
Do not compress so much as to avoid damage to the valve spring.
Valve spring compressor:
90890-01253
Valve spring compressor
attachment:
90890-04108
NB402010
VALVES AND VALVE GUIDES
1. Measure:
Stem-to-guide clearance
Stem-to-guide clearance =
valve guide inside diameter a –
valve stem diameter b
Out of specification Replace the valve
guide.
Clearance (stem to guide):
Intake:
0.010 0.037 mm
<Limit: 0.08 mm>
Exhaust:
0.025 0.052 mm
<Limit: 0.10 mm>
2. Replace:
Valve guide
***************************************
Replacement steps:
NOTE:
Heat the cylinder head in an oven to 100C to
ease guide removal and installation and to
maintain correct fit.
Remove the valve guide using a valve guide
remover 1 .
4-15
VALVES AND VALVE SPRINGS
ENG
Install the new valve guide using a valve guide
installer 2 and valve guide remover 1 .
After installing the valve guide, bore the valve
guide using a valve guide reamer 3 to obtain
proper stem-to-guide clearance.
Valve guide remover (6 mm):
90890-04064
Valve guide installer (6 mm):
90890-04065
Valve guide reamer (6 mm):
90890-04066
NOTE:
Reface the valve seat after replacing the valve
guide.
***************************************
3. Eliminate:
Carbon deposits (from the valve face)
4. Inspect:
Valvel face
Pitting/wear Grind the face.
Valve stem end
Mushroom shape or diameter larger than the
body of the stem Replace.
5. Measure:
Margin thickness a
Out of specification Replace.
Margin thickness:
Intake
0.8 1.2 mm
Exhaust
0.8 1.2 mm
6. Measure:
Runout (valve stem)
Out of specification Replace.
Runout:
Less than 0.03 mm
NOTE:
Always replace the guide when installing a
new valve.
Always replace the oil seal if the valve is removed or replaced.
4-16
VALVES AND VALVE SPRINGS
ENG
EB402020
VALVE SEATS INSPECTION
1. Eliminate:
Carbon deposits
(from the valve face and valve seat)
2. Inspect:
Valve seats
Pitting/wear Reface the valve seat.
3. Measure:
Valve seat width a
Out of specification Reface the valve seat.
Valve seat width:
Intake:
0.9 1.1 mm
<Limit: 1.6 mm>
Exhaust:
0.9 1.1 mm
<Limit: 1.6 mm>
***************************************
Measurement steps:
Apply Mechanic’s blueing dye (Dykem) 1 to
the valve face.
Install the valve into 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 replaced.
***************************************
EB402020
4. Lap:
Valve face
Valve seat
NOTE:
After replacing the valve seat, valve and valve
guide, the valve seat and valve face should be
lapped.
***************************************
Lapping steps:
Apply a coarse lapping compound a to the
valve face.
CAUTION:
Do not let compound enter the gap between
the valve stem and the guide.
4-17
VALVES AND VALVE SPRINGS
ENG
Apply molybdenum disulfide oil to the valve
stem.
Install the valve into the cylinder head.
Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
compound.
Valve lapper:
90890-04101
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your hand.
Apply a fine lapping compound 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) b to
the valve face.
Install the valve into 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 c again.
***************************************
EB404032
VALVES AND VALVE SPRINGS
INSTALLATION
1. Deburr:
Valve stem end
Use an oil stone to smooth the stem end.
4-18
VALVES AND VALVE SPRINGS
ENG
2. Apply:
Molybdenum disulfide oil
(onto the valve stem 3 and oil seal 2 )
Molybdenum disulfide oil
3. Install:
Valve spring seat 1
Valve stem seat 2 New
Valve 3
(into the cylinder head)
Valve spring 4
Spring retainer 5
NOTE:
Install the valve spring with the larger pitch a
facing upwards.
b Smaller pitch
4. Install:
Valve cotters 1
NOTE:
Install the valve cotters while compressing the
valve spring with a valve spring compressor and
attachment 2 .
Valve spring compressor:
90890-01253
Valve spring compressor
attachment:
90890-04108
5. Secure the valve cotters onto the valve stem
by tapping lightly with a piece of wood.
CAUTION:
Do not hit so much as to damage the valve.
4-19
CYLINDER AND PISTON
ENG
CYLINDER AND PISTON
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Cylinder and piston removal
Cylinder head
Timing chain guide (exhaust side)
Cylinder/O-ring
O-ring
Dowel pin
Cylinder gasket
Piston pin circlip
Piston pin
Piston
Piston ring set
Q’ty
Remarks
Remove the parts in order.
Refer to “CYLINDER HEAD” section.
1
1/1
1
2
1
2
1
1
1
Refer to “PISTON RINGS, PISTON AND
CYLINDER INSTALLATION” section.
Refer to “PISTON AND PISTON RINGS
REMOVAL” section.
Refer to “PISTON RINGS, PISTON AND
CYLINDER INSTALLATION” section.
Reverse the removal procedure for
installation.
4-20
CYLINDER AND PISTON
ENG
YP******
PISTON AND PISTON RINGS REMOVAL
1. Remove:
Piston pin circlip 1
Piston pin 2
Piston 3
NOTE:
Before removing the piston pin circlip, cover the
crankcase opening with a clean towel or rag to
prevent the circlip from falling into the
crankcase cavity.
2. Remove:
Top ring
2nd ring
Oil ring
NOTE:
When removing the piston ring, open the end
gap of the ring by fingers, and push up the other
side of the ring.
EB402100
CYLINDER AND PISTON INSPECTION
1. Inspect:
Cylinder and piston walls
Vertical scratches Rebore or replace the
cylinder and the piston.
2. Measure:
Piston-to-cylinder clearance
***************************************
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.
4-21
CYLINDER AND PISTON
Cylinder bore “C”
ENG
57.00 57.02 mm
Taper limit “T”
0.05mm
Out of round “R”
0.01mm
“C” = Maximum D
“T” = (Maximum D1 or D2) –
(Maximum D5 or D6)
“R” = (Maximum D1, D3 or D5)
– (Minimum D2, D4 or D6)
If out of specification, rebore or replace the cylinder, and replace the piston and piston rings
as a set.
2nd step:
Measure the piston skirt diameter “P” with a
micrometer.
a 5.5 mm from from the piston bottom edge.
Piston size P
Standard
56.960 56.975 mm
Oversize 1
0.25 mm
Oversize 2
0.50 mm
If out of specification, replace the piston 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”
Piston-to-cylinder clearance:
0.025 0.045 mm
If out of specification, rebore or replace the cylinder, and replace the piston and piston rings
as a set.
***************************************
4-22
CYLINDER AND PISTON
ENG
EB402110
PISTON RING INSPECTION
1. Measure:
Side clearance
Out of specification Replace the piston
and the piston rings as a set.
NOTE:
Eliminate the carbon deposits from the piston
ring grooves and rings before measuring the
side clearance.
Side clearance:
Top ring: <Limit>
0.03 0.07 mm <0.15 mm>
2nd ring: <Limit>
0.02 0.06 mm <0.15 mm>
2. Position:
Piston ring
(into the cylinder)
NOTE:
Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
a 5 mm
3. Measure:
End gap
Out of specification 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.
End gap:
Top ring: <Limit>
0.15 0.35 mm <0.60 mm>
2nd ring: <Limit>
0.15 0.35 mm <0.60 mm>
Oil ring:
0.3 0.9 mm
4-23
CYLINDER AND PISTON
ENG
EB402120
PISTON PIN INSPECTION
1. Inspect:
Piston pin
Blue discoloration/grooves Replace, then
inspect the lubrication system.
2. Measure:
Piston pin-to-piston clearance
***************************************
Measurement steps:
Measure the piston pin outside diameter a .
If out of specification, replace the piston pin.
Outside diameter (piston pin):
14.978 14.992 mm
<Limit> 14.975 mm
Measure the piston inside diameter b .
Calculate the piston pin-to-piston clearance
using the following formula:
Piston pin-to-piston clearance =
Bore size (piston pin) b –
Outside diameter (piston pin) a
If out of specification, replace the piston.
Clearance (piston pin-to-piston):
0.010 0.035 mm
***************************************
EB404184
PISTON RINGS, PISTON AND CYLINDER
INSTALLATION
1. Install:
Top ring 1
2nd ring 2
Side rails (oil ring) 3
Expander spacer (oil ring) 4
NOTE:
Make sure to install the piston rings so that the
manufacturer’s marks or numbers are located
on the upper side of the rings.
Lubricate the pistons and piston rings liberally
with engine oil.
4-24
CYLINDER AND PISTON
ENG
2. Install:
Piston 1
Piston pin 2
Piston pin clip 3 New
NOTE:
Apply engine oil onto the piston pins.
The “” mark a on the piston must face the
exhaust side of the cylinder.
Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crankcase.
Make sure to install each piston in its respective cylinder.
3. Install:
Gasket (cylinder) New
Dowel pins
4. Position:
Piston rings
NOTE:
Offset the piston ring end gaps as shown.
a
b
c
d
Top ring end
Oil ring end (lower)
Oil ring end (upper)
2nd ring end
5. Lubricate:
Piston outer surface
Piston ring
Cylinder inner surface
Engine oil
6. Install:
Gasket (cylinder) 1 New
Cylinder 2
NOTE:
Install the cylinder with one hand while compressing the piston rings with the other hand.
Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
4-25
CLUTCH
ENG
CLUTCH
CRANKCASE COVER (RIGHT)
45 Nm (4.5 mkg)
7 Nm (0.7 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in order.
Refer to “ENGINE OIL REPLACEMENT”
section in CHAPTER 3.
Crankcase cover (right) removal
Drain the engine oil
1
2
3
4
5
6
Remarks
1
1
1
1
1
2
Nut
Foot rest (right)
Clutch cable
Crankcase cover (right)
Crankcase cover gasket (right)
Dowel pins
Reverse the removal procedure for
installation.
4-26
CLUTCH
ENG
CLUTCH
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
12 Nm (1.2 mkg)
6 Nm (0.6 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Clutch removal
Sprocket cover
Clutch springs
Pressure plate
Friction plates
Clutch plates
Nut/Lock washer
Clutch boss
Plate washer
Primary driven gear
Ball
Push rod #2
Push lever screw/Gasket
Q’ty
Remarks
Remove the parts in order.
Refer to “ENGINE REMOVAL” section.
4
1
4
3
1/1
1
1
1
1
1
1/1
4-27
Refer to “CLUTCH INSTALLATION”
section.
Refer to “CLUTCH REMOVAL/
INSTALLATION” section.
Refer to “CLUTCH INSTALLATION”
section.
CLUTCH
ENG
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
12 Nm (1.2 mkg)
6 Nm (0.6 mkg)
Order
12
13
14
15
16
17
18
Job name/Part name
Push lever axle
Torsion spring
Circlip
Oil seal
Nut/Washer
Push rod #1/O-ring
Push plate
Q’ty
Remarks
1
1
1
1
1/1
1/1
1
Refer to “CLUTCH INSTALLATION” section.
Refer to “CLUTCH INSTALLATION” section.
Reverse the removal procedure for
installation.
4-28
CLUTCH
ENG
SR401061
CLUTCH REMOVAL
1. Remove:
Nut 1 (clutch boss)
Lock washer 2
Clutch boss 3
Straighten the lock washer tab 2 .
NOTE:
Loosen the clutch boss nut 1 while holding the
clutch boss with a clutch holding tool 4 .
Clutch holding tool:
90890-04086
SR402181
CLUTCH INSPECTION
1. Inspect:
Friction plates
Damage/wear Replace the friction plates
as a set.
2. Measure:
Friction plate thickness
Out of specification Replace the friction
plates as a set.
Measure at four places.
Thickness (friction plate):
2.9 3.1 mm
<Limit: 2.7 mm>
3. Inspect:
Clutch plates
Damage Replace the clutch plates as a
set.
4. Measure:
Clutch plate warpage
Out of specification Replace the clutch
plates as a set.
Use a surface plate and a feeler gauge 1 .
Warp limit (clutch plate):
Less tan 0.05 mm
5. Inspect:
Clutch springs
Damage Replace the clutch springs as a
set.
4-29
CLUTCH
ENG
6. Measure:
Free length (clutch spring) a
Out of specification Replace the clutch
springs as a set.
Free length (clutch spring):
34.5 mm
<Lilmit: 32.9 mm>
7. Inspect:
Dogs on the primary driven gear 1
Scoring/wear/damage Deburr or replace.
Clutch boss splines 2
Scoring/wear/damage Replace clutch
boss.
NOTE:
Scoring on the clutch housing dogs and the
clutch boss splines will cause erratic operation.
SR********
PUSH ROD INSPECTION
1. Inspect:
Push rod #1 1
Ball 2
Push rod #2 3
Wear/crack/damage Replace.
SR******
CLUTCH INSTALLATION
1. Install:
Push lever axle 1
Gasket 2 New
Screw 3
12 Nm (1.2 mkg)
2. Install:
Primary driven gear 1
Plate washer 2
Clutch boss 3
NOTE:
Tighten the nut (primary drive gear) while holding the rotor with the sheave holder 3 .
4-30
CLUTCH
ENG
3. Install:
Lock washer 1 New
Nut 2 (clutch boss)
70 Nm (7.0 mkg)
NOTE:
Install the clutch boss nut 2 while holding the
clutch boss with a clutch holding tool 3 .
Clutch holding tool:
90890-04086
4. Bend:
Lock washer tab
(along a flat side of the end)
5. Install:
Friction plate 1
Clutch plate 2
NOTE:
Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.
Coat all clutch and friction plates with engine
oil before installation.
6. Install:
Push rod #2
Ball
7. Install:
Push rod #1 1
O-ring 2 New
Push plate 3
Plate washer 4
Nut 5 (push rod #1)
8. Install:
Pressure plate 1
Compression springs 2
Bolts 3 (clutch springs)
6 Nm (0.6 mkg)
NOTE:
Tighten the clutch spring bolts in stage, using a
crisscross pattern.
4-31
CLUTCH
ENG
9. Check:
Push lever position
Push the push lever assembly in the arrow
direction and make sure that match marks
are be aligned Adjust.
a Match mark on the push lever assembly
b Match mark on the crankcase
10. Adjust:
Push lever position
***************************************
Adjustment steps:
Loosen the locknut 1 .
Turn the adjuster 2 clockwise or counterclockwise to match alignment marks.
Hold the adjuster to prevent it from moving and
tighten the locknut to specification.
CAUTION:
Take care not to overtighten the adjuster 2
and to remove the free play between both
push rods.
Tighten the lock nut 1 .
8 Nm (0.8 mkg)
***************************************
4-32
OIL PUMP
ENG
OIL PUMP
50 Nm (5.0 mkg)
7 Nm (0.7 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Refer to “CLUTCH” section.
Oil pump removal
Clutch
1
2
3
4
5
Nut
Lock washer
Primary drive gear
Oil pump cover
Oil pump assembly
1
1
1
1
1
6
Gasket (oil pump cover)
1
Refer to “PRIMARY DRIVE GEAR
REMOVAL/INSTALLATION” section.
Refer to “OIL PUMP REMOVAL/INSTALLATION” section
Reverse the removal procedure for
installation.
4-33
OIL PUMP
ENG
7 Nm (0.7 mkg)
Order
1
2
3
4
5
6
7
Job name/Part name
Q’ty
Remarks
Disassemble the parts in order.
Oil pump disassembly
Oil pump housing
Dowel pin
Oil pump driven gear
Dowel pins
Inner rotor
Outer rotor
Housing
1
1
1
2
1
1
1
Reverse the disassembly procedure for
assembly.
4-34
OIL PUMP
ENG
SR401070
PRIMARY DRIVE GEAR REMOVAL
NOTE:
Straighten the lock washer tab.
1. Remove:
Nut (primary drive gear) 1
Lock washer 2
Primary drive gear 3
NOTE:
Place a folded aluminium plate or copper washer a between the teeth of the balancer drive
gear 4 and balancer driven gear 5 .
T402140
OIL PUMP INSPECTION
1. Measure:
Tip clearance A
(between the inner rotor 1 and the outer rotor 2 )
Side clearance B
(between the outer rotor 2 and the pump
housing 3 )
Out of specification Replace the oil pump
assembly.
Housing and rotor clearance C
(between the pump housing 3 and the rotors 1 , 2 .)
Out of specification Replace the oil pump
assembly.
Tip clearance A :
0.03 0.09 mm
<Limit: 0.14 mm>
Side clearance B :
0.10 0.15 mm
<Limit: 0.35 mm>
Housing and rotor clearance C :
0.03 0.09 mm
<Limit: 0.14 mm>
SR******
OIL DELIVERY PASSAGE INSPECTION (CRANK CASE COVER (right))
1. Check:
Oil delivery passage
Blockage Blow by the compressed air.
4-35
OIL PUMP
ENG
SR404010
OIL PUMP INSTALLATION
1. Lubricate:
Oil delivery passage (crankcase right)
Oil pump assembly
Recommended lubricant:
Engine oil
SR404140
PRIMARY DRIVE GEAR INSTALLATION
1. Install:
Primary drive gear 1
Lock washer 2 New
Nut (primary drive gear) 3
50 Nm (5.0 mkg)
NOTE:
Place a folded aluminium plate or copper
washer a between the teeth of the balancer
drive gear 4 and balancer driven gear 5 .
Bend the lock washer tab, after tighten the nut
flats.
4-36
BALANCER GEAR
ENG
BALANCER GEAR
50 Nm (5.0 mkg)
Order
Job name/Part name
1
2
Balancer gear removal
Clutch
Primary drive gear
Nut/Lock washer
Balancer driven gear
3
4
5
6
7
8
9
10
Woodruff key
Claw washer
Balancer drive gear
Buffer boss
Compression spring
Dowel pins
Woodruff key
Plate washer
Q’ty
1/1
1
1
1
1
1
6
3
1
1
Remarks
Remove the parts in order.
Refer to “CLUTCH” section.
Refer to “OIL PUMP” section.
Refer to “BALANCER DRIVEN GEAR
REMOVAL/BALANCER GEAR
INSTALLATION” section.
Refer to “BALANCER DRIVE GEAR
ASSEMBLY” section.
Reverse the removal procedure for
installation.
4-37
BALANCER GEAR
ENG
SR******
BALANCER DRIVEN GEAR REMOVAL
NOTE:
Straighten the lock washer tab.
1. Remove:
Nut (balancer driven gear) 1
Lock washer 2
Balancer driven gear 3
NOTE:
Place a folded aluminium plate or copper washer a between the teeth of the balancer drive
gear 4 and balancer driven gear 3 .
SR******
DRIVE GEAR INSPECTION
1. Inspect:
Balancer drive gear 1
Buffer boss 2
Compression spring 3
Dowel pins 4
Wear/Pitting/Scratches Replace.
SR******
BALANCER DRIVE GEAR ASSEMBLY
1. Assembly:
Dowel pins 1
Compression springs 2
NOTE:
Install the dowel pins and compression springs
alternately as shown as.
2. Install:
Buffer boss 1
NOTE:
Align the punched mark a on the buffer boss
with the one on the balancer drive gear.
4-38
BALANCER GEAR
ENG
SR******
BALANCER GEAR INSTALLATION
1. Install:
Balancer driven gear 1
NOTE:
Install the balancer driven gear, then mesh the
balancer driven gear match mark a and balancer drive gear assembly match mark b .
2. Install:
Lock washer 1 New
Nut (balancer drive gear) 2
50 Nm (5.0 mkg)
NOTE:
Place a folded aluminium plate or copper
washer a between the teeth of the balancer
drive gear 3 and balancer driven gear 4 .
Bend the lock washer tab, after tighten the nut
flats.
4-39
SHIFT SHAFT AND SEGMENT
ENG
SHIFT SHAFT AND SEGMENT
12 Nm (1.2 mkg)
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Refer to “CLUTCH” section.
Refer to “ENGINE REMOVAL” section.
Shift shaft and segment removal
Clutch
Shift pedal
Shift shaft
Plate washer
Torsion spring
Stopper lever
Plate washer
Circlip
Torsion spring
Collar
Tension spring
1
1
1
1
1
1
1
1
1
4-40
Refer to “SHIFT SHAFT
REMOVAL/INSTALLATION” section.
SHIFT SHAFT AND SEGMENT
ENG
12 Nm (1.2 mkg)
Order
10
11
12
13
Job name/Part name
Q’ty
Screw
Segment
Dowel pins (short length)
Dowel pins (long length)
1
1
4
1
Remarks
Refer to “SEGMENT INSTALLATION”
section.
Reverse the removal procedure for
installation.
4-41
SHIFT SHAFT AND SEGMENT
ENG
SR******
SHIFT SHAFT REMOVAL
1. Remove:
Shift shaft assembly 1
NOTE:
Push the shift lever arm 2 and the stopper lever
3 to the arrow direction and remove them from
the segment.
T402200
SHIFT SHAFT INSPECTION
1. Inspect:
Stopper lever
Roller turns roughly Replace.
Bends/damage Replace.
2. Inspect:
Torsion springs (stopper lever and shift arm)
Wear/damage Replace.
3. Inspect:
Shift shaft assembly 1
Shift lever 2
Bends/wear/damage Replace.
SR******
SEGMENT INSTALLATION
1. Install:
Segment 1
Dowel pins 2 (short length)
Dowel pin 3 (long length)
NOTE:
Install the dowel pin 2 (long length) into the
hole beside the match mark a position.
4-42
SHIFT SHAFT AND SEGMENT
ENG
2. Install:
Segment 1
NOTE:
Fit the dowel pin 2 (long length) on the segment to the locating hole a on the sift cam and
install the segment.
3. Tighten:
Screw 1
12 Nm (1.2 mkg)
SR******
SIFT SHAFT INSTALLATION
1. Install:
Shift shaft assembly
***************************************
Instaling steps:
Set the stopper lever and return spring to the
shift shaft.
Mesh the stopper lever 1 with the shift cam
segment.
Install the shift lever 2 to the shift cam segment.
After installing the shift shaft, check the shift
cam for smooth operation by turning the shift
shaft with your hand.
***************************************
2. Check:
Shift lever 1 position
Gaps a and b are not equal Replace the
defective parts.
4-43
CDI MAGNETO AND STARTER CLUTCH
ENG
CDI MAGNETO AND STARTER CLUTCH
CRANKCASE COVER (LEFT)
7 Nm (0.7 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in order.
Refer to “ENGINE OIL REPLACEMENT”
section in CHAPTER 3.
Refer to “SIDE COVER, SEAT AND
FUEL TANK” section in CHAPTER 3.
Crankcase cover (left) removal
Drain the engine oil
Side cover
1
2
3
4
Remarks
Drive sprocket cover
DCI magneto lead couplers
Neutral switch lead connector
Crankcase cover (left)
Gasket
Dowel pins
Refer to “ENGINE REMOVAL” section.
1
1
1
2
Reverse the removal procedure for
installation.
4-44
CDI MAGNETO AND STARTER CLUTCH
ENG
PICKUP COIL AND STATOR COIL
3 Nm (0.3 mkg)
7 Nm (0.7 mkg)
Order
1
2
3
4
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Pickup coil and stator coil removal
Clamp (stator coil)
Clamp (pickup coil)
Pickup coil
Stator coil
1
1
1
1
Reverse the removal procedure for
installation.
4-45
CDI MAGNETO AND STARTER CLUTCH
ENG
CDI MAGNETO AND STARTER CLUTCH
30 Nm (3.0 mkg)
50 Nm (5.0 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
1
CDI magneto and starter clutch
removal
CDI magneto
1
2
3
4
5
6
7
8
9
10
11
Idle shaft/collar
Starter idle gear
Woodruff key
Starter wheel gear
Shim
Dowel pins (Inner)
Spring caps
Compression springs
Dowel pins (outer)
Starter clutch
1
1
1
1
1
3
3
3
3
1
Refer to “CDI MAGNETO
REMOVAL/INSTALLATION” section.
Refer to “CDI MAGNETO
INSTALLATION” section.
Refer to “STARTER CLUTCH
INSTALLATION” seciton.
Remove the removal procedure tor
installation.
4-46
CDI MAGNETO AND STARTER CLUTCH
ENG
YP401081
C.D.I. MAGNETO REMOVAL
1. Remove:
Bolt 1 (magneto)
Plain washer 2
NOTE:
Loosen the bolt (magneto) 1 while holding
the rotor with a sheave holder 3 .
Do not allow the sheave holder to touch the
projection on the magneto.
Sheave holder:
90890-01701
2. Remove:
CDI magneto assembly 1
Woodruff key
NOTE:
Remove the magneto using sheave holder 2 ,
rotor puller 3 and rotor puller attachment 4 .
Rotor puller:
90890-01080
Rotor puller attachment:
90890-04052
SR402163
STARTER CLUTCH INSPECTION
1. Check:
Starter clutch operation
Push the dowel pins to the arrow direction.
Unsmooth operation Replace.
***************************************
Checking steps:
Hold the starter clutch.
When turning the starter wheel gear clockwise
a , the starter clutch and the starter wheel
gear should be engaged.
If not, the starter clutch is faulty. Replace it.
When turning the starter wheel gear counterclockwise b , it should turn freely.
If not, the starter clutch is faulty. Replace it.
***************************************
2. Inspect:
Dowel pins 1
Compression springs 2
Spring caps 3
Wear/Damage Replace.
4-47
CDI MAGNETO AND STARTER CLUTCH
ENG
3. Inspect:
Starter wheel gear
(contacting surface)
Pitting/Wear/Damage Replace.
SR******
STARTER CLUTCH INSTALLATION
1. Install:
Starter clutch assembly 1
30 Nm (3.0 mkg)
2. Unloosen the starter clutch assembly by using the center punch.
3. Install:
Compression springs 1
Spring caps 2
Dowel pins 3
YP404131
C.D.I. MAGNETO INSTALLATION
1. Install:
Shim 1
Starter wheel gear 2
Woodruff key 3
2. Install:
C.D.I. magneto assembly 1
NOTE:
Clean the tapered portion of the crankshaft
and the magneto hub.
When installing the magneto rotor, make sure
the woodruff key is properly seated in the key
way of the crankshaft and turning the stater
wheel gear 2 clockwise.
4-48
CDI MAGNETO AND STARTER CLUTCH
ENG
3. Tighten:
CDI magneto assembly 1
50 Nm (5.0 mkg)
NOTE:
Tighten the bolt while holding the CDI magneto
assembly with the sheave holder 2 .
Sheave holder:
90890-01701
4-49
CRANKCASE AND CRANK SHAFT
ENG
CRANK CASE AND CRANKSHAFT
CRANKCASE
8 Nm (0.8 mkg)
7 Nm (0.7 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in order.
Refer to “ENGINE REMOVAL” section.
Refer to “CYLINDER HEAD” section.
Refer to “CYLINDER AND PISTON”
section.
Refer to “CLUTCH” section.
Refer to “OIL PUMP” section.
Refer to “BALANCER DRIVE GEAR”
section.
Refer to “SHIFT SHAFT AND
SEGMENT” section.
Refer to “CDI MAGNETO AND
STARTER CLUTCH” section.
Crankcase separation
Engine
Cylinder head
Cylinder and piston
Clutch
Primary drive gear/oil pump
Balancer weight drive gear
Shift shaft and segment
CDI magneto/starter clutch
1
Remarks
Timing chain guide (intake)
1
4-50
CRANKCASE AND CRANK SHAFT
ENG
8 Nm (0.8 mkg)
7 Nm (0.7 mkg)
Order
Job name/Part name
Q’ty
2
3
Timing chain
Crankcase
1
1
4
Dowel pins
2
Remarks
Refer to “CRANKCASE
SEPARATION/INSTALLATION” section.
Reverse the removal procedure for
installation.
4-51
CRANKCASE AND CRANK SHAFT
ENG
CRANKSHAFT AND BALANCER WEIGHT
Order
1
2
3
4
5
6
7
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Crankshaft and balancer weight
removal
Balancer weight
Crankshaft assembly
Dowel pin
Plunger seal
Compression spring
Bearing (balancer weight)
Bearing (crankshaft right)
1
1
1
1
1
1
1
Refer to “BALANCER WEIGHT
INSTALLATION” seciton.
Refer to “PLUNGER SEAL
REMOVAL/INSTALLATION” section.
Reverse the removal procedure for
installation.
4-52
CRANKCASE AND CRANK SHAFT
ENG
SR401132
CRANKCASE SEPARATION
1. Remove:
Crankcase screws
NOTE:
The numbers embossed on the crankcase indicate the tightening sequence. Loosen the
screws in decreasing numerical order (see
numbers on the illustration).
Loosen each screw 1/4 turn at a time and remove them after all are loose.
2. Remove:
Right crankcase half
NOTE:
Set the left crankcase half under then put in the
flat head screw driver to the separating slit a .
CAUTION:
Do not use the flat head screw driver except place as shown.
The left crankcase half should be under.
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.
SR******
PLUNGER SEAL REMOVAL
1. Remove:
Dowel pin 1
Plunger seal 2
Compression spring 3
NOTE:
Remove the plunger seal and compression
spring, push the plunger seal lightly and remove
the dowel pin.
4-53
CRANKCASE AND CRANK SHAFT
ENG
T******
CRANKSHAFT INSPECTION
1. Measure:
Crankshaft runout
Out of specification Replace crankshaft
and/or bearing.
NOTE:
Measure the crankshaft runout with the crankshaft assembly turning slowly.
Runout limit:
0.03 mm
2. Measure:
Big end side clearance
Out of specification Replace big end bearing, crank pin and/or connecting rod.
Big end side clearance:
0.35 0.65 mm
Limit
0.1 mm
3. Measure:
Crank width
Out of specification Replace crankshaft.
Crank width:
55.95 56.00 mm
4. Inspect:
Timing chain sprocket 1
Wear/Damage Replace crankshaft.
Bearing 2
Wear/Crack/Damage Replace crankshaft.
5. Inspect:
Crankshaft journal
Clogged Blow out the journal with compressed air.
4-54
CRANKCASE AND CRANK SHAFT
ENG
SR******
PLUNGER SEAL INSTALLATION
1. Install:
Compression spring 1
Plunger seal 2
Dowel pin 3
2. Check the plunger seal smooth operation
pushing the plunger seal by your finger.
T*****
BALANCER WEIGHT INSTALLATION
1. Install:
Crankshaft assembly 1
Balancer weight assembly 2
CAUTION:
Do not use the hammer forcefully during
installation of the crankshaft. Damage the
crankcase oil seal lip and gear teeth.
SR404073
CRANKCASE INSTALLATION
1. Clean all the gasket mating surface and
crankcase mating surface thoroughly.
2. Apply:
Sealant
(onto the crankcase mating surfaces)
Yamaha bond No.1215:
90890-85505
NOTE:
DO NOT ALLOW any sealant to come in contact with the oil gallery a .
3. Tighten:
Crankcase right half
7 Nm (0.7 mkg)
NOTE:
Tighten the screws in decreasing numerical order (see numbers on the illustration).
4-55
TRANSMISSION SIFT CAM AND SHIFT FORK
ENG
TRANSMISSION, SHIFT CAM AND SHIFT FORK
Order
Job name/Part name
Q’ty
Remove the parts in order.
Transmission, shift cam and
shift fork removal
Crankcase separating
1
2
3
4
5
6
7
8
9
10
Remarks
Refer to “CRANKCASE AND
CRANKSHAFT” section.
1
1
1
1
1
1
1
1
1
1
Shift fork guide bar 2 (short length)
Shift fork guide bar 1 (long length)
Shift cam
Shift fork 1 “C” (center)
Shift fork 2 “R” (right)
Shift fork 3 “L” (left)
Main axle assembly
Plate washer
Drive axle assembly
Plate washer
Refer to “TRANSMISSION, SHIFT CAM
AND SHIFT FORK INSTALLATION”
section.
Refer to “TRANSMISSION, SHIFT CAM
AND SHIFT FORK REMOVAL/
INSTALLATION” section.
Reverse the removal procedure for
installation.
4-56
TRANSMISSION SIFT CAM AND SHIFT FORK
ENG
DRIVE AXLE AND MAIN AXLE
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job name/Part name
Drive axle and main axle
disassembly
Second wheel gear
First wheel gear
Fifth wheel gear
Circlip/washer
Third wheel gear
Forth wheel gear
Drive axle
Second pinion gear
Forth pinion gear
Third pinion gear
Circlip/washer
Fifth pinion gear gear
Main axle
Q’ty
Remarks
Disassemble the parts in order.
1
1
1
1/1
1
1
1
1
1
1
1/1
1
1
Reverse the disassembly procedure for
assembly.
4-57
TRANSMISSION SIFT CAM AND SHIFT FORK
ENG
SR******
TRANSMISSION, SHIFT CAM AND SHIFT
FORK REMOVAL
1. Install:
O-Ring 1
To the drive sprocket groove.
2. Remove:
Drive axle assembly 1
Main axle assembly 2
Remove them at same the time.
T402190
SHIFT FORK SHIFT CAM INSPECTION
1. Inspect:
Shift fork cam follower 1
Shift fork pawl 2
Scoring/bends/wear/damage Replace.
2. Inspect:
Shift cam grooves
Wear/damage/scratches Replace.
Shift cam segment
Damage/wear Replace.
3. Inspect:
Shift fork 1 “C” (center) 1
Shift fork 2 “R” (right) 2
Shift fork 3 “L” (left) 3
Guide bar 4
Shift cam 5
Dowel pin 6
Roll the guide bar on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent guide
bar.
4-58
TRANSMISSION SIFT CAM AND SHIFT FORK
ENG
4. Check:
Shift fork movement
(on the guide bar)
Unsmooth operation Replace the shift
fork and the guide bar.
NOTE:
When damaged the shift fork and mission gear,
replace the facing each gear as set.
SR******
TRANSMISSION, SHIFT CAM AND SHIFT
FORK INSTALLATION
1. Measure:
Main axle assembled length a
Assembled length (main axle):
90.9 91.1 mm
2. Install:
O-ring 1
To the drive sprocket folder groove.
3. Install:
Shift fork 3 “L” (left) 1
(face the “L” side for the clutch side.)
Shift fork 2 “R” (right) 2
(face the “R” side for the clutch side.)
Shift fork 1 “C” (center) 3
(face the “C” side for the magneto side.)
Shift fork guide bar 1 4 (long)
Shift fork guide bar 2 5 (short)
NOTE:
Install the shift forks with the embossed mark to
the right and in sequence (R, C, L) beginning
from the right.
4. Check:
Shift cam operation
Unsmooth operation Repair.
NOTE:
Check the transmission and shift forks for
smooth operation by turning the shift cam with
your hand.
4-59
ENG
CHAPTER 5.
CARBURETION
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
FUEL LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CARBURETOR
CARB
EB600000
CARBURETION
CARBURETOR
Order
Job name/Part name
Q’ty
Remove the parts in order.
Carburetor removal
Side cover
Seat
Fuel tank
Heater unit lead
1
2
3
4
Remarks
Refer to “SIDE COVER, SEAT AND
FUEL TANK” section in CHAPTER 3.
NOTE:
Disconnect the cable from wireharness.
Carburetor joint clamp screw
Air filter joint clamp screw
Carburetor assembly
Carburetor top
1
1
1
1
NOTE:
Loosen.
Reverse the removal procedure for
installation.
5-1
CARBURETOR
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Q’ty
CARB
Remarks
Disassemble the parts in order.
Carburetor disassembly
Throttle cable
Throttle valve assembly
Throttle valve spring
Mixing chamber top/O-ring
Drain screw assembly
Float chamber
Gasket (float chamber)
Float pin/float
Needle valve assembly
Main jet
Main nozzle/O-ring
1
1
1
1/1
1
1
1
1/1
1
1
1/1
5-2
Refer to “CARBURETOR ASSEMBLY”
section.
CARBURETOR
Order
12
13
14
15
16
17
Job name/Part name
CARB
Q’ty
Remarks
1
1
1
1
1/1
1/1
Refer to “CARBURETOR ASSEMBLY”
section.
Pilot screw assembly
Pilot jet
Throttle stop screw assembly
Starter plunger assembly
Screw/gasket
Heater unit/washer
Reverse the disassembly procedure for
assembly.
5-3
CARBURETOR
CARB
SR******
CARBURETOR ASSEMBLY
CAUTION:
Do not use a wire for cleaning.
Before assembling, wash all parts in clean
petroleum based solvent.
Always use a new gasket.
1. Install:
Pilot jet 1
Pilot screw assembly 2
Pilot screw (turn out):
2 turns out
2. Install:
O-ring New
Main nozzle 1
Main jet 2
3. Install:
Valve seat 1
Needle valve 2
4. Install:
Float 1
Float pin 2
5-4
CARBURETOR
CARB
YP600060
FUEL LEVEL ADJUSTMENT
1. Measure:
Fuel level a
Out of specification Adjust.
Fuel level:
2.5 3.5 mm below the
float chamber line
***************************************
Measurement and adjustment steps:
Place the motorcycle on a level surface.
Put a garage jack under the engine to ensure
that the carburetors are positioned vertically.
Connect the fuel level gauge 1 to the drain
pipe 2 .
Fuel level gauge:
90890-01312
Loosen the drain screw 3 .
Hold the gauge vertically next to the float
chamber line.
Measure the fuel level a with the gauge.
If the fuel level is incorrect, adjust the fuel level.
Remove the carburetor.
Inspect the valve seat and needle valve.
If either is worn, replace them both.
If both are fine, adjust float level by bending the
float tang 4 slightly.
Install the carburetor.
Recheck the fuel level.
***************************************
5-5
CARB
CHAPTER 6.
CHASSIS
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL STATIC BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . .
6-1
6-3
6-3
6-4
6-4
6-5
6-6
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8
6-8
6-9
6-10
6-12
6-12
6-13
6-15
6-17
6-17
6-17
6-18
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN . . . . . . . . . . . . . . . .
REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CHAIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE SHOE PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-20
6-20
6-24
6-25
6-25
6-25
6-26
6-27
6-28
6-28
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-29
6-31
6-31
6-32
6-34
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-35
6-37
6-37
6-37
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-39
6-39
6-41
6-41
STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . 6-43
SWINGARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
FRONT WHEEL AND BRAKE DISC
CHAS
EB700000
CHASSIS
FRONT WHEEL AND BRAKE DISC
20 Nm (2.0 mkg)
59 Nm (5.9 mkg)
23 Nm (2.3 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Front wheel and brake disc removal
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
1
2
Speedometer cable
Axle pinch bolt
1
1
3
4
5
6
7
Wheel axle
Front wheel assembly
Collar
Meter gear unit assembly
Brake disc
1
1
1
1
1
6-1
NOTE:
Loosen the axle pinch bolt.
Refer to “FRONT WHEEL
INSTALLATION” section.
Refer to “FRONT WHEEL ASSEMBLY”
section.
Reverse the removal procedure for
installation.
FRONT WHEEL AND BRAKE DISC
Order
Job name/Part name
Q’ty
CHAS
Remarks
1
Front wheel disassembly
Oil seal
1
Disassemble the parts in order.
Refer to “FRONT WHEEL ASSEMBLY”
section.
2
3
4
5
Bearing
Spacer
Spacer flange
Bearing
1
1
1
1
Refer to “FRONT WHEEL
DISASSEMBLY/ASSEMBLY” section.
Reverse the disassembly procedure for
reassembly.
6-2
FRONT WHEEL AND BRAKE DISC
CHAS
T******
FRONT WHEEL DISASSEMBLY
1. Remove:
Bearings 1
Spacer
Remove the bearings using a general bearing puller 2 .
CAUTION:
Handle the wheel with care not to damage
the brake disc. If the brake disc is damaged,
replace.
T700021
FRONT WHEEL INSPECTION
1. Inspect:
Front wheel axle
(by rolling it on a flat surface)
Bends Replace.
WARNING
Do not attempt to straighten a bent axle.
Wheel axle bending limit:
0.25 mm
2. Inspect:
Front tire
Wear/damage Replace.
Refer to “TIRE INSPECTION” in CHAPTER
3.
Front wheel
Refer to “WHEEL INSPECTION” in CHAPTER 3.
3. Check:
Spokes
Bends/damage Replace.
Loose spokes Retighten.
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 tightening
the spokes.
6-3
FRONT WHEEL AND BRAKE DISC
CHAS
5. Measure:
Front wheel runout
Over the specified limits Replace.
Front wheel runout limits:
Radial 1 : 2.0 mm
Lateral 2 : 2.0 mm
6. Inspect:
Front wheel bearings
Bearings allow free play in the wheel hub or
the wheel does not turn smoothly Replace.
Oil seals
Wear/damage Replace.
7. Inspect:
Collar
Grooved wear Replace the collar and the
oil seal as a set.
YP******
BRAKE DISC INSPECTION
1. Measure:
Brake disc deflection
Maximum deflection:
0.15 mm
Out of specification Replace.
2. Measure:
Brake disc thickness
Brake disc thickness:
4.0 mm
Minimum thickness:
3.5 mm
Out of specification Replace.
YP******
FRONT WHEEL ASSEMBLY
1. Install:
Bearing 1
Spacer 2
Spacer flange 3
Bearing 4
Oil seal 5
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Use a socket that matches the outside diameter of the race of the bearing.
Always use a new oil seal.
Install the oil seal with its manufacturer’s
marks or numbers facing outward.
6-4
FRONT WHEEL AND BRAKE DISC
CHAS
CAUTION:
Do not strike the inner race of balls of the
bearing. Contact should be made only with
the outer race.
2. Install:
Brake disc 1
23 Nm (2.3 mkg)
NOTE:
Tighten the bolts (brake disc) in stage using a
crisscross pattern.
SR700030
FRONT WHEEL INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points.
1. Lubricate:
Front wheel axle
Bearings
Oil seal (lips)
Drive/driven gear (speedometer)
Recommended lubricant:
Lithium soap base grease
2. Install:
Speedometer gear unit 1
NOTE:
Make sure that the wheel hub and the
speedometer gear unit are installed with the two
projections a meshed into the two slots b .
3. Install:
Front wheel
NOTE:
Make sure that the slot a in the speedometer
gear unit fits over the stopper b on the front fork
outer tube.
6-5
FRONT WHEEL AND BRAKE DISC
4. Tighten:
: Front wheel axle
: Axle pinch bolt
CHAS
59 Nm (5.9 m:kg)
20 Nm (2.0 m:kg)
CAUTION:
Before tightening the wheel axle, stroke the
front fork several times to check for proper
fork operation.
WARNING
Make sure that the brake hose is routed
properly.
YP700040
WHEEL STATIC BALANCE ADJUSTMENT
NOTE:
: After replacing the fire and/or rim, the wheel
static balance should be adjusted.
: Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
: Balancing weight 1
2. Set:
: Wheel
(on a suitable stand)
3. Find:
: Heavy spot
***************************************
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X1” mark is 90_
up.
d. Release the wheel and wait for it to rest.
Put an “X2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d. several times
until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
***************************************
6-6
FRONT WHEEL AND BRAKE DISC
CHAS
4. Adjust:
: Wheel static balance
***************************************
Adjusting steps:
: Install a balancing weight 1 on the rim exactly
opposite to the heavy spot “X”.
NOTE:
Start with the smallest weight.
: Turn the wheel so that the heavy spot is 90_
up.
: Check that the heavy spot is at rest there. If
not, try another weight until the wheel is balanced.
***************************************
5. Check:
: Wheel static balance
***************************************
Checking steps:
: Turn the wheel so that it comes to each point
as shown.
: Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
***************************************
6-7
FRONT BRAKE
CHAS
FRONT BRAKE
BRAKE PAD
23 Nm (2.3 mkg)
Order
1
2
3
Job name/Part name
Q’ty
Brake pad removal
Bolt (caliper support bolt)
Brake pads
Pad support
Remarks
Remove the parts in order.
1
2
1
Refer to “BRAKE PAD REPLACEMENT”
section.
Reverse the removal procedure for
installation.
6-8
FRONT BRAKE
CHAS
SR702010
BRAKE PAD REPLACEMENT
NOTE:
It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads.
1. Remove:
Bolt (caliper support bolt) 1
Move the direction brake caliper 2 to the arrow mark.
2. Remove:
Brake pads 1
NOTE:
Install new brake pad springs 2 when the
brake pads have to be replaced.
Replace the brake pads as a set if either is
found to be worn to the wear limit.
3. Push the caliper piston into the brake caliper
by finger.
CAUTION:
When pushing the caliper piston into the
brake caliper, brake fluid level in reservoir
tank is increasing higher.
4. Install:
Brake pad 1
Install the brake pad, and move the brake
caliper to the allow mark direction.
5. Install:
Bolt (caliper support bolt)
23 Nm (2.3 mkg)
6. Inspect:
Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPECTION” section in CHAPTER 3.
7. Check:
Brake lever operation
Soft spongy feeling Bleed the brake system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
6-9
FRONT BRAKE
CHAS
MASTER CYLINDER
2 Nm (0.2 mkg)
9 Nm (0.9 mkg)
30 Nm (3.0 mkg)
Order
1
2
3
4
5
6
7
8
Job name/Part name
Master cylinder removal
Drain the brake fluid
Rear view mirror (right)
Brake lever/compression spring
Brake switch
Union bolt
Plate washer
Brake hose
Bracket (master cylinder)
Master cylinder
Q’ty
Remarks
Remove the parts in order.
1
1/1
1
1
2
1
1
1
Refer to “MASTER CYLINDER
INSTALLATION” section.
Reverse the removal procedure for
installation.
6-10
FRONT BRAKE
Order
1
2
3
4
Job name/Part name
Q’ty
CHAS
Remarks
Disassemble the parts in order.
Master cylinder disassembly
Rubber boots
Circlip
Master cylinder kit
Spring
1
1
1
Refer to “MASTER CYLINDER
ASSEMBLY” section.
Reverse the disassembly procedure for
reassembly.
6-11
FRONT BRAKE
CHAS
YP702040
MASTER CYLINDER INSPECTION
1. Inspect:
Master cylinder piston 1
Wear/scratches Replace the master cylinder kit.
Master cylinder cup 2
Cracks/damage Replace.
2. Inspect:
Master cylinder
Scratches/wear/damage Replace the
master cylinder assembly.
3. Inspect:
Diaphragm
Wear/damage Replace.
YP******
MASTER CYLINDER ASSEMBLY
WARNING
All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid:
DOT #4 or DOT #3
Replace the piston seals and dust seals
whenever a master cylinder is disassembled.
1. Install:
Spring 1
Install the spring with its smaller diameter to
the master cylinder piston.
Master cylinder kit 2
6-12
FRONT BRAKE
CHAS
2. Install:
Circlip 1 New
Install the circlip securely into the master cylinder groove.
Rubber boot 2
YP******
MASTER CYLINDER INSTALLATION
1. Install:
Master cylinder 1
Master cylinder bracket 2
9 Nm (0.9 mkg)
CAUTION:
Install the master cylinder bracket 2 with
the “UP” mark facing upward.
2. Install:
Plain washer 1 New
Brake hose 2
Plain washer 3 New
Union bolt 4
A
30 Nm (3.0 mkg)
NOTE:
Install the brake hose as shown.
3. Fill:
Reservoir tank
Recommended brake fluid:
DOT #4 or DOT #3
CAUTION:
Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled brake
fluid immediately.
6-13
FRONT BRAKE
CHAS
WARNING
Use only designated quality brake fluid:
Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
Refill with the same type of brake fluid:mixing fluids may result in a harmful chemical
reaction and lead to poor performance.
Be careful that water does not enter the significantly lower the boiling point of the
fluid may result in vapor lock.
4. Air bleed:
Brake system
Refer to “AIR BLEEDING” section in CHAPTER 3.
5. Inspect:
Brake fluid level
Brake fluid level is under the “LOWER” level
line Fill up.
Refer to “BRAKE FLUID INSPECTION”
section in CHAPTER 3.
6-14
FRONT BRAKE
CHAS
CALIPER
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)
Order
1
2
3
4
5
6
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Caliper removal
Drain teh brake fluid
Brake hose holder
Union bolt
Plain washer
Brake hose
Caliper support bolt
Caliper assembly
1
1
1
1
1
1
Refer to “CALIPER INSTALLATION”
section.
Reverse the removal procedure for
installation
6-15
FRONT BRAKE
CHAS
6 Nm (0.6 mkg)
Order
1
2
3
4
Job name/Part name
Q’ty
Remarks
Disassemble the parts i order.
Refer to “BRAKE PAD” section.
Caliper disassembly
Brake pad
Caliper piston
Dust seal
Piston seal
Bleed screw/Cap
2
2
2
1
Refer to “BRAKE CALIPER
DISASSEMBLY/ASSEMBLY” section.
Reverse the disassembly procedure for
reassembly.
6-16
FRONT BRAKE
CHAS
SR******
BRAKE CALIPER DISASSEMBLY
NOTE:
Before disassembling either brake caliper,
drain the brake fluid from the brake hose, master cylinder, brake caliper and reservoir tank.
1. Remove:
Brake caliper pistons
Caliper piston seals/dust seals
***************************************
Removal steps:
Use a piece of wood 1 to secure the smaller
side caliper pistons.
To force out the bigger side caliper pistons
from the brake caliper body blow compressed
air into the hose joint opening a .
Remove the caliper piston seals and reinstall
the bigger side caliper pistons.
Repeat the previous steps to force out the
smaller side caliper pistons from the brake caliper body.
WARNING
Never try to pry out the caliper piston.
***************************************
YP******
CALIPER INSPECTION
1. Inspect:
Caliper cylinder 1
Caliper piston 2
Scratches, wear Replace caliper assembly.
EB702050
BRAKE CALIPER ASSEMBLY
WARNING
All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid:
DOT #4 or DOT #3
Replace the caliper piston seals whenever
a brake caliper is disassembled.
6-17
FRONT BRAKE
CHAS
1. Install:
Piston seals 1 New
Dust seal 2 New
WARNING
Always use new caliper piston seals.
2. Install:
Caliper piston 1
Apply brake fluid to the outer surface and
install.
YP******
CALIPER INSTALLATION
1. Install:
Caliper 1
Caliper support bolt 2
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)
Brake hose 3
Plain washer 4 New
Union bolt 5
30 Nm (3.0 mkg)
CAUTION:
When installing the brake hose to the caliper, lightly touch the brake hose with the
stopper a on the caliper.
2. Fill:
Reservoir tank
Recommended brake fluid:
DOT #4 or DOT #3
CAUTION:
Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled brake
fluid immediately.
6-18
FRONT BRAKE
CHAS
WARNING
Use only the designated quality brake
fluid: other brake fluids may deteriorate the
rubber seals, causing leakage and poor
brake performance.
Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful
chemical reaction and lead to poor brake
performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3. Air bleed:
Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
4. Inspect:
Brake fluid level
Brake fluid level is under the “LOWER” level
line Fill up.
Refer to “BRAKE FLUID LEVEL INSPECTION” in CHAPTER 3.
6-19
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN
CHAS
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN
REAR WHEEL AND REAR BRAKE
40 Nm (4.0 mkg)
65 Nm (6.5 mkg)
20 Nm (2.0 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
1
2
3
4
5
6
Rear wheel and rear brake removal
Adjuster
Brake rod
Pin
Compression spring
Cotter pin
Tension bar
1
1
1
1
1
1
7
8
9
10
11
Chain case
Axle nut
Chain puller
Wheel axle
Collar
1
1
2
1
1
6-20
NOTE:
Bend the end after installing.
REAR WHEEL REAR BRAKE AND DRIVE CHAIN
CHAS
40 Nm (4.0 mkg)
65 Nm (6.5 mkg)
20 Nm (2.0 mkg)
Order
12
13
14
15
16
17
18
Job name/Part name
Q’ty
1
1
1
4
1
1
1
Rear wheel assembly
Collar
Shoe plate
Nut (driven sprocket)
Circlip
Washer
Driven sprocket
Remarks
Refer to “REAR WHEEL ASSEMBLY”
section.
Reverse the removal procedure for
installation.
6-21
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN
Order
1
2
3
4
5
Job name/Part name
Q’ty
CHAS
Remarks
Disassemble the parts in order.
Rear wheel disassembly
Bearing
Collar
Spacer
Oil seal
Bearing
1
1
1
1
1
Refer to “REAR WHEEL
DISASSEMBLY/ASSEMBLY” section.
Reverse the disassembly procedure for
reassembly.
6-22
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN
CHAS
9 Nm (0.9 mkg)
Order
1
2
3
4
5
Job name/Part name
Q’ty
Remarks
Disassemble the parts in order.
Brake shoe plate disassembly
Brake shoe kit
Tension springs
Cam lever
Indicator plate
Camshaft
2
2
1
1
1
Refer to “BRAKE SHOE PLATE
ASSEMBLY” section.
Reverse the disassembly procedure for
reassembly.
6-23
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN
CHAS
DRIVE CHAIN
65 Nm (6.5 mkg)
10 Nm (1.0 mkg)
7 Nm (0.7 mkg)
8 Nm (0.8 mkg)
Order
Job name/Part name
Q’ty
Drive chain removal
Chain case
1
Axle nut
1
2
3
4
5
6
7
8
9
Shift pedal
Sprocket cover
Sprocket holder
Clip
Plate
Chain joint
Drive chain
Drive sprocket
1
1
1
1
1
1
1
1
Remarks
Remove the parts in order.
Refer to “REAR WHEEL, REAR BRAKE
AND DRIVE CHAIN” section.
NOTE:
Loosen the axle nut and slacken the
drive chain.
Refer to “DRIVE CHAIN INSTALLATION”
section.
Reverse the removal procedure for
installation.
6-24
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN
CHAS
T******
REAR WHEEL DISASSEMBLY
1. Remove:
Bearings 1
Spacer 2
Collar 3
Refer to “FRONT WHEEL”.
SR701020
REAR WHEEL INSPECTION
1. Inspect:
Rear wheel axle
Rear wheel
Rear wheel bearings
Oil seals
Refer to “FRONT WHEEL”.
2. Inspect:
Clutch hub damper
Wear/damage Replace.
SR701021
REAR BRAKE INSPECTION
1. Inspect:
Brake lining surface
Wear/damage Replace.
2. Measure:
Brake lining thickness a
Out of specification Replace.
Brake lining thickness:
Standard:
4 mm
Limit:
2 mm
WARNING
When inspecting the brake lining, do not
spill oil or grease on the brake lining.
3. Inspect:
Brake drum inner surface
Oil
Scratches
Wear/damage Replace.
4. Measure:
Brake drum inside diameter a
Out of specification Replace.
Brake drum inside diameter:
Standard:
110 mm
Limit:
111 mm
6-25
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN
CHAS
5. Inspect:
Cam shaft face
T701020
DRIVE CHAIN INSPECTION
1. Inspect:
Drive chain stiffness
Stiffness Clean and lubricate or replace.
2. Inspect:
Drive chain 1
Driven sprocket 2
More than 1/2 tooth a wear Replace the
drive chain.
Use new driven sprocket.
3. Measure:
10 link length a (drive chain)
Out of specification Replace the drive
chain.
10 link length limit:
122 mm
NOTE:
Tighten the drive chain with a finger before
measuring.
10 link length is the distance between the
inside edge of roller 1 and 11 as shown.
10 link length measurement should be done at
two or three different places.
6-26
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN
CHAS
4. Clean:
Drive chain
Put it in kerosene, and brush off as much dirt
as possible. Then remove the drive chain
from the kerosene and dry it.
Drive chain lubricant:
Engine oil
SR******
BRAKE SHOE PLATE ASSEMBLY
1. Install:
Camshaft 1
Indicator plate 2
***************************************
Installation steps:
Align the projection a on the indicator plate
with the camshaft notch b and install.
Check the proper position of the brake shoe.
***************************************
2. Install:
Cam lever 1
9 Nm (0.9 mkg)
NOTE:
Align the punch mark c on the cam shaft with
the mark made on the cam lever d .
Apply lithium soap base grease onto the brake
cam shaft and pin.
3. Install:
Brake shoes 1
Tension springs 2 New
NOTE:
When installing the springs and brake shoes,
take care not to damage the springs.
Replace the tension spring as a set when replace the brake shoes.
WARNING
After installing the rear brake cam shaft, remove the excess grease.
6-27
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN
CHAS
SR******
REAR WHEEL ASSEMBLY
1. Install:
Bearing 1
Spacer 2
Collar 3
Bearing 4
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Use a socket that matches the outside diameter of the race of the bearing.
Always use a new oil seal.
Install the oil seal with its manufacturer’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of balls of the
bearing. Contact should be made only with
the outer race.
2. Install:
Driven sprocket 1
Washer 2
Circlip 3 New
Nut 4
40 Nm (4.0 mkg)
T*****
DRIVE CHAIN INSTALLATION
1. Install:
Drive chain 1
Chain joint 2
Plate 3
2. Install:
Clip 1 New
CAUTION:
Be sure to install the chain joint clip to the
direction as shown.
6-28
FRONT FORK
CHAS
FRONT FORK
48 Nm (4.8 mkg)
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in order.
Refer to “FRONT WHEEL AND BRAKE
DISC” section.
Front fork removal
Front wheel
1
2
3
4
5
6
Brake hose holder
Caliper
Front fender
Cover
Bolt/washer
Bolt (under bracket)
7
8
Front fork assembly (left)
Front fork assembly (right)
Remarks
1
1
1
1
1/1
1
1
1
Refer to “FRONT FORK INSTALLATION”
section.
NOTE:
Loosen the bolt.
Reverse the removal procedure for
installation.
6-29
FRONT FORK
CHAS
65 Nm (86.5 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Front fork disassembly
Cap bolt/O-ring
Collar/washer
Fork spring
Dust cover
Retaining clip
Washer (oil seal)
Inner tube assembly
Oil seal
Piston metal
Damper rod
Outer tube
Q’ty
Remarks
Disassemble the parts in order.
1/1
1/1
1
1
1
1
1
1
1
1
1
NOTE:
Drain the fork oil.
Refer to “FRONT FORK
DISASSEMBLY/ASSEMBLY” section.
Refer to “FRONT FORK ASSEMBLY”
section.
Reverse the disassembly procedure for
assembly.
6-30
FRONT FORK
CHAS
SR******
FRONT FORK DISASSEMBLY
1. Remove:
Cap bolt 1
Collar 2
Washer 3
Fork spring 4
2. Remove:
Dust cover 1
Retaining clip 2
(using a slotted-head screwdriver)
Washer (oil seal) 3
CAUTION:
Take care not to scratch the inner tube.
3. Remove:
Inner tube
***************************************
Removal steps:
Hold the fork leg horizontally.
Securely clamp the outer tube in a vise with
soft jaws.
Separate the inner tube from the outer tube by
pulling forcefully but carefully the inner tube.
CAUTION:
Excessive force will damage the oil seal
and/or the metal. damaged oil seal and metal must be replaced.
***************************************
YP703030
FRONT FORK INSPECTION
1. Inspect:
Inner tube bending
Inner tube bending limit:
0.2 mm
Scratches/bends/damage Replace.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken the
tube.
6-31
FRONT FORK
CHAS
2. Measure:
Fork spring a
Front fork spring free length:
326.1 mm
<Wear limit>
321 mm
Over the specified limit Replace.
3. Inspect:
Rod assembly 1
Bends/damage Replace.
CAUTION:
The front fork has a built-in piston rod and
a very sophisticated internal construction
which are particularly sensitive to foreign
material.
When disassembling and assembling the
front fork do not allow any foreign material
to enter the oil.
SR******
FRONT FORK ASSEMBLY
Reverse the “DISASSEMBLY” procedure.
Note the following points.
NOTE:
When assembling the front fork be sure to replace the following parts.
* Piston metal
* Slide metal
* Oil seal
* Dust seal
Before assembling the fork, make sure that all
of the components are clean.
1. Install:
Damper rod 1
Inner tube 2
NOTE:
Install the damper rod into the inner tube before
install to the outer tube.
6-32
FRONT FORK
CHAS
2. Install:
Piston metal 1 New
Oil seal 2 New
Use the fork seal driver weight 3 and the attachment 4 .
NOTE:
Before installing the oil seal 2 , apply lithium
soap base grease onto the oil seal lips.
CAUTION:
Make sure that the oil seal numbered side
faces upward.
Fork seal driver weight:
90890-01400
Attachment:
90890-01367
3. Install:
Washer (oil seal) 1
Retaining clip 2 New
Dust seal 3
NOTE:
Adjust the retaining clip so that it fits into the outer tube groove.
4. Inspect:
Inner tube operation
Unsmooth operation Disassembly and recheck.
5. Fill:
Fork oil 1
Oil quantity:
0.177 L
Recommended oil:
Fork oil 15WT or equivalent
6. After filling up, slowly pump the fork up and
down to distribute the fork oil.
6-33
FRONT FORK
CHAS
7. Measure:
Oil level a
Out of specification Adjust.
Oil level:
165 mm
(from the top of the inner tube
fully compressed and without
the fork spring)
NOTE:
Hold the fork in an upright position.
8. Install:
Front fork spring 1
NOTE:
Install the fork spring with its smaller pitch upward.
Before installing the cap bolt, apply grease to
the O-ring.
Temporarily tighten the cap bolt.
9. Install:
Plate washer
Spacer
O-ring New
Cap bolt
65 Nm (6.5 mkg)
EB70307250
FRONT FORK INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points.
1. Install:
Front fork 1
Plate washer 2
Temporary tighten the pinch bolts.
NOTE:
Pull up the inner tube until its end flushes the top
of the under bracket, then temporarily tighten
the bolt (under bracket lower).
2. Tighten:
48 Nm (4.8 mkg)
Cap bolts 3
Pinch bolts (under bracket)
30 Nm (3.0 mkg)
6-34
HANDLEBAR
CHAS
HANDLEBAR
9 Nm (0.9 mkg)
20 Nm (2.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Q’ty
Handlebar removal
Headlight assembly
Handlebar switch lead (left and right),
front brake switch lead and clutch
switch lead
Master cylinder bracket
Master cylinder
Housing (throttle grip)
Throttle cable
Throttle grip assembly
Handle bar switch (right)
Clutch switch
Clutch cable
6-35
Remarks
Remove the parts in order.
1
1
1
1
1
1
1
1
1
1
NOTE:
Disconnect the connector.
Refer to “HANDLEBAR INSTALLATION”
section.
HANDLEBAR
CHAS
9 Nm (0.9 mkg)
20 Nm (2.0 mkg)
Order
Job name/Part name
Q’ty
11
12
Handlebar switch (left)
Grip (left)
1
1
13
14
15
Lever holder (left)
Upper holder
Handlebar
1
2
1
6-36
Remarks
Refer to “HANDLEBAR REMOVAL”
section.
Refer to “HANDLEBAR INSTALLATION”
section.
Reverse the removal procedure for
installation.
HANDLEBAR
CHAS
YP******
HANDLEBAR REMOVAL
1. Remove:
Grip (Left)
***************************************
Removal steps:
Remove the grip end (left).
Blow with compressed air between the hadlebar and adhesive side of the grip to remove.
***************************************
YP704020
HANDLEBAR INSPECTION
1. Inspect:
Handlebar
Bends/Cracks/Damage Replace.
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken the
handlebar.
SR******
HANDLEBAR INSTALLATION
1. Install:
Handlebar 1
Upper handlebar holder 2
20 Nm (2.0 mkg)
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 a to the forward,
then tighten the front bolt as shown.
2. Install:
Handlebar switch (right) 1
Grip assembly
Throttle cable
Cover (throttle grip)
NOTE:
Align the projection a on the handlebar switch
with the hole b in the handlebar.
WARNING
Check the throttle grip for smooth operation.
6-37
HANDLEBAR
CHAS
3. Install:
Master cylinder 1
Master cylinder bracket 2
9 Nm (0.9 mkg)
NOTE:
Install the master cylinder bracket with the “UP”
mark facing upward.
4. Adjust:
Throttle cable free play
Brake operation.
Refer to “THROTTLE CABLE ADJUSTMENT/BRAKE LEVER ADJUSTMENT”
section in CHAPTER 3.
6-38
STEERING
CHAS
STEERING
UNDER BRACKET
40 Nm (4.0 mkg)
1st step:
38 Nm (3.8 mkg)
2nd step:
7 Nm (0.7 mkg)
Order
Job name/Part name
1
2
3
4
5
6
7
Under bracket removal
Front fork
Handlebar
Flasher light assembly (left)
Flasher light assembly (right)
Cover
Meter cable/Meter lead
Meter assembly/Handlebar crown
Horn
Ring nut
8
9
Ball race cover
Under bracket
Q’ty
Remarks
Remove the parts in order.
Refer to “FRONT FORK” section.
Refer to “HANDLEBAR” section.
1
1
1
1/1
1/1
1
1
1
1
6-39
NOTE:
Disconnect the connector.
Refer to “STEERING
REMOVAL/INSTALLATION” section.
STEERING
CHAS
40 Nm (4.0 mkg)
1st step:
38 Nm (3.8 mkg)2nd
step:
7 Nm (0.7 mkg)
Order
10
11
12
13
14
Job name/Part name
Q’ty
1
22
19
1
1
Ball race (upper)
Ball
Ball
Ball race (center)
Ball race (lower)
Remarks
Refer to “STEERING REMOVAL/
INSTALLATION” section.
Reverse the removal procedure for
installation.
6-40
STEERING
CHAS
YP704010
STEERING REMOVAL
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
Stand the motorcycle on a level surface.
1. Remove:
Ring nut 1
Use a exhaust and steering nut wrench 2 .
Exhaust and steering out wrench:
90890-01268
WARNING
Securely support the steering shaft so that
there is no danger of it falling down.
STEERING INSPECTION
1. Wash the bearing and ball races with a solvent.
2. Inspect:
Bearings
Ball races
Pitting/Damage Replace.
***************************************
Bearing race replacement steps:
Remove the ball races on the head pipe using
long rod 1 and the hammer as shown.
Remove the ball race on the under bracket using the floor chisel 2 and the hammer as
shown.
Install the new dust seat and races.
***************************************
NOTE:
Always replace bearings and races as a set.
Replace the dust seal whenever a steering
head disassembled.
CAUTION:
If the bearing race is not fitted squarely, the
head pipe could be damaged.
6-41
STEERING
CHAS
EB704030
STEERING INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points.
1. Lubricate:
Bearings (upper and lower)
Ball races
Recommended lubricant
Lithium-soap base grease
2. Install:
7 Nm (0.7 mkg)
Ring nut 1
Refer to “STEERING HEAD INSPECTION”
section in CHAPTER 3.
6-42
REAR SHOCK ABSORBER AND SWINGARM
CHAS
REAR SHOCK ABSORBER AND SWINGARM
40 Nm (4.0 mkg)
45 Nm (4.5 mkg)
20 Nm (2.0 mkg)
30 Nm (3.0 mkg)
Order
Job name/Part name
Q’ty
1
2
3
4
5
6
7
8
9
Rear shock absorber and swingarm
removal
Rear wheel
Chain case
Drive chain
Rear shock absorber
Nut
Footrest assembly (right)
Pivot shaft
Footrest assembly (left)
Swingarm
Tension bar
Cover (swingarm)
Bush
Remarks
Remove the parts in order.
Refer to “REAR WHEEL, REAR BRAKE
AND DRIVE CHAIN” section.
2
1
1
1
1
1
1
1
2
Reverse the removal procedure for
installation.
6-43
REAR SHOCK ABSORBER AND SWINGARM
CHAS
T*****
SWINGARM INSPECTION
1. Inspect:
Swingarm side play
Free play exists Check side clearance.
Swingarm up and down movement
Unsmooth movement/bending/rough spots
Grease or replace bearings, solid bushes
and collars.
6-44
CHAPTER 7.
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH CONNECTION AS SHOWN IN THIS MANUAL . . . . . . . . .
SWITCH CONTINUITY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
7-2
7-2
7-3
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10
7-10
7-11
7-12
7-16
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-23
7-23
7-24
7-25
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-28
7-28
7-29
7-31
ELECTRICAL COMPONENTS
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
Horn
Flasher relay
Main switch
Starter relay
Rectifier/ Regulator
Battery
Fuse holder assembly
8
9
10
11
12
13
14
Neutral relay
Thermo switch
Sidestand switch
Rear brake switch
Neutral switch
Spark plug cap
Ignition coil
7-1
15 C.D.I. unit
ELEC
SWITCH INSPECTION
ELEC
YP-N
SWITCH INSPECTION
INSPECTION STEPS
Using pocket tester, check switches for continuity between their terminals to determine whether they are correctly connected.
Replace the switch component if any of the
combinations does not produce the correct
reading.
Pocket tester:
90890-03112
NOTE:
Turn the switch to the “ON”, “OFF” positions
several times.
Adjust the pocket tester to correct “0” position
before checking switches.
Set the pocket tester selector to “1” Ω.
SWITCH CONNECTION AS SHOWN IN THIS
MANUAL
This manual contains connection charts, like
the one shown on the left, showing the terminal
connections of switches (e.g. the main switch,
handlebar switch, brake switch, lighting switch
etc.)
The column on the extreme left indicates the different switch positions, the top line indicates the
colors of the leads connected to the terminals
on the switch.
“—” indicates terminals between which
there is continuity, i.e. a closed circuit, in the given switch position.
In this chart:
“Br and R” have continuity with the switch in the
“ON” position.
7-2
SWITCH INSPECTION
ELEC
SWITCH CONTINUITY INSPECTION
Refer to “SWITCH INSPECTION” and check for continuity between lead terminals.
Poor connection, no continuity Correct or replace.
* The coupler locations are circled.
1
2
3
4
5
6
Clutch switch
Turn switch
Dimmer switch
Horn switch
Main switch
Front brake switch
7
8
9
10
11
12
Engine stop switch
Start switch
Rear brake switch
Neutral switch
Sidestand switch
Fuse
7-3
13 Thermo switch
IGNITION SYSTEM
EB802000
IGNITION SYSTEM
CIRCUIT DIAGRAM
1
6
10
12
13
14
15
C.D.I. magneto
Main switch
Engine stop switch
C.D.I. unit
Ignition coil
Spark plug
Sidestand switch
7-4
ELEC
IGNITION SYSTEM
ELEC
SR802010
TROUBLESHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE.
(NO SPARK OR INTERMITTENT SPARK)
Procedure
Check:
1. Spark plug
2. Ignition spark gap
3. Spark plug cap resistance
4. Ignition coil
5. Pickup coil resistance
6.
7.
8.
9.
10.
NOTE:
Remove the following parts before troubleshooting.
1) Side cover (left and right)
2) Seat
3) Fuel tank
4) Headlight unit
Source coil resistance
Main switch
Engine stop switch
Sidestand switch
Wiring connection
(entire ignition system)
Use the special tools specified in the trouble
shooting section.
Ignition checker:
90890-06754
Pocket tester:
90890-03112
YP*****
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.
Standard spark plug:
DR8EA/NGK
OUT OF SPECIFICATION
Spark plug gap:
0.6 0.7 mm
Repair or replace the spark plug
MEETS
SPECIFICATION
7-5
IGNITION SYSTEM
ELEC
:
YP*****
2. Ignition spark gap
S Disconnect the spark plug cap from the
spark plug.
S Connect the ignition checker 1 as shown.
2 Spark plug cap
S Turn the main switch to “ON”.
S Check the ignition spark gap a .
S Check the spark by pushing the starter
switch, and increase the spark gap until a
misfire occurs.
MEETS SPECIFICATION
Minimum spark gap:
6 mm
The ignition system is not faulty.
OUT OF SPECIFICATION OR NO SPARK
YP*****
Tester (+) lead Spark plug side 1
Tester (–) lead High tension cord side 2
3. Spark plug cap resistance
S Remove the spark plug cap.
S Connect the pocket tester (Ω 1k) to the
spark plug cap.
NOTE:
S When removing the spark plug cap, do not
pull the spark plug cap from high tension
cord.
Remove Turning counterclockwise.
Connect Turning clockwise.
S Check the high tension cord when connecting the spark plug cap.
S When connecting the spark plug cap, cut the
high tension cord about 5 mm.
OUT OF SPECIFICATION
Spark plug cap resistance:
10 kΩ (20_C)
Replace the spark plug cap.
MEETS
SPECIFICATION
:
7-6
IGNITION SYSTEM
:
YP*****
Tester (+) lead Orange Terminal 1
Tester (–) lead Ground Terminal 2
4. Ignition coil resistance
S Disconnect the ignition coil connector from
the wireharness.
S Connect the pocket tester (Ω
1) to the
ignition coil.
S Check if the primary coil has the specified resistance.
Primary coil resistance:
0.32 X 0.48 Ω (20_C)
Tester (+) lead Spark plug lead 1
Tester (–) lead Orange Terminal 2
S Connect the pocket tester (Ω
1k) to the
ignition coil.
S Check the secondary has the specified resistance.
OUT OF SPECIFICATION
Secondary coil resistance:
5.68 X 8.52 kΩ (20_C)
Replace the ignition coil.
BOTH MEET
SPECIFICATION
:
7-7
ELEC
IGNITION SYSTEM
:
YP******
5. Pickup coil resistance
S Disconnect the pickup coil coupler from the
wireharness.
S Connect the pocket tester (Ω
100) to the
pickup coil coupler.
Tester (+) lead White Terminal 1
Tester (–) lead Red Terminal 2
S Check the pickup coil has the specified resistance.
OUT OF SPECIFICATION
Pickup coil resistance:
659 X 984 Ω (20_C)
Replace the pickup coil.
MEETS
SPECIFICATION
T******
6. Source coil resistance
S Disconnect the source coil coupler from the
wireharness.
S Connect the pocket tester (Ω
100) to the
charging coil coupler.
Tester (+) lead Brown Terminal 1
Tester (–) lead Green Terminal 2
S Check the source coil has the specified resistance.
OUT OF SPECIFICATION
Source coil resistance:
624 X 936 Ω (20_C)
Replace the source coil.
MEETS
SPECIFICATION
YP*****
NO CONTINUITY
7. Main switch
Refer to “SWITCH INSPECTION” section.
Replace the main switch.
CONTINUITY
:
7-8
ELEC
IGNITION SYSTEM
ELEC
:
YP*****
NO CONTINUITY
8. Engine stop switch
Refer to “SWITCH INSPECTION” section.
Replace the handlebar switch (right).
CONTINUITY
YP*****
NO CONTINUITY
9. Sidestand switch
Refer to “SWITCH INSPECTION” section.
Replace the sidestand switch
CONTINUITY
YP*****
10.Wiring connection
S Check the connection of the entire ignition
system.
Refer to “CIRCUIT DIAGRAM”.
POOR CONNECTIONS
Correct.
CORRECT
Replace the C.D.I. unit.
7-9
ELECTRIC STARTING SYSTEM
EB80300
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
3
4
5
6
10
11
15
16
17
24
38
Starter relay
Battery
Fuse
Main switch
Engine stop switch
Start switch
Clutch switch
Sidestand switch
Neutral relay
Neutral switch
Starter motor
7-10
ELEC
ELECTRICAL STARTING SYSTEM
ELEC
SR******
STARTING CIRCUIT OPERATION
The starting circuit on this model consists of the
starter motor, starter relay, and the neutral relay.
If the engine stop switch and the main switch
are both closed, the starter motor can operate
only if:
The transmission is in neutral (the neutral
relay is closed).
or if
The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED
IN
Battery
Main fuse
Main switch
Engine stop switch
Neutral relay
Clutch switch
Sidestand switch
Neutral switch
Start switch
10 Starter relay
11 Starter motor
1
2
3
4
5
6
7
8
9
7-11
ELECTRICAL STARTING SYSTEM
ELEC
YP803020
TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO OPERATE.
Procedure
Check:
1. Fuse
2. Battery
3. Starter motor
4. Starter relay
5. Neutral relay
6. Main switch
7.
8.
9.
10.
11.
12.
NOTE:
Remove the following parts before troubleshooting.
1) Side cover (left and right)
2) Headlight unit
3) Seat
4) Fuel tank
Engine stop switch
Neutral switch
Sidestand switch
Clutch switch
Start switch
Wiring connection (entire starting system)
Use the special tools specified in the troubleshooting section.
Pocket tester:
90890-03112
YP******
NO CONTINUITY
1. Fuse
Refer to “SWITCH INSPECTION” section.
Replace the fuse.
CONTINUITY
YP******
2. Battery
Check the battery condition.
Refer to “BATTERY INSPECTION” section
in CHAPTER 3.
INCORRECT
Specific gravity:
1.280 at 20C
Refill the battery fluid.
Clean battery terminals.
Recharge or replace the battery.
CORRECT
7-12
ELECTRICAL STARTING SYSTEM
ELEC
:
YP******
*
3. Starter motor
WARNING
S Connect the battery positive terminal 1
and starter motor cable 2 using a jumper
lead 3 *.
S Check the starter motor operation.
S A wire used as a jumper lead must have the
equivalent capacity as that of the battery
lead or more, otherwise it may burn.
S This check is likely to produce sparks, so
be sure that no flammable gas or fluid is in
the vicinity.
DOES NOT MOVE
Repair or replace the starter motor.
MOVES
YP******
4. Starter relay
S Disconnect the relay unit coupler from the
wireharness.
S Connect the pocket tester (Ω 1) and battery (12 V) to the relay unit coupler terminals.
Battery (+) lead Blue/White terminal 1
Battery (–) lead Red/White terminal 2
S Check the starter relay for continuity.
NO CONTINUITY
Tester (+) lead 3 terminal
Tester (–) lead 4 terminal
Replace the starter relay.
CONTINUITY
:
7-13
ELECTRICAL STARTING SYSTEM
ELEC
:
YP******
5. Neutral relay
S Remove the relay from the frame.
S Connect the pocket tester (Ω 100) to the
Battery and the relay connecter.
Tester (+) lead Terminal 1
Tester (–) lead Terminal 3
Battery (+) lead Terminal 2
Battery (–) lead Terminal 4
1
2
3
NO CONTINUITY
4
Check the Terminal 1 and 3 for continuity.
Replace the neutral relay.
CONTINUITY
YP******
NO CONTINUITY
6. Main switch
Refer to “SWITCH INSPECTION” section.
Replace the main switch
CONTINUITY
YP******
NO CONTINUITY
7. Engine stop switch
Refer to “SWITCH INSPECTION” section.
Replace the handlebar switch (right).
CONTINUITY
YP******
8. Neutral switch
NO CONTINUITY (at NEUTRAL position)
Refer to “SWITCH INSPECTION” section.
CONTINUITY
(at NEUTRAL position)
Replace the neutral switch.
YP******
NO CONTINUITY
9. Sidestand switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
Replace the sidestand switch.
:
7-14
ELECTRICAL STARTING SYSTEM
ELEC
:
YP******
NO CONTINUITY
10.Clutch switch
Refer to “SWITCH INSPECTION” section.
Replace the clutch switch.
CONTINUITY
YP******
NO CONTINUITY
11. Start switch
Refer to “SWITCH INSPECTION” section.
Replace the handlebar switch (right).
CONTINUITY
YP******
12.Wiring connection
S Check the connections of the entire starting
system.
Refer to “CIRCUIT DIAGRAM”.
POOR CONNECTION
Correct.
7-15
ELECTRICAL STARTING SYSTEM
ELEC
STARTER MOTOR
7 Nm (0.7 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in order.
Refer to “ENGINE OIL REPLACEMENT”
section in CHAPTER 3.
Refer to “CLUTCH REMOVAL” section in
CHAPTER 4.
Starter motor removal
Drain the engine oil
Crankcase cover (right)
1
2
3
Remarks
1
1
1
Starter motor lead
Starter motor
O-ring
Reverse the removal procedure for
installation.
1
2
3
4
5
6
Disassemble the parts in order.
Starter motor disassembly
Front bracket
Washer set
Rear bracket
Washer set
Brush holder/brush
Armature coil
1
1
1
1
1
1
Refer to “Assembly” section.
Reverse the disassembly procedure for
assembly.
7-16
ELEC
ELECTRICAL STARTING SYSTEM
YP803034
Inspection and repair
1. Inspect:
Commutator
Dirt Clean it with #600 grit sandpaper.
2. Measure:
Commutator diameter a
Commutator wear limit:
27 mm
Out of specification Replace the starter
motor
3. Measure:
Mica undercut a
Mica undercut:
0.7 mm
Out of specification Scrape the mica to the
proper value (a hacksaw blade can be
ground to fit).
NOTE:
The mica insulation of the commutator must be
undercut to ensure proper operation of commutator.
4. Inspect:
Armature coil resistances
(installation/continuity)
Defects Replace the starter motor.
If commutator is dirty, clean it with sandpaper.
Good
condition
Bad condition
A
B
: Continuity
: No continuity
Bad condition Replace.
5. Measure:
Brush length a
Out of specification Replace.
Brush length wear limit:
3.5 mm
7-17
ELECTRICAL STARTING SYSTEM
ELEC
6. Measure:
Brush spring force
Fatigue/out of specification Replace as a
set.
Brush spring force:
540 X 660 g
7. Inspect:
Oil seal
Wear/damage Replace.
YP******
Assembly
Reverse the “Disassembly” procedure.
Note the following points.
1. Install:
Brush holder 1
NOTE:
Align the lib on the brush holder with the slot a
on the bracket, before assembly.
2. Install:
Washer set 1
Armature coil 2
3. Install:
Ring 1 New
Stator assembly 2
Washer set 3
Front bracket
3 Nm (0.3 mkg)
NOTE:
Apply molybdenum grease lightly on to the
bearings of the starter motor.
Align the match marks on the yoke with the
match marks on the brackets.
7-18
CHARGING SYSTEM
YP804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
1
2
4
5
C.D.I. magneto
Rectifier/ Regulator
Battery
Fuse
7-19
ELEC
CHARGING SYSTEM
ELEC
YP804010
TROUBLESHOOTING
IF THE BATTERY IS NOT CHARGED
Procedure
Check:
1. Fuse
2. Battery
3. Charging voltage
4. Stator coil resistance
5. Wiring system (entire charging system)
NOTE:
Remove the following parts before troubleshooting.
1) Side cover (left and right)
2) Seat
3) Fuse
Use the special tools specified in the troubleshooting section.
Engine tachometer
90890-03113
Pocket tester:
90890-03112
YP******
NO CONTINUITY
1. Fuse
Refer to “SWITCH INSPECTION” section.
CONTINUITY
Replace the fuse.
YP******
2. Battery
Check the battery condition.
Refer to “BATTERY INSPECTION” section
in CHAPTER 3.
INCORRECT
Specific gravity:
1.280 at 20C
Refill the battery fluid.
Clean battery terminals.
Recharge or replace the battery.
CORRECT
7-20
CHARGING SYSTEM
ELEC
:
YP******
3. Charging voltage
S Connect the engine tachometer to the spark
plug lead.
S Connect the pocket tester (DC20V) to the
battery.
Tester (+) lead Battery (+) terminal 1
Tester (–) lead Battery (–) terminal 2
S Measure the battery terminal voltage.
S Start the engine and accelerate to about
5,000 r/min.
S Check the terminal voltage.
Left side
Right side
MEETS SPECIFICATION
Charging voltage:
14.5 V at 5,000 r/min
NOTE:
Use a fully charged battery.
The charging circuit is not faulty.
Replace the battery.
OUT OF
SPECIFICATION
YP******
4. Stator coil resistance
S Remove the C.D.I. magneto coupler from
wireharness.
S Connect the pocket tester (Ω 1) to the stator coil.
Tester (+) lead White terminal
Tester (–) lead White terminal
S Measure the stator coil resistance.
Stator coil resistance:
0.48 X 0.72 Ω (20_C)
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Replace the stator coil.
:
7-21
CHARGING SYSTEM
YP******
5. Wiring connection
Check the entire charging system for connections.
Refer to “CIRCUIT DIAGRAM” section.
POOR CONNECTION
Correct.
CORRECT
Replace the rectifier/regulator.
7-22
ELEC
LIGHTING SYSTEM
EB804000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
4
5
6
22
23
26
30
34
36
39
Battery
Fuse
Main switch
High beam indicator light
Meter light
Tail/ Brake light
Auxiliary light
Lights switch
Dimmer switch
Headlight
7-23
ELEC
LIGHTING SYSTEM
ELEC
YP805010
TROUBLESHOOTING
IF THE HEADLIGHT, AUXILIARY LIGHT, HIGH BEAM INDICATOR LIGHT,
TAILLIGHT AND/OR METER LIGHT FAIL TO COME ON.
Procedure
Check:
1. Fuse
2. Battery
3. Main switch
4. Lights switch
5. Dimmer switch
6. Wiring connection (entire lighting system)
NOTE:
Remove the following parts before troubleshooting.
1) Seat
2) Fuel tank
3) Side cover (left and right)
4) Headlight unit
Use the special tools specified in the troubleshooting section.
Pocket tester:
90890-03112
YP******
NO CONTINUITY
1. Fuse
Refer to “SWITCH INSPECTION” section.
CONTINUITY
Replace the fuse.
YP******
2. Battery
Check the battery condition.
Refer to “BATTERY INSPECTION” section
in CHAPTER 3.
INCORRECT
Specific gravity:
1.280 at 20C
Refill the battery fluid.
Clean battery terminals.
Recharge or replace the battery.
CORRECT
YP******
3. Main switch
NO CONTINUITY
Refer to “SWITCH INSPECTION” section.
CONTINUITY
Replace the main switch.
7-24
LIGHTING SYSTEM
ELEC
:
NO CONTINUITY
YP******
4. Lights switch
Refer to “SWITCH INSPECTION” section.
Replace the handlebar switch (left).
CONTINUITY
YP******
NO CONTINUITY
5. Dimmer switch
Refer to “SWITCH INSPECTION” section.
CONTINUITY
Replace the handlebar switch (left).
YP******
6. Wiring connection
S Check the connections of the entire lighting
system.
Refer to “WIRING DIAGRAM”.
POOR CONNECTIONS
Correct.
CORRECT
Check the condition of each of the lighting
system’s circuits.
Refer to “LIGHTING SYSTEM CHECK”
SR805020
LIGHTING SYSTEM CHECK
1. If the headlight and the high beam indicator light fail to come on.
NO CONTINUITY
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
CONTINUITY
Replace the bulb and/or bulb socket.
2. Voltage
S Connect the pocket tester (DC20V) to the
headlight and high beam indicator light couplers.
A When the dimmer switch is on low beam.
B When dimmer switch is on high beam.
Headlight:
Tester (+) lead Green 1 or Yellow 2
lead
Tester negative (–) lead Black 3 lead
High beam indicator light:
Tester (+) lead Yellow 4 lead
Tester (–) lead Black 5 lead
B
:
7-25
LIGHTING SYSTEM
ELEC
:
S Turn the main switch to on position.
S Turn the lights switch to on position.
S Turn the dimmer switch to low beam or high
beam.
S Check for voltage (12 V) on the lead at bulb
socket connectors.
OUT OF SPECIFICATION
The wiring circuit from the main switch to bulb
socket connector is faulty. Repair.
MEETS
SPECIFICATION
This circuit is not faulty.
SR805021
2. If the meter light fails to come on.
NO CONTINUITY
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
CONTINUITY
Replace the bulb and/or bulb socket.
2. Voltage
S Connect the pocket tester (DC20V) to the
bulb socket coupler.
Tester (+) lead Blue terminal 1
Tester (–) lead Black terminal 2
S Turn the main switch to on.
S Turn the lights switch to on position.
S Turn the dimmer switch to low beam or high
beam.
S Check the voltage (12 V) of the leads on the
bulb socket connector.
OUT OF SPECIFICATION
The wiring circuit from main switch to bulb
socket is faulty. Repair.
MEETS
SPECIFICATION
This circuit is not faulty.
7-26
LIGHTING SYSTEM
ELEC
YP805022
3. The taillight fails to come on.
NO CONTINUITY
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
Replace the bulb and/or bulb socket.
CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to the
bulb socket connector.
Tester (+) lead Blue terminal 1
Tester (–) lead Black terminal 2
Turn the main switch to on position.
Turn the lights switch to on position.
Turn the dimmer switch to low beam or high
beam.
Check the voltage (12 V) on the bulb socket
connector.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
The wiring circuit from main switch to bulb
connector is faulty. Repair.
This circuit is not faulty.
SR******
4. The auxiliary light fails to come on.
NO CONTINUITY
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
Replace the bulb and/or bulb socket.
CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to the
bulb socket connector.
Tester (+) lead Blue/Red terminal 1
Tester (–) lead Black terminal 2
Turn the main switch to on position.
Turn the lights switch to on position.
Turn the dimmer switch to low beam or high
beam.
Check the voltage (12 V) on the bulb socket
connector.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
The wiring circuit from main switch to bulb
connector is faulty. Repair.
This circuit is not faulty.
7-27
SIGNAL SYSTEM
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
4
5
6
7
8
19
20
21
24
25
26
27
Battery
Fuse
Main switch
Thermo switch
Heater unit
Neutral indicator light
Turn indicator light (left)
Turn indicator light (right)
Neutral switch
Rear flasher lights
Tail/ Brake light
Front brake switch
28
29
31
32
35
37
Rear brake switch
Front flasher lights
Flasher relay
Horn
Horn switch
Turn switch
7-28
ELEC
SIGNAL SYSTEM
ELEC
YP806010
TROUBLESHOOTING
IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON.
IF THE HORN FAILS TO SOUND.
Procedure
Check:
1. Fuse
2. Battery
3. Main switch
4. Wiring connection (entire signal system)
NOTE:
S Remove the following parts before troubleshooting.
1) Headlight unit
2) Side cover (left and right)
S Use the special tools in the troubleshooting
section.
Pocket tester:
90890-03112
YP******
NO CONTINUITY
1. Fuse
Refer to “SWITCH INSPECTION” section.
Replace the fuse.
CONTINUITY
YP******
2. Battery
S Check the battery condition.
Refer to “BATTERY INSPECTION” section
in CHAPTER 3.
INCORRECT
Specific gravity:
1.280 at 20_C
S Refill the battery fluid.
S Clean battery terminals.
S Recharge or replace the battery.
CORRECT
YP******
NO CONTINUITY
3. Main switch
Refer to “SWITCH INSPECTION” section.
Replace the main switch.
CONTINUITY
:
7-29
SIGNAL SYSTEM
:
YP******
4. Wireharness
S Check the connections of the entire signal
system.
Refer to “CIRCUIT SYSTEM WIRING DIAGRAM” section.
POOR CONNECTION
Correct.
CORRECT
Check condition of each of the signal system’s circuits.
Refer to “SIGNAL SYSTEM CHECK” section.
7-30
ELEC
SIGNAL SYSTEM
ELEC
YP806020
SIGNAL SYSTEM CHECK
1. If the horn fails to sound.
NO CONTINUITY
1. Horn switch
Refer to “SWITCH INSPECTION” section.
Replace the left handlebar switch (left).
CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to the
horn lead.
Tester (+) lead Brown terminal 1
Tester (–) lead Frame ground
Turn the main switch to on.
Check for voltage (12V) on the “Brown” lead
at the horn terminal.
OUT OF SPECIFICATION
The wiring circuit from the main switch to the
horn is faulty. Repair.
MEETS
SPECIFICATION
3. Horn
Connect the pocket tester (DC20V) to the
horn at the “Pink” terminal.
Tester (+) lead Pink 1 terminal
Tester (–) lead Frame ground
Turn the main switch to on.
Check for voltage (12V) on the “Pink” lead to
frame ground.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Replace the horn.
Adjust or replace horn.
7-31
SIGNAL SYSTEM
ELEC
YP806022
2. If the brake light fails to come on:
NO CONTINUITY
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
Replace the bulb and/or bulb socket.
CONTINUITY
NO CONTINUITY
2. Brake switch (Front/Rear)
Refer to “SWITCH INSPECTION” section.
Replace brake switch.
CONTINUITY
3. Voltage
Connect the pocket tester (DC20V) to the
bulb socket connector.
Tester (+) lead Yellow terminal 1
Tester (–) lead Black terminal 2
Turn the main switch to on.
The brake lever (or brake pedal) is pulled in
(down).
Check for voltage (12V) of the “Yellow” lead
on the bulb socket connector.
OUT OF SPECIFICATION
4. Wiring connection
MEETS
SPECIFICATION
Wiring circuit from the main switch to the bulb
socket connector is faulty. Repair.
Refer to “SIGNAL SYSTEM WIRING DIAGRAM”.
This circuit is not faulty.
7-32
SIGNAL SYSTEM
ELEC
YP806023
3. If the flasher light and/or turn indicator light
fails to blink.
NO CONTINUITY
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
Replace the bulb and/or bulb socket.
CONTINUITY
NO CONTINUITY
2. Turn switch
Refer to “SWITCH INSPECTION” section.
Replace the left handlebar switch (left).
CONTINUITY
3. Voltage
S Connect the pocket tester (DC20V) to the
flasher relay coupler.
Tester (+) lead Brown terminal 1
Tester (–) lead Frame ground
S Turn the main switch to on.
S Check for voltage (12V) of the “Brown” 1
lead at the flasher relay terminal.
OUT OF SPECIFICATION
The wiring circuit from main switch to flasher
relay connector is faulty. Repair.
MEETS
SPECIFICATION
4. Flasher relay
S Connect the pocket tester (DC20V) to the
flasher relay coupler.
Tester (+) lead Brown/White terminal 1
Tester (–) lead Frame ground
S Turn the main switch to on.
S Check for voltage (12V) on the “Brown/
White” lead at the flasher relay terminal.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
The flasher relay is faulty. Replace.
:
7-33
SIGNAL SYSTEM
ELEC
:
5. Voltage
S Connect the pocket tester (DC20V) to the
bulb socket connector.
At flasher light (left)
Tester (+) lead Chocolate lead 1
Tester (–) lead Black terminal 3
At flasher light (right)
Tester (+) lead Dark green lead 2
Tester (–) lead Black terminal 3
S Turn the main switch to on.
S Turn the turn switch to left or right.
S Check for voltage (12V) on the “Chocolate”
lead and “Dark green” at the flasher light terminal.
OUT OF SPECIFICATION
Wiring connection
Wiring circuit from the turn switch to bulb
socket connector is fault. Repair.
Refer to “CIRCUIT DIAGRAM”.
MEETS
SPECIFICATION
This circuit is not faulty.
SR806027
4. If the neutral indicator lights fails to operate.
NO CONTINUITY
1. Bulb and bulb socket
Refer to “SWITCH INSPECTION” section.
Replace the bulb and/or bulb socket.
CONTINUITY
2. Neutral switch
NO CONTINUITY
Refer to “SWITCH INSPECTION” section.
CONTINUITY
Replace the left neutral switch.
:
7-34
SIGNAL SYSTEM
ELEC
:
3. Voltage
S Connect the pocket tester (DC20V) to the
fuel gauge coupler.
Tester (+) lead Brown terminal 1
Tester (–) lead Sky blue terminal 2
S Turn the main switch to on position.
S Select the gear position in neutral.
S Check for voltage (12V) of the “Sky blue”
lead on the neutral switch.
OUT OF SPECIFICATION
Check the connection of the entire signal system.
Refer to “CIRCUIT DIAGRAM”.
MEETS
SPECIFICATION
This circuit is not faulty.
SR******
5. If the carburetor heater fails to operate.
1. Thermo switch
S Disconnect the thermo switch connector
from the wireharness.
S Connect the pocket tester (Ω 1) to the
thermo switch lead.
Tester (+) lead Black terminal 1
Tester (–) lead Black terminal 2
S Check the Terminal 1 and 3 for continuity.
OUT OF SPECIFICATION
A COOL DOWN
B HEAT UP
MEETS
SPECIFICATION
Replace the thermo switch.
:
7-35
SIGNAL SYSTEM
:
2. Heater unit resistance
S Remove the heater unit from the carburetor.
S Connect the pocket tester (Ω
1) to the
heater unit.
Tester (+) lead Terminal 1
Tester (–) lead Terminal 2
S Check the heater unit for specificated resistance.
Heater unit resistance:
6 X 10 Ω (20_C)
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Replace the heater unit.
3. Wiring connection
S Check the connections of the entire signal
system.
Refer to “WIRING DIAGRAM”.
7-36
ELEC
CHAPTER 8.
TROUBLE SHOOTING
STARTING FAILURE/HARD STARING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE . . . . . . . . . . . . . 8-3
POOR SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
OVER HEATING OR OVER-COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
FRONT FORK MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
STARTER MOTOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . 8-7
FAULTY SIGNAL AND LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8-8
STARTING FAILURE/HARD STARTING
TRBL
SHTG
EB90000
TROUBLESHOOTING
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 relative procedure in this manual for inspection,
adjustment and replacement of parts.
SR90000
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
Fuel tank
Empty
Clogged fuel tank cap breather hole
Deteriorated fuel or fuel containing water or
foreign material
Fuel cock
Clogged fuel hose
Clogged fuel cock
Carburetor
Deteriorated fuel or fuel containing water or
foreign material
Clogged pilot jet
Clogged air passage
Improperly set pilot screw
Clogged pilot air passage
Improperly sealed valve seat
Improperly adjusted fuel level
Clogged starter jet
Damaged carburetor joint
Improperly tightened carburetor joint clamp
hose
Starter plunger malfunction
Clogged emulsion (heated water) tube
Sucked-in air
Air filter
Clogged air filter element
Improper air filter setting
COMPRESSION SYSTEM
Cylinder and cylinder head
Loose spark plug
Loose cylinder head
Broken cylinder head gasket
Broken cylinder gasket
Worn, damaged or seized cylinder
Piston and piston ring
Worn piston
Worn, fatigued or broken piston ring
Seized piston ring
Seized or damaged piston
Valve system
Improperly adjusted valve clearance
Improperly sealed valve
Improperly contacted valve and valve seat
Improper valve timing
Broken valve spring
Seized valve
8-1
POOR IDLE SPEED PERFORMANCE
IGNITION SYSTEM
Battery
Improperly charged battery
Faulty battery
Fuse
Burnt out, improper connection
Spark plug
Improper plug gap
Worn electrodes
Wire between terminals broken
Improper heat range
Faulty spark plug cap
Ignition coil
Broken or shorted primary/secondary coil
Faulty high tension cord
Broken ignition coil body
TRBL
SHTG
Ignition system
Faulty C.D.I. unit
Faulty pick up coil
Broken magneto woodruff key
Switch
Faulty main switch
Faulty “ENGINE STOP” switch
Faulty front and/or rear brake switch
Faulty sidestand switch
Wiring
Loose battery terminal
Loose coupler connection
Improperly grounded
Broken wireharness
SR901000
POOR IDLE SPEED PERFORMANCE
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 pick up coil
Faulty ignition coil
Valve system
Improperly adjusted valve clearance
8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE
TRBL
SHTG
EB902000
POOR MEDIUM AND HIGH SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING” section. (Fuel system, electrical system, compression system and valve train)
Carburetor
Air filter
Improperly adjusted fuel level
Clogged air filter element
Clogged main nozzle
Clogged or loose pilot jet
SR******
POOR SPEED PERFORMANCE
POOR SPEED PERFORMANCE
Ignition system
Dirty spark plug
Improper heat range
Faulty C.D.I. unit
Faulty pick up coil
Fuel system
Clogged fuel tank cap breather hole
Clogged air cleaner element
Clogged jet
Improperly adjusted fuel level
Compression system
Worn cylinder
Worn or seized piston ring
Cylinder head gasket broken
Cylinder gasket broken
Carbon deposit build-up
Improperly adjusted valve clearance
Improperly contacted valve and valve seat
Faulty valve timing
Clutch
Refer to “CLUTCH SLIPPING/DRAGGING”
section
Engine oil
Improper oil level (low or over oil level)
Improper quality (Low oil viscosity)
Deterioration
Clogged oil passage
Brakes
Dragging brake
8-3
FAULTY CLUTCH/FAULTY GEAR SHIFTING
TRBL
SHTG
EB904000
EB903000
CLUTCH SLIPPING/DRAGGING
FAULTY GEAR SHIFTING
CLUTCH SLIPPING
Clutch
Improperly adjusted clutch cable
Loose clutch spring
Fatigued clutch spring
Worn friction plate/clutch plate
Incorrectly assembled clutch
Engine oil
Improper oil level
Improper quality/(low viscosity)
Deterioration
HARD SHIFTING
Refer to “CLUTCH DRAGGING”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
Improperly adjusted shift rod
Bent shift shaft
Shift cam, shift fork
Groove jammed with impurities
Seized shift fork
Bent shift fork guide bar
Transmission
Seized transmission gear
Jammed impurities
Incorrectly assembled transmission
JUMP-OUT GEAR
Shift shaft
Improperly adjusted shift lever position
Improperly returned stopper lever
Shift fork
Worn shift fork
Shift cam
Improper thrust play
Worn shift cam groove
Transmission
Worn gear dog
CLUTCH DRAGGING
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
Match marks not aligned
Engine oil
Improper oil level
Improper quality/(high viscosity)
Deterioration
8-4
OVER HEATING/FAULTY BRAKE
SR905000
SR906001
OVER HEATING OR OVER-COOLING
FAULTY BRAKE
TRBL
SHTG
POOR BRAKING EFFECT
Front brake
Worn brake pad
Worn brake disc
Air in brake fluid
Leaking brake fluid
Faulty master cylinder kit
Faulty caliper seal kit
Loose union bolt
Broken brake hose
Oily or greasy brake pad
Oily or greasy brake disc
Rear brake
Improper brake pedal adjustment
Worn brake shoe
Improper brake shoe contact
Worn camshaft
Worn brake drum
Mud or water into brake drum inside
Oily or greasy brake lining
Faulty brake cable
Broken or fatigued tension spring
Faulty camshaft, cam lever
OVER HEATING
Ignition system
Improper spark plug gap
Improper spark plug heat range
Faulty C.D.I. unit
Fuel system
Improper carburetor setting
Improper fuel level adjustment
Clogged air filter element
Compression system
Heavy carbon deposit build-up
Improperly adjusted valve timing
Improperly adjusted valve clearance
Engine oil
Incorrect engine oil level
Improper engine oil quality (High viscosity)
Low engine oil quality
Brakes
Dragging brake
8-5
FRONT FORK MALFUNCTION/INSTABLE HANDLING
TRBL
SHTG
SR907000
SR908000
FRONT FORK MALFUNCTION
INSTABLE HANDLING
OIL LEAKAGE
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
MALFUNCTION
Bent inner tube
Deformed outer tube
Damaged fork spring
Bent cylinder complete
Improper oil viscosity (High viscosity)
Improper oil level
Worn or damaged slide metal
INSTABLE HANDLING
Handlebars
Improperly installed or bent
Loose handlebar tightening bolt
Steering
Improperly installed handlebar crown
Loose or overtightening 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
Wheels
Incorrect wheel balance
Loose spooks
Deformed wheel rim
Unevenly worn tires
Incorrect tire pressure
Loose bearing
Bent or loose wheel axle
Excessive wheel runout
Frame
Twisted
Improperly installed bearing race
Damaged head pipe bearings
Rear arm
Faulty bearings
Worm or damaged
Faulty bushing
Bent rear arm
Rear shock absorber
Fatigued spring
Improperly adjusted spring preload
Oil leakage
Drive chain
Improperly adjusted chain line
8-6
STARTER MOTOR DOES NOT OPERATE
SR******
STARTER MOTOR DOES NOT OPERATE
STARTER MOTOR DOES NOT OPERATE
Battery
Insufficient battery capacity
Faulty battery
Fuse
Burnt out, improper connection
Switch
Faulty main switch
Faulty starter switch
Faulty clutch switch
Faulty neutral switch
Faulty sidestand switch
Faulty starting circuit cut-off relay
Faulty starter relay
Wireharness
Loose battery terminal
Loosely connected coupler
Improperly grounded
Broken wireharness
Starter motor
Worn brush
Faulty commutator
Broken armature coil
Engine
Faulty starter clutch
Seized engine
8-7
TRBL
SHTG
FAULTY SIGNAL AND LIGHTING SYSTEM
TRBL
SHTG
YP909000
FAULTY SIGNAL AND LIGHTING SYSTEM
FLASHER BLINKS SLOWER
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
Faulty battery
Faulty fuse
Faulty main and/or horn switch
Improper horn adjustment
Faulty horn (burnt coil, connector)
Broken wireharness
HEADLIGHT DARK
Improper bulb
Too many electric accessories
Hard charging
Faulty rectifier/regulator
Faulty battery
Improperly connected coupler, connector,
wireharness
Improperly grounded
Faulty main switch or Lights (dimmer) switch
Bulb life expired
BULB BURNT OUT
Improper bulb
Faulty battery
Faulty rectifier/regulator
Improperly grounded
Improperly mounting light unit
Bulb life expired
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)
8-8
1
2
3
4
5
6
7
8
9
SR125 ’97 WIRING DIAGRAM
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
COLOR CODE
B .....
Br . . . .
Ch . . .
Dg . . .
G ....
L .....
O ....
Black
Brown
Chocolate
Dark green
Green
Blue
Orange
Sb . . . .
P .....
R.....
Y .....
W ....
Br / L . .
Br / W .
Sky blue
Pink
Red
Yellow
White
Brown/ Blue
Brown/ White
G/Y . .
L/ B . . .
L/ R . . .
L/ W . .
L/ Y . . .
Y/R . . .
R/ W . .
Green / Yellow
Blue/ Black
Blue/ Red
Blue/ White
Blue/ Yellow
Yellow/ Red
Red/ White
W / L . . White / Blue
W / R . . White / Red
C.D.I. magneto
Rectifier / Regulator
Starter relay
Battery
Fuse
Main switch
Thermo switch
Heater unit
Handlebar switches (right)
Engine stop switch
Start switch
C.D.I. unit
Ignition coil
Spark plug
Clutch switch
Sidestand switch
Neutral relay
Speedometer
Neutral indicator light
Turn indicator light (left)
Turn indicator light (right)
Hi-beam indicator light
Meter light
Neutral switch
Rear flasher lights
Tail/ Brake light
Front brake switch
Rear brake switch
Front flasher lights
Auxilialy light
Flasher relay
Horn
Handlebar switches (left)
Lights switch
Horn switch
Dimmer switch
Turn switch
Starting motor
Headlight
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