s1d ,
YAMAH ...j,' ..i. -'.'
.,;.
-..
This lvlanual is prepared by EscortsYamaha Motor Ltd. primarily
for use by Company Authorised Dealership and their qualified mechanics. lt is nol possible to put an entire Mechanic's education in to one lvlanual, so it is assumed that persons using this book to pedorm maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in the motorcycle repair technology. Without such knowledge, attempted repairs or service of this model may render it unfit for use and/or unsafe. Escorts Yamaha N,4otor Ltd. is continually striving to improve all models manufactured. Modifications and significant changes in specifications or procedures will be forwarded to all Company Authorised Dealerships; and will wherever applicable, appear in future editions of this Manual.
Service Department EscortsYamaha Motor Ltd.
LEGENDS WARNING IT INDICATES SPECIAL PROCEDURESTHAT MUST BE FOLLOWED TO AVOID INJURYTOTHE MOTORCYCLE RIDER OR PERSON INSPECTING OR REPAIRING THIS MOTORCYCLE.
to It lndlcates SPecial Procedures that musi be lollowed to avold damage
the Moiorcyc e
€
IMPORTANT
It provides KeY Inlormation related with procedures and opera_ tions which must be clearlY understood.
MANUAL FORMAT A of the procedures in th s manual are organised in a sequentlal, step by slep ror read' mat. Tl]e Inforrratlon has Deen compiled to provlde the mechanic with an easy to harldy reierence that contajns comprehensive explanation of all disassernbly, repa r' as sembly and inspection operallons ln this revised format, the condilion ol lau ty component will precede and the course of action required will tollow the symbol e g Bear ngs Plttlng,/damage then FeP ace EXPLODED DIAGRAM Each chapter provi.les exploded diagrams before each disassmbly sectlon lor ease in dentifying correct disassembly and assembly procedures lllustralians in ih/s l4lorkshop l',tlanual may not necessartly match with the physical appearance af the l"lolaict'cle
t
E.
i
INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE
CARBURETTOR CHASSIS
ELECTRICALS TROUBLE SHOOTING SERVICE INFORMATION
] GENERAL INFORMATION
GEN INFO
rff
APPLY GREASE
PERIODIC INSPECTION &
lR
ADJUSTI\,,1ENT
APPLY ENGINE
ENG
A
n
orL
CARBURETTOR TIGHTENING
CHASSIS
CHAS
E'E^I EL:
ELECTRICALS
l-
TROUBLE SHOOTING
TRSH
SERV INFO
Cr
\
SERVICE INFORN/ATION
ff
SERVICE LIMIT, CLEARANCE
r!
CHAPTER
1
GENERAL INFOBMATION I,'OTORCYCLE IDENTIFICATION
NUMBER =',: \E SERIAL NUM8ER,,,,,.,.. -
t
_ : SS S SERIAL
I,I
1-1 1-1
POFTANT INFORMATION
-__ -:-L4UEtVtE:t\ I TAt-it -_
- :- :' ) d \JtL -trALJ.....
_ -_,/1>-trnD i:-* \\, q \LJ \rtL Jtr4LJ................ =__
-r
)s
tr
=ctAL
t-J
sERVtcE TOOLS...............
fi,i:
&5l
CHASSIS SERIAL NU|\,4BER . The Frame Serial No it is sramped n to the righi side ol the Steering Head Pipe.
ENGINE SERIAL NO
I
. The Engine Serial Number il rs stamped In to the Left Side of the Engine. (Engine Serial No does not contain Year and lvlonth of productir'rJ
AI,IIPER WITH ANY OF THESE NUMBEBS. IT MAY LEAD TO LEGAL
XXXXXX
YEAR OF
::CDUCTION
I ::i-cl
cn
MONTH CODE
MODEL
cooE
UNIT PRODUCTION NUMBER
2 Digits standing for last t\/o digits of year
F9.96 -1996,97-1997..
SeIial Number:
::
r,
,
:
One alphabet standing for Month Eg. A - January, B - February........ L - December RXG 1 L5-000001
c g ts denote year ot prod uction Code, Next dig it represents Month ci",ed by Model Code and the remaining six dig-its a;e the Unit pro_
'-: :-',,mber.
GEN 'I iffi;
EEl ALL REPLACEMENT PARTS '1. We recommend to use ESCORTS YAMAHA genuine parls for all replacements, to ensure safe long and trouble tree performance of Motorcycle. Use oil orgrease recommended by ESCORTS YAMAHA IVIOTOR LTD. for assembly and adjustmenl.
GASKETS OIL SEALS AND 'O' RINGS '1. All Gaskets and Oil Seals should be replaced when an Engine ls overhauled. All Gasket Surfaces, Oil Seals lip and'O Rings must be cleaned. 2. Properly oil all Mating Parts and Bear ings during reassembly. Apply grease to the Oil Seal Lips. LOCK WASHERS/COTTER PINS 1. All Lock Washers/Cotter Pins must be replaced when they are removed. Lock Tabs should be benl along the Bolt or Nut flat(s) a{ter the Bolt or Nut has been properly tightened.
BEARINGS AND OIL SEALS 1. Installthe Bearing(s) O and Oil Seal(s) with their manufacturefs mark or numbers facing Upward. (ln other words, the stamped letters must be on the side exposed to view). When installing Oil Seals, apply a light coating of light lithium base grease (e.9. Servo Grease l\,4.P or equivalent) to the Seal Lips. Oil the Bearings liberally when insta ling. IMPORTANT Oo nol use compressed air
Bearinq Surfaces.
io spin the bearings dry.This causes damage lo the
GEN INFO
&6
ctRcLlPs 1. All Circlips should be inspected carefully before reassembly. Always replace Piston Pin Clips after one use. Replace
distorted Circlips. When installing a Circlip O make sure that the sharp' edged corner is positioned opposite of the thrust it receives. See the sectional view Shaft.
GTTMPoRTANT I
@ I
would cause it to iump ott groove and damage related
components.
L
Io,
ll" The Special Service Tools are required for complete and accurate tune-up and assembly. Using the correct Special Service Tool will help prevent damage caused by the use of improper tools or improvised techniques.
S NO. TOOL NO 1
FIGURE
DESCRIPTION To hold the Rotor of Magneto Assy.
ES tvt201
I
MAGNETO HOLDEF
2
To remove the Flotor of Magneto Assy
ESt\,1202
IllAGNETO PULLER
3
ESM205
To hold the Driving Sprocket
DRIVING SPFOCKET HOLDER
To remove the Piston Pin from th€ Piston
ES M 507
PISTON PIN REPLACEB
5
To compress Piston Blngs for instalf
ES l\i151 0
ng the Cyl nder.
PISTON BING COlllPBESSOF
6
i
EStvt213
Tc Hold the TFF plunger
.....4
FBONT FORK INNEF TUAE NUT HOLDE F
--_
I
Ir_.-
\s\q.\sq\-s.q 14
\tre'se.s-
\
ESM 265
qqsqR\e\\q\ To separate RH & LH Crankoases and to pull out Crankshaft.
CRANKSHAFT/CRAN KCASE SEPABATINGTOOL
l3
#p
ESM 266
To install the Crankshaft.
CRANKSHAFT INSTALLING TOOL
To remove
ESM27O
ll-F ull Dea
TFF OIL SEAL REMOVALTOOL
17
To install
ESM275
TFF OIL SEAL INSTALLINGTOOL
lFl- utl Sea
I
CHAPTER 2 PERIODIC INSPECTIONS AND ADJUSTMENTS
.,:-:s oN |\4A|NTENANCE. ............. 2-1 ::: 3DlC MAINTENANCE SCHEDULE ..................... 2-3 :
.-
:
,
:TITIVE MAINTENANCE/LUBRICATION............ 2-5
:'. :
.-": - uG
'J
S
..........2-7
SIS
.2-17
.2-18
2-21
! _::-RtcAL 2-22 I
J
INSP.
ADJ.
1. Thoroughly clean the Frarfe and Engine ot dirt and dust, in order to prevent it from entering the lnside ol the Engine.
2.
Keep ofi the F re lfom the maintenance area.
3.
When the Special Service Tools are required, use them judiciously to prevent any damage to the Motorcyc e parts. When working on the Motorcycte it rs a musl to use the recommended lypes of tools and instruments. (e.g. Avoid usfrg an open-end wrench as much as possible,
n place of a box or socket wrench.
)
4. Always use a new casket (pack ng), O Bing, Cotter Pin, Circtip, Lock Wastrer, etc. lo, repa rs. Always use Genuine Escorts Yamaha pans, recommended grade of Oils and Grease of superior
quality.
5.
During Serv ce,lake Spec a Caresornal you dont get njured or burnt from rne Englne, Exhaust Pipe or Siencer.
tr
6. BATTERY
.
Take care so that the Battery Fluid dc€s
IlD\ b)\\ Dl\D\l Molorc'yc\e.
!\\\s\,s\N) $
.\
7. NOTES ON DISASSEMBLY AND REAS SEI\,4BLY
.
Place allDisassembled Parts neatly aal
separately in groups so that lhey T?
not be confused or lost. (especia '
c?
. .
Washers and Spacors) Whenever Screws of dilferent lengths a-. taken out from various assemblies idetify them separately. Wash the Engine andTransmrssion Pa= in kerosene and blow them drywith co-presseo arr.
.Install the Parls after checking tF:
.
'
smooth movement. Oil the contact surfaces ol the Mov'n: Parts. Tighten the Parts to lhe specified torou: by using the Torque Wrench.
Always keep your environment clean.
E
. -:qs
PEBIODIC MAINTENANCE SCHEDULE INITIAL
REMARKS
Check Clean or replace. . Rep ace (Warm Engine Before D'a ning).
Check/adjust idle speed, Starler lever (choke) operal on and c ean
a
a
ti ln
Check ensure bleeding to avo d ai
5'
a
a Check lor any damage or crack. Replace, il necessary ta
Check
al
Eng
fe nuts and
bo ts
1o
t: I
Remove cafbon (Cyl/Cyl. head/ P
ston Assy
llluij
er elc
)
il 'Check
e echolyte
il
leve and add
d slrled water every 1s days
N
iclreck
specil c srav ty (++) and breather pipe ior propef roll ng.
Check operai
on
a
Rep ace, if
Check,adlust bearn
a
1
INSP.
ADJ.
.
Drive chain*
PERIODIC MAINTENANCE SCHEDULE
Check and adiust lension/lubricat C1ean, Lubficale and alrgn
Check fof damage/Bim run oul &
wneet aearings"
Check tor damage wear'
looseness/lighlness RePlace
ck tor tyre P€ssure.
iteering eearins*
Check
lor oosenesslighlness
C'hech lor oPeralron and orl
All Nuls & Bolts
Check ior Iooseness.
OilTank
Check and lop uP Engine(2T) oil
Check Reaf Swing Fork AssY lor
looseness {ReP ace sllenl b ock bushes aiter 24000 Kms or
CLean Feplace rf necessarY COI\I!PANY AUTHOBISED DEALERSHIPS + L3: _ ls recommended lhat lhese nerns be s€rv c€d DY or sPecialYamaha oil++ battery spec I c gra 175!3ml Servo 1e eschocab or oi special Escorts oll
*lt
1.240 at 20'c
ffir" "-bo*,""o.mendations are only for general guidance' .Actuar period of service rarserv oeryl9.:. ill.:l:^Yt"-* ::iY?:lXl3t:*t"* aurHoRrsED DEALERSHTPS'
;;ffi !",";;;';;;i"ontJ"t'corirpnrY
:
INSP.
ADJ,
THROTTLE
AUTOLUBE PUMP
FRONT BRAKE
NIINIMUMPt MP STFOKE 0.204.25 mm
t
SPARK PLUG _ \
r
ir\
< f---i.. lla!6qP
\:_ll? REAR BRAKE
::ECTRICALS
TRANSMISSION OIL
TYPE
2OW4O
MULIIGRADE OIL
SILENCER
EAN EVERY3OOOKII/I.
l
It
' Jr
2-6 rr
INSP ADJ. SPARK PLUG PLI.
::_
airv d ft from around the Spark Plug base.
:: -.ect the Spark P ug Cap. Remove the Spark Plug with the Box Spanner No 21 . : r nspect the Spark Piug Electrodes for wear. The Centre E ectrode shouci have : : edges and the side electrodes should not be efoded. D scard the Spark P ug I there :-.::ent wear. & if the insulator s cracked/ chipped. '= :Jre thai ihe Spark P ug Gap ill is - : 7 mm. Measure the gap us ng a : -. pe Feeler Gauge. lf adjustment is ::: ,:,r,,, do it by bending ony the sde -:
- Lo,c u,,y.
: : : - e that the PlLrg Washer is in Good ' '_: P lrg Washer attached, screw - jn : :,..{ P ug by hand to prevent cross ::r --i \t' th the Box Spanner. tighten : :- ilrn after tl're Plug seats fully.
Recommended Spark Plug (NGK JAPAN)
:
BPRBHS
Spark Plug is new, tighlen t (14.0 Fr. Lb)
lhe Box Spanner to cornpress
I:
:' over tighten or cross thread the Spark Plug as the Threads of Atuminium _:?r Head may be damaged. -:: 3llolv any Foreign Panicles to enter the Engine through Spark plug Hole .e P ug is removed. Please ensure that the l-lole is covered co with a cloth. se the recommended ed type tvpe of Spark Soark Plug Plud lest it wor would alfect the Engine PlLrg nd cates how the Engine has been operat ng. From the co our and Spark P ug the Engine and the riding cond tions of the Motorcycle can be n the tollowing lable. .
] T ON
COLOUR AND APPEARANCE nsLr
Du
lor tip grey sh yellow
to
INDICATION
ight brown
. Every Thing s in order. . Clogged Air Flter.
b ack velvely carbon depos ts.
.
\s\ !.\\\\s\a \\s\
. E\ec\\ode Gap \\\o\ e
" Co d'P ug used.
!
nsuff c enl H.T. vo tage . Pro onged ld ng ol Enq ne.
S. ning black wet carbon deposits
ifsulator burni while
wth
ieposits ol efoded Electrodes.
peafy
'O i-F!e M xture rich. ' Worn-out Cyhnder/Piston Rrngs Fuel'ArMxturelean. mproper Seating oi PlLrg. Hol'P ug used.
2--t
AIR CLEANER ELEMENT
A) Opening ot Air Cleaner Assembly '1. Remove Cover Side-2 @ (on right hand side) by opening 1 No Screw.
2. Unsc.e\'r, cap Assembly Air Cleaner @ by
opening 3 Nos Screws,
B) Inspection of Air
Cleaner Assem-
blv
l.
Inspect for any existing Air Leakage into the Case Air Filter. (lt is observed that
there is dust accumulation at the leakage Point.) 2. lf there exists any air leakage Check for : A) Warpage oI Case Air Filter or Cap Assembly Air Cleaner{Fig A) B) Proper seating and condition ol Seal Case Air Filter. (Fig B) ll damaged or cut replace it with a new one. C) Grooves ol Case Air Filter and Edge of Cap Assembly Air Cleaner for damaged maiing surlace. (Fig C)
D) Condition ol Element Air Cleaner. lf damaged or cut then Replace it with a new one. (Fig D)
INSP.
ADJ.
C) Cleaning of Element Air Cleaner
L
Centll pullout Flcmenl Air ( leaner O &om Cap Assembly AirCleaner. @.
2. . Clean Element Air Cleanet
in
clear
Petrol (without any oiltrace), thoroughly, in a clean kay. . Repeat the procedure tillall the dusydirt has been washed off.
3.
Squeeze out the excess petrol by pressing the Element Air Cleaner in the fist .
D) Oiling of Element Cleaner . 1. Take 2T Oil in a Clean Tray. . Dip the Element Air Cleaner in 2T Oilfor unitorm Soaking. (Keep the ltairy surtace Down).
HAIRY SURFACE
INSP.
ADJ.
1/
2.
,,n'
Squeeze out excess 2T Oii by pressing The Elemenl Air Cleaner in the Fisl as shown in Fig 1.
.a Check for Unitorm Application of 2T Oil all over lhe entire surface (both sides) of the Etement Air CleanerAfterthe excess 2TOit has beeh Squeezed out.
. Do not wring Elenrent Air Cleaner as shown in Flg 2.
. No such strong force should be apptied to the Element Air Cleaner, while squeezing, Which may caLrse tear ng or damage to the Element Air Cleaner.
E) Installation of Air Cleaner Assembly 1. Assemb e the Air Cleaner
assembly n re
verse sequenc-A. Check for : The blockages in the Air Passage ofthe Body Air Ceaner Clean it with a ctean cioth.
Screws Tightening Sequence
.
The screws of the Cap Assy Air Fi[er sholld be tightened as per the shown sequence, in two steps. (All the three screws to be tightened genfly first and then fu y tightened in the same sequence.)
When install ng the Element Air Cleaner in its Cap Assy, be sure its sealng surface matches perfecl y with the sealing surface oi the Case Air Filier to prevenl anv A r Leakaoe.
IMPOFTANT
. Dirty Element Air Cleaner causes excessive fuel consumption, wear of piston Rings and loss ot oower.
. Clean Element Air Cleaner every 1000 KMs.
. The Element Air Cleaner should be cleaned and lubrlcated more frequenfly (every 1O0O kms or earlier), it Motorcycle is operated in very dusty (e.g. unpaved, dust laden roads) or wet conditions.
TRANSMISSION OIL CHECKING '1. Check Oil Levelwith Motorcycle on Central Stand. lvlotorcycle Rear Wheel lifted ofl ground and Front Wheel touching the ground.
2.
Transmission Oil Level should always be belween maximum & minimum levels on Plug Oil Level.O Screwed on Cover Assy. 2 on R.H. Side.
3. Top up
if required.
REPLACEMENT 1. Warm up the Engine with Motorcycle on Central Stand. 2. Keep Oil Pan below the Engine. 3. Rernove Drain Bolt @ along with the casket @ and drain out Oi, completely.. 4. lnstall Drain Bolt @ with its casket €). Drain Bolt 2.0 Kq.m. 't4 Ft. Lb
5. Fill Transrn ission Oil. 6. Check oil level with the help of Plug Level
Oil
O RECOMMENOED
.20W40 Oil of Superior grade quality. QUANTITY : . For Overhaul : 700cc t 20 cc . For exchange : 650cc a 20 cc during Service
1T'PORTANT
"
r/;ats
usc only recommended grade/quantity of Transmission Oil. -'ci add any chemical additives into the Gear Box as cear Box oil also lubricates tfE C'lch. and additives can cause the Clutch to sliD_
-h
t.r
AUTOLUBE PUMP CABLE ADJUSTMENT 1. Check to see if the Pump Guide Pin (Dis aligned with the mark on Plate Adjusting @with the Throttle in closed position having no play-
2.
lI Pump Guide Pin is not aligned, align by lurning Adiuster @ in or out, loosening Locknut @ and then retightening.
MINIMUM PUMP STROKE AA'USTMENT 1. Throttle Grip full closed position.
2. 3.
4. Minimum Pump Stroke 0.20 - 0.25 mm
5.
Remove Spark Plug Slowly move the Kick Crank downwards by hand, holding the Kick Crank at the position where the clearance between adiust Pulley and Plale adjustrng is maximum. Measurc lvlinimum Pump Stroke (t with Feeler Gauge.
lf clearance is not cor.ect adjust by the Shims @. Adding Shims will increase the stroke and vice versa.
When insening theThickness cauge between the Plate Adiusting and the Adjusting Pulley, be carelul that neither the Plate nor lhe Pulley is moved.
2-12
AIR BLEEDING 1
. REMOVE:
.
Pump Bleed Screw @ and keep oil run-
ning out until all the air bubbles disap-
pear 2. INSTALL:
. .
3.
Gasket Hteeo Sctew
(,
Start the Engine, disconnect the Outlet Pipe ol the Oil Pump from the Carbureltor. Pullthe Oil Pump Cable (O allthe way oui to sel pump stroke to a maximum lor Iew minutes, to ensurethat allairbubbles are removed and smooth oilflow is taking place. Beconnect the Outlet Pipe back to the Carburettor
THROTTLE THROTTLE GRIP FREE PLAY . LOOSEN: . Locknut G) 2. ADJUST: . Cable free play 1-2 mm by turning Cable Adjuster @ in or out. 3. TIGHTEN: . Locknut (D 1
THROTTLE CABLE FREE PLAY , LOOSEN: . Locknut @ 2. ADJUST: . Cable free play @ 5-8 mm.Turn cable adjuster @ in or out. 1
3. TIGHTEN: . Locknut O
CARBURETTOR IDLE SPEED '1
.
Start the Engine and warm for 5 minuies
2. Turn Pilot Air
Screw @ ln unti lghtil
-d
seated-
3.
Back out by specified number ot tufns
wit.
screw drlver
Pilot Ait ScrewTurn Out 1 Y2 ! o.sTurns
o 4.
Turn Throttle Stop Screw oul until specr-
fied ldle Speed is attalned.
Engine ldle speed 1700 ! 100 R.PM. (Uptill Bunning in Period ie. First 1000 Kms.)
r
100 R.PM. (After Running in Period Kms.) 1500
,:.e.
After First '1000
STARTER LEVER FREE PLAY LOOSEN: . Locknut @) 2. ADJUST: . Cable lree play @ 3-5 mm by turn ng Cable Adjuster O in or out. 1.
3.
TIGHTEN: . Locknul €)
Starter Lever Cable Free Play : 3-5
I
l\4M
{ {
E@ CLUTCH CABLE ADJUSTIV]ENT 1. LOOSEN: Locknut O
2. ADJUST;
.
Cable Ffee Play @ 2-3 mm by turning Cable Adjusler @ in or oul.
3. TIGHTEN :Locknut O
SLUTCH MECHANISM ADJUSTMENT
:alr4OVEl
.
:avef Crankcase-1
G) (On left hand side)
2. POSITION The Push Lever a.rd ad.usr
(t
by the Cable Adjuslere) ai lo75 nm.
Lpve'riegl.t
3. INSTALL :Cover Crankcase -1 G)
a w ,
:EVOVE: Generator Cover Assy. O
€
llPoRrANr
li
5. LOOSEN ;Locknut €) on Cover CrankCase -1 6. SCRFW lN : Adjuster €) until tighl and
7.
back t out by 1/4 turn. TIGHTEN :Locknut @
-:eiore Adiusting the Clutch Lever free play, the clutch Mechanism should be adiusted.
L
f
F
@ BRAKES FRONT
,
r;t
'1
. LOOSEN :Locknut O
2. ADJUST : Free Play
@ by
Adjuster
@
3. TIGHTEN:Locknut O FBEE PLAY O 5-8 mm (lndian Markets) 2.5-3.5 mm (Other Markels)
. The
Front Brake play can be Adjusled eilner oa tl_e Adjuster e) on Brake -evel or by the Adjuster @ loodted on Fronl Wheel Plate Brake Shoe.
REAR 1
. ADJUST:
.
.
Free Play 6r of Rear Brake Pedal @ to 20-30 mm by turning the Adjuster O near the right hand side of the Rear Wheel in orout (To increase ihe play turn Anticlockwlse and to decrease the play turn clockwise.)
Brakes ensure personal safety and
should always be maintained for proper adjustmeni.
. Always check Brake Lighl operation after Front and Rear brakes adjustment is done. . Proper Lever Free Play is essentialto avoid excessive brake Drag-
:
d
t! I :
BRAKE LINING WEAR INSPECTION 1. Depress the Brake Pedal @
2, INSPECT
.
Position of Wear Indicator @ lf Indicator reaches the wear limit line then
replace Brake Shoes.
WHEELS 1, INSPECT
.
WHEEL lf Crack/ Bend/ Warpage then replace
2, INSPECT
.
Spoke
Tap each Spoke with an iron rod lor sound or feel the looseness ot the Spokes by hand. lf any Spoke makes a dullllat sound, Inspect it lor looseness
3. TIGHTEN
. .
Spoke Nipple True the Wheel if necessary.
Always balance the wheel when a tyre or wheel has been changed or replaced
2-17
INSP.
EIEE
ADJ.
TYRES 1
, INSPECT: Tyre wear
-{
Wear Limit: 1 mm Wear indicatof O Replacement limit @ :
'1
if rm ,N G
MM
2, CHECK: . Air pressure with tyre nozzle in down position as in figure.
FRONT
REAR
2.50-18
2.75-18
4PR
4PR
NYLON
NYLON
Single Rider
22PSl
28 PSI
Double Rider
22 PSI
32 PSI
Tyre Specification
L,"-:
Qbu^*^r^uz
.W
:r
TYRE CONDITION OVER INFLATED O Risky/Poor Boad Holding.
PROPERLY INFLATED O Good and safe riding.
UNDER INFLATED €) Higher Tyfe Wear & Low Fuel Economy
An mproperly inflaled Tyre may lead to loss of Motoreycle Road Contact causing accident /injufy to Rider.
IMPORTANT
.Tyre pressure should be checked and corrected under cold conditions (Tyre temperature equals ambient lemperature) . Always check tyre condition before riding lllotorcycle. li badly worn oll then replace Tyre immediately . .In case nail/glass/sharp item is embedded in Tyre. please ensure same is removed before vulcanising /puncture repair.
,q
rdl
4fi!
.{n
,"ifl ri
7-F f
@
.
DRIVE CHAIN
:-te
:'
Chain Slack 20-30 mm
I'l. Side
_,
.- :- .
n----a 5u
SLACK INSPECTION . Park Molorcycle on Level Ground on Central Stand. . Remove Rubber Cap O from lnsoection Window @ on Chain Case . . Rotate Rear Wheel @ several revolutions in Forward direction and checkTotal Slack upward & downward several times to find "Maximum Slack Point" @. SLACK ADJUSTMENT . Park Motorcycle on Central Stand and loosen Rear Brak€ CableAdiusteron RH sne . Remove Cotter Pin @ of Rear Wheel Axl6 Nut with Dlier on LH side. . Loosen RearWheelAxle Nut @ usino Ring Spanner No 22 and Main Sprocket Shaft Nut. @ using Ring Spanner No 27 on LH side. . Loosen Chain Puller Lock nuts @ on each side (LH and RH side). . To tighten Chain, turn Chain Puller Adjusters @ clockwiseand to loosen Chain, turn Adjusters anticlockwise and push RearWheel Forward . Ensure that the matching ofthe notch on the adiusler with the alignment marks on Rearonthe ReatSwing Fork ia same on LH and RH side. . Atter adjustment , be sure to tighten Lock Nuts, Sprocket Shaft Nut. Wheel Axle Nut and adjust the Rear Brake. . Insert a new Cotter Pin into the Rear WheelAxle and bend the end ofthe pin.
IIPORTANT
&"Fr adjusting the Drive Chain Slack, Rear Brake pedal Free play should always be -e4{ed and adjusted, il required. rc.r'ect alignment adversely affects the lile of Tyres, Wheel Bearings, Sprockets and
,
:r,e Chain. :-s-€ configuration
ot Drive Chain to be same when assembled. .efitting ' flrts' e Chain Lock on Drive Chain, please ensure its Closed End is alwavs in '|!E -rr.eclion of Chain Rotation.
2-19
DRIVE CHAIN CLEANING AND LUBRICATION
,.-7.' ,-:pw,,'^
_
Bemove the Drive Chain trom the Motorcyoe. Dip the Drive Chain in Kerosene for aboul 20 minutes to loosen the dirtfrom internal surfaces as shown in figure.
Clean the chain with wire brush. Again dip the drive chain thoroughiy rcrear Kerosene
Fj.:: v1a?: ^,:
r{
6.
Hang the Drive Chain vertcally and dry it by using compressed alr.
6.
Dip the Drive Chain in 20W40 Oil Batf to restore the rnterna ubrication
I
7.
2-20
Hang the chain in such a manner that the excessive oil drips off in to the oll bath
8.
Inspecl the Drive Chain lor wear if da.r aged of worn out, the Drive Chain along with Both the Sprockets should be replaced as a set.
STEERING CHECK\NG . RAISE
1
.
Front Wheel otf the ground.
2, CHECK
.
Steering Head Bearing for looseness Gently fock Front Fork Assembly backward and forward. lf loose then adjust.
ADJUSTMENT 1
. REMOVE . Cover Crown
O
by opening 2 Nos.
Screws.
2. LOOSEN: . Steering Fitting Bolt @ . Ftonl ForK Htncn tJotls lJl 3, ADJUST . Steenng Heao Ri.rg Nut @ by usrng Special Service Tool ESI\l-221.@ Tighten the Nut until Steering Head is tight without binding. lf heavy binding then replace Race Bearings. 4, TIGHTEN
.
.
Steering Fitting Bolt @ Fronl Fork Pinch Boll @
5. ASSEN,lBLE
.
uover urown
tll
Steering Fining Bolt 3.1 Kgm(22Ft.Lb)
BATTERY BATTERY FLUID CHECK
o 3f-
'1.
CHECK
il
:
lll
.
Fluid level Fluid Level Should be between up.. and lower level line. . For tightness o{ Termlnals. . Specific Gravity of the Battery F . c : using Hydrometer. It should be 1 .230 i 0.005 (1.225-- .: :: 2. Use only disiilled water for topping. BATTERY CHARGING (NEW BAITERY 1, ELECTROLYTE PREPARATION
. Mi\ one part of SulphJric Acid ro.- : parts of disrilled water to get tl'e de) :: Electrolyle .e. In 100 ml sulphLflc : add 250m1 of water. Checkfo.tf'e Specif c Graviryof lhe polyle I shoLld be 1.230 r 0.005 , --: 1.235) The Soecrfrc Cravrly shoLd al!{a/. : Checked us'ng a proper hycirori, (size 5.00mm)
r
. .
r'
2. Fill Electrolyte of specil ed gravity L: : "Upper Level" Mark in each Cellol the E:' ,|ety.
Leave the Battery idle for 30 to 60 - utes aiter lilling the Electfo yte for sc.. ing the Plales in the Electrolyte. 4. In case the Elecirolyte Level fa ls be : r the "Upper Level" during the above sc: ' ing period then lop it up again. 5 Charge the batlery as per following 3.
6
IMPORTANT
Incase the battery is more than
3
monihs old (fromthe month ol manufacture), duration of initial charging to be extended till lull charqe condi-
2-22
Charging Current = 0.25 Ampres. Charging Duration =15 Hours Us ng a good Battery Charger Slop chargrng the battery when spe, : grav ty of the e ectro yte in each ce : ta ns a value of 1.240 ndicat ng ', Charged Conditjon.
1
I
'il
I
;
:
INSP ADJ. IMPORTANT
. Maintain Electrolyte at Upper Level. . Do not add Electrolyte when recharging the Battery .Top up only with Distilled Water. .The Ballery should be firmly mounted. . The Breather pipe ol the Battery and its mounting should not have any lolds o blockages and should be done as per the given illustration. . Whenever Battery is not in the Circuit (i.e..emoved for Charging etc.) the Headligh switch must be shifted to "ON" position, otherwise Neutral Light Bulb wilt Fuse an BR unit will get damaged. . Check for the Fuse in the Fuse box. 'Check for the proper coupler connections of RR unit.
2-23
CHAPTER 3 ENGINE ENGINE DISASSEMBLY CYLINDER HEAD AND CYLINDER PtsToN .............. CRANKCASE COVERS GENERATOR ASSY ................ DRTVE SPROCKET........................ cLUTCH ............ (ICK STARTER .. SHIFT SHAFT CRANKCASE TRANSMISSION AND SHIFTER... CRANK SHAFT INSPECTION AND REPAIR CYLINDER HEAD ,,, ,,.,,,,, .. CYLINDER
3-1
J-t J-l
3-2 3-2 3-3
3-4 3-4 3-5 3-5 3-6
c1UTCH.............
3-7 3-7 3-8 3-9 3-9 3-10
KICK STARTER,,
3-1
PtsroN.............. PTSTON RING
PISTON PIN AND SIVALL END BEARING,,,
1
CBANK SHAFT TRANSM ISS ION
J- t.t
BEARING & OIL SEAL .......
3-14 (contd....)
ENGINE ASSEMBLY AND ADJUSTMENTS CRANK TRANSMISSION AND CRANKCASE GENERATOR ASSY
SHAFT
..'".. 3-15
..... 3-16 SHIFTER... ... . . 3-18 ASSEMBLY ......... 3-19 ................. ... 3-20 sHtFT SHAFT ...... 3-21 KICK STARTER. ...... 3-23 C1UTCH... ...... .............. 3-25 PR VARY DRIVE GEAR ....... .... 3-2s DRTV|NG SPROCKET....... ... ... .......... 3-25 CRANKCASE COVERS ..... 3-26 PIsToN. ........... .-.-'. .....3-27 cYLINDER --.-' 3-28 ENGINE MOUNTING .................... ......... 3-29 cotvPoNENTS GRADING
.:4.
t
CYLINDER HEAD AND CYLINDEF 1
. REI\/OVE
. . . . .
Spark Plug O Cylinder Head Nuts @ (4 Nos.) Cylinder Head O Cylinder Nuts @ (4 Nos.) Cylinder O
PISTON 1. REI\,4OVE
.
1
, REMOVE
.
O O
Piston Pin Clips O (2 Nos.)
. . .
Piston Pin @ using Special Service Tool ESI\,4 507 @ (Piston Pin Replacer)
Needle Boller Bearing @ Piston @ Piston Rings and Expander
CRANKCASE COVERS 1
. REMOVE . Cfankcase Cover R H G) By Opening 9 Nos. Screws.
@)
GENERATOR ASSEMBLY ,1
. ATTACH
.
2@
36
Special Service Tool ESI\,4-201 €) Fcholding the Rotor Assembly.
2, REN4OVE
.
4@
. .
Botor Holding Nut No 19. Spring Washer @ Washer @
3. ATTACH
.
:
@
by using So
-:-
:
Special Seruice Tool ESlvl-202 @ (Ror: Assembly Pullerwith Left hand thfeads holding Rotor Assembly by Specia S:' vice Tool ESM 201 @
4. REMOVE:
.
Rotor Assembly. @
. Woodruft Key 5. REMOVE
. .
@
:
Stator Holding Screws @ (2 Nos) Neutral Switch Lead Wire @ Stator Assembly @
DBIVE SPROCKET 1
. FEMOVE Drlve Sprocket Nuto by using socket N:
26, and Holding the Sprocket cial Service Tool ESI\,I 205 @ Lock Washef @ Drive Sprocket @
by Spe-
I I
2, REI\4OVE
.
.
Shift Cam Blind Plug @ Gasket @
CLUTCH ,I
, REMOVE
. Clutch Spring Bolts O 4Nos. . Clutch Springs @ 4 Nos.
.
. . .
Pressure Plate @ Friction Plate @ 6 Nos. Clutch Plate G) 5 Nos. Push Rod @
2, ATTACH
.
Speclal Service Toot ESM-233 @ For holding the Driven cear Assembly @
REMOVE Driver Gear Assembly
.
Nut
s by ooen
ng
@
.
Washer Conical Spring
.
Washer Plate
. Plale Thrust-1 (] . Spacer O
@
(,
ATTACH . Botor Assembly on L. H. JoJ, ral of Cranl Sl^att and holo loySpecta. Serv.ceToo ESM 201 5. RE]\,1OVE
t.9
.
Pr mary Drive
.
Washer 6r
.
Prin'rary Drlve Gear @
. .
.
cear Nut
Straight Key @ Spacer t! O ISea Retainer @
@
KICK STARTEB 1
, REMOVE . Circlip O
.
Washer @ Kick ldle Gear @ . Washer @ . Circlip €)
.
2, UNHOOK
. 3.
Kick Return Spring @
REIVIOVE
.
Kick Starter Assembly @
SHIFT SHAFT
1. REIVIOVE
.
'
(On LH Side)
Circlip O Washer (9
2. REMOVE (On RH Side)
. . .
!t
lensron bpnnq Assemb y (9 treaflng Helalnel Flale L9 Stopper Lever Assembly (O by Socket No 12.
. Shlit Shaft
us.l
t
CRANKCASE 1
. REITIOVE
.
Crankcase Tightening Screws (13 Nos ) LH side.
2, ATTACH
.
t
Special Service Tool ESM-265 O for separating the Crankcase (On right hand side) (a by tighiening Securing Bolis
3. DISASSEMBLE
O & LH @ bY rotating the Special Service Tool ot the lever
.
Crankcase RH
ESM-265 Clockwise and gently tapprng the Hear end of the RH Crankoase with Mallel.
tBefore application ol the Special se vice Tool ESM 265 for separatin Crankcase, ensure that lhe mounlin nuts of the Engine Stand are removed . Make sure the tool body is parallel wi ihe Crankcase.
I
TRANSMISSION AND SHIFTER INSTALL
.
Engine Stand Mounting Nuts with Spacer on LH Crankcase
HEMOVE . Bar Shift Fork Guide -1 O . Bar Shift Fork Guide -2 O
.
.
.
Fork Shift -2 @ Fork Shift '3 @ Fork Shilt "1 @
I'
REI\,4OVE
.
Shift Carn Assembly
REIVIOVE
. .
Axle lMain Assembly €) Axle Drive Assembly @
CRANK SHAFT
1
. ATTACH
. Special Service Tool ESM-265 G) for separating CrankShaft €) from Crankoase LH O , by tightening Secur' ing Bolts @
2
REI\,IOVE
. Crankshalt Assembly by rotating the lever €) Clockwise While removing Crankshaft lrom LH Crankcase hold it trom the RH side to prevent it trom falling down.
CYLINDER HEAD
. REMOVE . Carbon deposit, Use rounded scrapef. 2, I\,4EASURE 1
.
Cylinder Head warpage using straight edge O, Feeler cauge @ lf out of
speciflcation, resurlace or replace.
CYLINDER 1. REMOVE
.
Carbon deposit from the Exhaust Port. Use rounded scraper.
2. INSPECT
. Cylinder Wall for Wear/ Scralches Rebore or Replace 3. MEASURE
.
Bore using Cylinder cauge 10 mm from TDC at Poinls shown.
I out of speclfication, rebore the Cylin0et,
PISTON 1. INSPECT
.
Wear Scratches/Damages or reolac.
2. REI,4OVE
.
:
:
Carbon deposit lrom the Piston crown Use Rounded Scfaper.
Do not use a sharp ihstrument and avoid
damage or scratching.
Aller correcting, clean the Piston with clean cloth.
a
3. IVEASURE
. Piston outside diameter wlth . Micrometer. lf out of specillcation , replace
16
Standard
57.967
57.985
Oversize
-
57.982
1
Oversize 2 4. PISTON CLEARANCE
.
li oui of specif cation, replace p ston anc or rebore Cylinder.
IMPORTANT
Measurement should be madeal a point 10 mm above the bottom edge ol the Piston skirt & perpendicular to the axis of the Piston Pin.
Piston Clearance = Minimum Cylinder Bore - Piston Diameter 0.034
-
0.039
PISTON RING '1
. MEASURE : . Side Clearance @ Use a Feeler Gauge @ out of specification th€n replace Piston and / or Piston Rings.
lf
Side Clearance : 0.03 to 0.05 mm
2.
N,IEASURE
.Endgap:O Use Feeler Gauge @
Out of specification, Replace Piston Rjngs as a set.
Standard
Limit
End Gap
0.25 to 0.45 0.6 mm mm
0nsralled)
PISTON PIN AND SMALL END BEARING 1, INSTALL
.
Pislon Pin O and Bearing after Lubrication (into small end of Connecting Rod @)
3. CHECK
.
i
Free Play
lf
free play is excessive, Inspect Connecting Rod Small End and Piston Pin lorWear. 4. INSTALL . Piston Pin O (in to Piston) 5, CHECK :
.
Free Play ll lree play out of specification, replace Piston Pin and/or Piston.
3-9
CLUTCH DRIVEN GEAB ASSEMBLY
1. INSPECT
. . .
Dogs on Housing O lf CracksMea/Damage then Debur
replace Circumferential Play €), lf Play specif icatlon then replace. Gear Teeth @ of Driven Gear Assernc
CLUTCH BOSS '1,
INSPECT : . clutch Boss Splines @ Scor ng Wear/Dar.age ther DebL ' Replace.
FRICTION PLATE '1.
INSPECT
.
:
Friction Plates
ll Damages/Wear, Replace as a set 2, I\iIEASURE Friction Plate thickness N4easLre al dll lhe fo rr poinls as.ho Wear
limit
: 2.7 mm
Warp
limit
: 0.05 mm
CLUTCH PLATE 1
, MEASURE . Waroage of ClJrch Plate 5. Use IaCe tslale L9, anO ieeleT bauqe I li oul of specification then Replace
IMPORTANT
Plates Solines will cause erratic operation-
:
.
Minimum Lengih
CLUTCH SPRING 1. MEASURE
.
Free length lf less than the length specified, Replace the Clutch Springs as a set.
STANDARD LENGTH
34.5 mm
SERVICE LIMIT 33 rnm
KICK STARTEB 1
. INSPECT
. . .
Splines of Kick Shaft Assembly O KtcK uear teeln t4r Kick ldle GearTeeih @ Teeth wofn out/darnaged then replace the concerned Gear.
2. CHECK
.
:
:
Kick Geaf movement smoothly over spllnes.
3, I\,1EASURE . Kick Clip Friclion Force Out of specification then Replace Kick Clip.
-'
G
clron Fotce u.u
CAUTION
--3
K ck
gear should be firmly held in the V se whie measuring the Kick Clip Friction
3-1
1
CRANKSHAFT Runout limit 0.02 mm
1, MEASURE
.
Runout Use Dial gauge. lf out ol specification then Replace.
2. [/]EASURE . Crank Width lf Out of specification then Replace
CrankWidth :55.90 to 55.95 mm g end side Clearance 0.2 to 0.7mm
3.IVIEASUBE
.
Big End Side Clearance Use Feeler Gauge lf out oJ specification then Beplace
4, I\4EASURE . Small End Ffee PLay ll out of specilication then Replace
Small end free play 0.03 to 0.18 mm
:
IMPORTANT
Crankshaft & Connecting Rod to be replaced as a set il the above paramelers indicate the need. Reoair ofeither CrankShaft or Connect-
ing Rod is not recommended as it would affect the Engine performance.
3-12
TRANSMISSION SHIFT SHAFT 1. INSPECT
.
. .
I
Shift Shaft O bpnnqs La Stopper Lever Assembly O lf Weaf/Bend, Replace
SHIFT FORK '1.
INSPECT
. .
Shift Forks at (On the Gear and Shift Carn contact sunace) Shift Fork cuide Bars @ Wear /Chaling/Bends/Damage then Replace Fork and/or cuide Bar.
SI{IFT CAM '1.
INSPECT
. .
Shifl Cam Grooves O Shifl Cam P ns @
Wear/Damage/Scratches then Replace
MAIN AXLE AND DRIVE AXLE
]
-Runout
limit
:
1
]\,4EASURE:
. Axle Runout !
k=r
se Cente'irg Devir.e and Dial Gauge I out of specificat on then replace.
0.1 mm
3-13
GEABS '1,
INSPECT
.
Gears lf DamageMear then RePlace
2, CHECK
.
Gear Movement It operalion ls not smootl' then Bep ace the concerned Gear'
3. INSPECT
.
***
Matching Dogs. lf Cracks, Wear, Damage observed ihen replace.
BEARING AND OIL SEALS
1. CHECK
ll Rough Spots/Play then RePlace
2. INSPECT
.
All Oil Seal Lips
li DamageMear then BePlace
Always replace Crankshaft Oil Seals whenever the Engine is opened.
CRANKSHAFT ASSEMBLY
CRANKSHAFT WOODRUFF KEY NEEDLE ROLLER BEARING
1. ATTACH : . Special Service Tool ESNI 266 (To lhe left side of the Crankcase)for installing the Crankshaft. @ 2. TIGHTEN: . Nut ofthe Special Service Tool ESM 266 .Hold the Conreciing Bod ar Top Dead Center.
O
i
Gf,MP{r
Belore assemb\ing the Engine , uash \ Crankshaft in mild solvent (perrol/ Ithe I
\
kerosene)
|
f
TBANSMISSION AND SHIFTER
^*4 *'u@k'
*w -.a
v4 SPROCKET DRIVE (15 T) AXLE DRIVE GtrAtr tqT \A/1.]trtrI CLUTCH DOG GEAR 3RD WHEEL (26 T) GEAR 4TH WHEEL (23 T) GEAR 1ST WHEEL (35 T) 2ND PtNtON GEAR (r 5 T) 3RD PTNTON GEAR (19 T) 4TH PTNTON GEAR (23 T) AXLE I\,1AIN PLATE COVER
3-16
16
13.
17. 18. '1 9.
20. 21. 22. 23
FORK SHIFT -1 FORK SHIFT - 3 BAR SHIFT FORK GUIDE - 2 PLUG BLIND GASKET PLUG BLIND SHIFT CAI\,I PINS PLATE SIDE STOPPER LEVER BAR SHIFT FORK GUIDE -1 FORK SHIFT " 2
1. INSTALL: Axle Drive Assembly @ Axle Main Assembly @ Shiti Cam Assembly @ Fork Shift"l @ Fork Shilt-3 Bar Shift Fork Guide-2 @ Fork Shi1r2 Bar Shift Fork Guide-'1
2. CHECK: . Rolate Cam Shift and Check l\4ovement of Fork and Sliding ol Attached cears lf Incorrect operation then Reassemble.
CRANKCASE ASSEMBLY
D
Kgm (11 Ft. Lb)
2.0 Kgm (14 Ft. Lb)
1.
2. 3. 4. 5. 6.
1
.
OIL SEAL BEARING 6304 BEARING (NRB) OIL SEAL CRANKCASE LH CRANKCASE RH
BEARING 6204 BEARING 6205 DRAIN PLUG OIL SEAL RETAINEFI OIL SEAL BEARING 6303 Z
APPLY:
. Yamaha
3 t\,4
Bond €) (to both
Crankcase mating surlaces.) 2. INSTALL: . Dowel Knock Pins @
The
3, INSTALL
.
R ght Hand
wth
Ma let)
Crankcase €) (Tap as sho$'.
4, TIGHTEN:
.
CrankcaseTightening Screws.(1 3 Nos.) Tighten the Screws in the shown sequence and in two steps (1) Semitighten (2) Full itighten. 0.7 Kgm (s.1 Ft. Lb)
FLYWHEEL MAGNETO
1
INSTALL Stator Assembly O
.
2
CONNECT
.
3
Neutral Switch Lead Wire @
1NSTALL
.
. .
Woodrulf Key Rolor Assembly @ Lock Washer
TIGHTEN
.
\ul E using socket No 19 with To'que W.erch holding Botor assembly w.th Special Service Tool ESN,I 201 6)
I
NESR\NN
E\,ra:f11r9l
crankcase (Left hand and Right Hand) should always be replaced as a set.
SHIFT SHAFT
o 1.0 Ksm (7'0
PIN CLEVIS SPLIT PIN ROD SHIFT WASHER PLATE CIRCLIP WASHER PLATE PEDAL SHIFT COVER SHIFT PEDAL ARM SHIFT
1, INSTALL: . Stopper Lever Assembly O . Plate Cover (a . Shift Shaft Assembly @
clRcLlP 10. ,11. WASHER PLATE 12, OIL SEAL 'I3. SHIFT SHAFT 14. SPRINGTORSON 15, SPRING TENSION 16. scREW 17, NUT
'18,
WASHER LOCK
2, INSTALL: . Washer @ . circlip @ 1.4 Kgm (10 Ft. Lb)
Ft Lb)
I
2, ADJUST:
. .
Shift Lever position (by Adjuster Screw @ and Locknut @) Gap @ to be equal on both the sides.
While adiusting the transmission should be engaged in the 2nd Gear.
,
I I
I
KICK STARTER
i
COVEF KICK LEVER K CK CRANK SPRING BALL BOSS KICK CRANK SPACER
SPRING TORSION COVER SPRING GEAR KICK GEAR KICK IDLE CLIP KICK AXLE ASSEMBLY
3-21
1, INSTALL . Kick Starier Assembly
2. POSITION . The Kick CliP @ in groove @ ot the crankcase as shown
3. HOOK . Return Spring @
4. INSTALL
.
Ckclip
.
Kick ldle Gear @ Washer @ Circlip €)
.
.
ENG
CLUTCH
N.
SN @; \%6 ^.%1, 1t
P,pg
26
=@
22
BOLT WITH WASHER SPRING COI\,lPRESSION PLATE PRESURE ROD PUSH 1 NUT WASHEF CONICAL SPRING PLATE FRICTION PLATE CLUTCH BOSS CLUTCH PLATE THRUST - 1 PBII\,'IARY DRIVEN GEAR
SPACER WASHER PLATE
14. BALL 15. ROD PUSH - 2 16. OIL SEAL 17. LEVER PUSH 18. SPRING 19. OIL SEAL 20. SCREW PUSH 21 BOLT SET 22. NUT 23. NUT 24 WASHER SPRING 25, GEAR PRIMARY DRIVE 26. STRAIGHT KEY 27, COLLAR 3-23
'1, INSTALL
.
Thrust Washer
.
O
Spacer @
. Driven Gear Assy. O . Thrust Washer @ . Oil Seal Retainer @
.
.
.
Spacer @ Straight Key @ Primary Drive Gear @
Insiallation ol Dliven Gear Assy. and Primary Drive Gear should be done Simultaneously
2. INSTALL
.
I
Cluich Boss @
. Washer
@
'Nut@ 3. TIGHTEN
'Driven Gear AssY Nut with Tc':-i W'ench ard no dlng tle Clulcf B' w,ll. Specral Se.v'ce Too FSV
:'
.: :
E\ \\1
[.*n'" (31 Fr. Lb)
The Clutch Plates must be so insta le: their cutways do not overJap each otf: except for the Plates 1 and 5
4, INSTALL
.
15 4
((
. )12
Friction Plates (6 Nos) @ Clutch Plates (5 nos)@.
'Ball@
'
Push Rod @
Arrow of Pressure Plate should matched with the Dot Mark on Boss
3-24
b€
clul]-
5, INSTALL
. .
.
Pressure Plate @ Springs @ Bolts @
6. TIGHTEN . Primary Drive Gear Nut along with washer by using Torque Wrench.
DRIVING SPROCKET 1
, INSTALL
.
.
5.5 Kgm (40 Ft. Lb)
Drive Sprocket O Lock Washer
TIGHTEN
.
Drive Sprocket Nut @ with torque wrench
having socket No 26, holding the Sprocket by Specral Service Tool ESlvl 205 @
CRANKCASE COVERS
l
INSTALL . Crankcase Cover RH O
b"
V4* YY'
s' a{4
s9 ,' 1.
2. 3. 4. 5. 6. 7.
SPARK PLUG NUT CYLINDEB HEAD GASKET CYLINDER HEAD BOLT STUD CYLINDER BOLT STUD
B.
L '1
0. 11.
12. 13. 1r1
15.
NUT GASKET CYLINDER RINGS EXPANDEF PISTON BEARING CYLINDRICAL PIN PISTON CIRCLIP
il
ENG
1, INSTALL . Piston O . Piston Rings with Expander @ . Needle Roller Bearing . Piston pin O using Special Service Tool ESM 507 @ (Piston Pin FePlacer) . Piston Pin clips (new) @
-
3
IMPORTANT Make sure Piston Ring Ends are property titted around Piston Ring Locating Pins in Piston Grooves The arrow on Piston Dome musl face Exhaust Side.
Belore installing the Piston Pin Clip cover the Crankcase with a Clean Rag
CYLINDEB
INSTALL . casket (new) at . Cylinder @l Using Special Service Tool qrng Compressorl ESVI 5'0 3 tPislon
TIGHTEN
.
Cylinder Nuts Gr (4 Nos )
Q*:"re{"i 3-27
1, INSTALL
.
Head Gasket O Head iO
il
. cylinder
{
I fi 1
2, TIGHTEN
.
Cylinder Head Nuts Ol 4 nos. with torque
wrench using Socket No 14 " Spark Plug €)
Q\.1,:lyll".-.'f ENGINE MOUNTING
...-:'
1. TIGHTEN
.
Engine Mountlng Bolts
.
Eng ne Mounting Bo
9\ IN
L.H. crankcase Cover
ILL GearBox Oil L.Fl. cfankcase Cover
.
3-28
le
*n* (* r,. .01
STALL
. F
..0
ts
i.0,
t i
DRIVEN GEAR ASSY, & GEAR PRII\,4ARY DRIVE GRADING
DF VEN GEAR ASSY
GRADE
DB]VEN GEAR
"r=h
@ PR MARYI
G B
A
A
c
B
c
D
B
E
D
e
E
.
(S]\,4ALL END) &
::DLE ROLLER BEARING (SIIIALL ROD(sE)
A
PR]N4ARY DRIVE
D
.{N
z
GEAR \
GRADE
:\]NECT NG ROD
GRADES
SPEC FIED ALLOWED CO]VBINAT ON
END)
COLOUB
CUT N,4ARK ON CAGE SIDE
COLOUR coDE (DOT)
CODES
'-\
WHITE
.--ir'rcrsEr\
BLUE BED
(D0T) (D0T)
SMALL END NEEDLE
(DoT)
I B {1 CUT MABK)
AII I (2 CUT |\4ARKS) CRANK SHAFT
UI 3 CUT MARKS
.
SPEC FIED ALLOWFD COI\,IBINATION .OLOUR BAND
STANDARD PISTON & STANDARD BODY CYLINDER
BODY CYL NDER ASSY. (STD )
J:IDE
l:
PUNCHED ON BASE FRONT TEXHAUST PORT SIDE)
..: :rnbLnalrnsol gra'lesareappL,.ablelo(standad l; rden ..y.vers'ze (OrS) gody Cy .ders the , .: il Pslon [.!d be delerm ned by lhe rebored .:.1fi€rnaloflhe
COLOUR BANDS
3CDY CTL lSTD.
(STD)
:
P STON (STD)
B.dy cy rnder
$n D
RED E'
e!41!GE
r.
GREEN
D
PURPLE
Er S
l
3- 29
!
CHAPTER 4 CARBURETTOR CARBURETTOR cARBURETTOR EXPLODED VtEW .......... ... .
...
.......4-1
opERAT|ON OF CARBU RETTOR ................................ 4-2 WORKING RANGE OF EACH COMPONENTS
DISASSEMBLY TNSPECTION REMOVAL AND
-
, .4-3
........4-4 -.....-...4-5
REED VALVE
TNSPECTTON
..........4-5
,l
19 1
F 116
&17
-,
CAP
12. FLOAT ASSY
GASKET SPRING THBOTTLE VALVE NEEDLE SET VALVE THROTTLE - 1 CABBURETTOR BODY AlR SCREW SET fLUNGER STARTER ASSY THROTTLE SCREW SET
13 FLOAT CHAMBER 14, GASKET FLOAT CHAIV]BER 15. JET PILOT
\LL\LL \NL\L N\S\.
-.
.P\N FLOAf
16. NOZZLE IVIAIN 17. JET MAIN 18. CLAN4P HOSE
9 JO NT CARBURETTOR 20 REED VALVE ]
2\ q}\\\.L\\\\\LSE\\
4-l
IG
f
@
CARB
OPERATION OF CARBURETTOR Throttle Valve opening Angle
Operating System
ldling
0
Piloi Jet
0 to 1/8
Piot Jet
Low
speed
Low and [/ed um Speeds 1/B
to
'114
Pilot Jet /Cutav'vay
Nledium and high Speeds
Marn Jet
114lo 314 [/ediL]m and high Speeds 3/4 to Full
Main Jet
LOW SPEED CONTROL SYSTEM
OTO 1/8 ffHROTTLE OPENING)
lr tl
\-:-r0-
1/8
llqT ourtE-
MrxrNG
-|l t! 4-
{
li,ru
LOW SPEED CONTROL SYSTEM Throllle va]velplsro.)
1/8 TO 1/4 (THROTTLE OPENTNG)
_t
MIXING
FUELi_}L8]!8I!EfI
MEDIUM SPEED CONTROL SYSTEM Thronle vaNe(piston)
1/4 TO 3/4 (THROTTLE OPENTNG) ENGINE NEEDLE JE
JET NEEDLE
HIGH SPEED CONTROL SYSTEM 3/4 TO FULL (THROTTLE OPENING)
NEEDLE JET
MIXING
tl 8-? 1_1 tTl Ai ffiL \9r+
WORKING RANGE OF EACH COMPONENT
S71
A) MAIN JET
B) NEEDLE JET AND JET NEEDLE C) THROTTLE VALVE CUTAWAY
ED1
1
8424
1
1
FULL OPEN
D) PILOT AIR SCREW & JET
r REMOVAL AND
DIS AS S
1 :=
E
tt'lB LY
.
"'3, S:e 2.ri . :r.:-
'
aa. Assernbll/ 3 \las saretls
RH side.
A r Cieaner G) by opening
2. LOOSEN
. Jo ni Arr C eaner Clamps Screw @ . C amp Carburettor Hose Scfew ol Jolnt Carburettor:r. 3, DISCONNECT:
. .
Fuel Hose @) Oil Delivery Hose
6
4. REN4oVE:
. Carburettor lO . CarburettorToP
@
5. DISCONNECT:
. Throttle . Throtile
Cable (O Valve AssY.
6. REMOVE:
.
Starter PlLlnger Assembly €l . Float Chamber @ by opening four nos scre\i/s. . Float @ by removing Pin Float (a . Needle Valve Assembly d, . lvain Jet by @ . Pilot Jet bY screw driver 6'
7, REMOVE . Reed Valve Assembly @ by opening,: No bolts (Reed Valve, Joint Carburettof Gasket)
IMPORTANT
. Never clean the Jets with a wire. . Alwavs clean the Carburettor lrom outside belore disassembly' . irpi6p"t of Float Height, C-lock on Jet Needle' and Air Screw can ca averagedrop in fuel""ning
CLEANING ANDINSPECTION 1. CLEAN
OdDp a-
.
Using high pressure air, blow out all passages anq lers. 2, INSPECT:
.
Needle Valve Assembly 1 Gasket O 2 Valve Seat @ 3 Needle Valve @
Damaged or Worn
3. INSPECT
. .
oul -Replaceasaset
:
Throttle Valve @
Jet Needle @ Scratch/Bent - Replace
4. MEASURE:
.
Float Height @ Without Gasket
wilh Needle Valve Assembly in posiiion lf found incorrect then Adjust
\\'@/2, N
ffi
]
5. ADJUST
.
Float Height by bending the Tang @ IMPORTANT
lf Float Height is more than specified, less petrol in Float Chamber. lf Float Height is lessthan specified, then
more petrol in Float Chamber.
4-5
T
CARB REED VALVE
, ,: ,: :i::3e'neight o a-: a' :3:. i ;alon -AdjLlst . ?ea. !a re gending g
oLt oi sPec flcatlon -RePlace
Valve StoPPer Height @ 9i0 3 Fteed Valve
Bending Limit O
0.2mm
Note the cut is in the lower corner or the Reed and the StoPPer Plate'
FUEL LEVEL
.
Place the Motorcycle on level surface Attach the FLlel Level Gauge Gl to the Float Chamber Nozzle . Loosen the Drdin Scle',i/ 2 and "larl I' Enqine. . Me;sure the Fuer Level J wilh OaJg" . lt the fuel level is incorrect adjusl the
.
Float
FUEL LEVEL:5.7 i 0.5 MM {MEASURED FROM THETOP EDGE OF THE FLOAT CHAMBER)
ThecalburettorisPresetattheFactoryaftermanytests.|fthesettings'aredisturbed Perfomance may result.
"i-tro"i
ftltlng
""V
technicat knowledge, poor Engine
FRONT WHEEL
12
"@-*^
n.,,.'
A6-
,{n'@
k'*,,
16
7
AXLE WHEEL COVER ASSEMBLY OIL SEAL
a. 2.
-0.
'1.
BEABING TYRE TU BE BAND BlM SPOKE SET HUB FBONT SPACER ASSEI\IBLY
12, 13. 14. 15. 16 17. 1B 19 20. 21 22
BEARING
BRAKE SHOE COMLPLETE CLUTCH METER GEAB DRIVE OIL SEAL CAM SHAFT PLATE BRAKE SHOE LEVEF CAM SHAFT 1 GEAR METER BUSH O L SEAL
tr...
CHAS
FRONT WHEEL REI,IOVAL
' :-ra: --: ','OIORCYCLE ON ITS a:'.-::3-i'.l 2 - a:: ='. t -.: -a:{_-: ! and screw n the adjuster : ic :aaa' tfre brake cable on the front \.;ree t are brake shoe.
3. DISCONNECT: . The brake cable @ by pressing Lever Camshafll L4l
4. DISCONNECT:
.
Removing the Ring Stop @ Disconnect the Speedometer Cable a6l
Relit TheWheel in Reverse Sequence.
{fi Y'
Front Axle Nut 4.3 Kg. m (31 FtrLb.\
5. REMO\E:
.
Colter Pin ill Axle Nut €) by using rlng spanne". . Axle Shaft O . Front Whee @
.
CHAS REAR WHEEL
'a 13
&..r{*t t t1,
fzs L"qJ *;'@"" ;* I
-4
-**
zsAXLE WHEEL PULLER CHAIN 2 COLLAR LEVER CAM SHAFT PLATE BRAKE SHOE CAI\,I SHAFT BRAKE SHOE SET TYRE TUBE BAND Rll\,1
SPOKE SET
17.
OIL SEAL BEAFING SPACER ASSEIMBLY 2 HUB BEARING DAI\,4PER
19.
24. 21
22. 23. 25.
CLUTCH HUB BEARING OIL SEAL AXLE SPROCKET CHAIN SPROCKET DRIVE PULLEF CHAIN 1
@o
T
ii!:
,I.gEL
--: .-_:
,,.
REMOVAL
:-SRCYCLE ON ITS
::A "
SUPPORT
.,
'anovLng splitpin and -s rg r ng spanner No
::t,'',
:
, : r' 1 :
t i: ': :':r:
. .
5
4,
.!
-
or -r screvlirg Nulwing hoo !
ca.npress So' vlasher P ate O
on
3
6
REN,4OVE:
. .
Split Pin O Axle Nut @ using Ring Spanner No 22.
5. REN4OVE|
.
Axle Wheel O While pressing the Assist Grip @ down with force.
. Collar @ . Rear Wheel @ tiiting the Motorcycle
to
Lelt Hand Side.
Cale should be taken that the'AxleWheell should not Rub the Silencer while it be.J ing pulled out from ihe Real Wheel.
REFIT THE WHEEL IN BEVERSE SE. OUENCE.
lQIe""'^'"]1s.2
Ks. m (66 FtLb.)
I
CHAS
SPROCKET DRIVEN & CHAIN REMOVAL 1, REN,4OVEi
.
.
Chain Case
1O
by open ng screws (4 Nos)
Dr ve Cha n lock
O and Drive Chain O.
2. FIEMOVE:
.
I
I
.
I
I
sprocket Assy @ by opening Nut Gl using Ring Spanner No 27. Sprocket Driven @ from Clutch Hub (a by un ocking and opening bolts screws (4Nos.)
{
INSPECTION 1.
INSPECT; . Axle Wheel (Beaf and Fronl) Roll the Axle Shaft on a Flat SLrrface lf Shaft Bent then Replace.
2. INSPECT:
. Wheel
lf
(Rear and Front) Tyre Cracked/Rim Heavily Bent then
tr6nl'.o
th6.^n.d.han
^rrt
3. MEASURE:
.
Wheel Runout
f out of
Specification then True the
Wheel or Replace. Rim Runout Limits FadialoMax 2.0 mm Latera\OMax 2.0 mm
4.
IN
SPECT;
. $Jf,ee\ Bear\ngs f excess play in the Bearings or Bearrng Jarnmed then Rep\aae.
5. MEASURE: . Brake Shoe thickness Out ol specification then Beplace.
Brake Shoe Wear
limit 2MM
6, NIEASURE:
.
Brake drum inside diameter Out ol specification, Beplace.
lBrake
'tl F@S
Drum Diameter
Limit
'13-1
mm. (max.)
T.INSPECT: . uflve SprocKel ql . Driven Sprocket @ ll Wear/BentTeeth ihen Replace both Sprockets and the Chain as a set.
8, MEASURE:
.
Drive chain length (10 Links) 'A' li Out of specification then Replace
Diive Chain Length (10 Links) Maximum Lim:t:'12'l mm
r:
CHAS
9. INSTALL
.
The Chain Clip O with rounded end facing the direction ol travel of Chaln
10.cHECK
. .
That bolh ihe RH and LH Chain Adjusl ers are adjusted to the same position to maintain correct Axle alignment. The Chain Slackness should be between 20 to 30 mm with Motorcycle on Centfal Stand.
KITIMPoRrlNrl
I Please lubricate Chain with Multigrade | 20w40 oil belore installing.
Note the following installation points
-
ghtLy grease the wheel oil seal lips and geaf teeth of the
Jears. LJse jghtwe ght, lithium base grease ) 3e sure that the tongue stopper is posiUoned cofrect
y.
speedometer drive and driven
I I
rI l
uti I
lnftxl l"" "tot l
:-
E I\,1BLE IM
FRONT FORK ASSEMBLY RH. UNDER BFACKET COMPLETE CAP FRONT FORK BOLT CAP SPACER SPRING SEAT SPRING
L 10. 11. 12. '1 3.
14. 15.
CYLINDEF COI\,4PLETE INNER TUBE COI\,lPLETE SPINDLETAPER SEAL DUST CLIP OIL SEAL OIL SEAL OUTER TUBE LH
REMOVAL 1
, REMOVE: . Front Wheel as described on page 5-1 . Front Fender bV opening bolts (4 Nos)
2. LOOSEN:
.
. .
Front Fork Pinch Bolt Upper Hemove uap hronl ForK !9 Bolt Cap @(2 Nos)
O
(2 Nos)
Use Specia' Servce Tool ESM.2l4 (Top Plug Spanneo
a
3. REMOVE:
.
Emblern 6) by opening screws (2Nos)
LOOSEN:
.
Front Fork Pinch Boll Lower @ (2 Nos) using Ring Spanner No 14
5. REMOVE:
.
Front Fofk Assembly L.H. & R.H.a0
DISASSEMBLY '1. RE]\,4OVE:
pl
. Botoap O
t
-
8,, !, E
f
spacer rg " Spring Seat O . Spri.g @
'
DISASSEMBLY
2 DFAI\
. Fr.ri F:'( O ci
-^
ns de
:h: O!iaf
Pumping InnerTube@
T.rbe
tt
3. OPEN:
.
Bolt Hexagonal Socket Head @ by us' ing Allen key No 8 Use Special ServiceTool G) {ES-\,4 - 213) (9 1o hold the CYlinder ComPlete
.
4. REMOVE: . tnnet tuoe 9 . Cylinder ComPlete @ . Spindle TaPer @
5, REMOVE:
. . .
.
Dust cover @ Clip Oilseal @
Washer () Oil Seal @ using Special Service Tool @ (ESM 270)
INSPECTION 1. INSPECT: l . lnner Tube il-
t." a** tr*
.
Outer Tube
Scratches/Bends/Dan'rage Rep ace Teourred.
\leasure Length of Fork Spring oi specificat on Then ReP ace Specified 296.5 mm Nlinimum limit 291.5
5-10
€l
lf Out
O Ring of Bolt CaP Cvl nder CornPlete for Damages C Seal ot Outer Tube lor dan]ages
t
ASSEMBLY 1. INSTALL:
.
Insert Cylinder Complete O (with Spring @) irom the top end ol the InnerTube @
.
Spindle Taper @ on the lower end of the Cylinder Complete
.
Inserttheaboveassemblyintothe outer tube 6)
.
Bolt Hex Socket Head @ Using allen key No 8 and Special Service Tool @ (ESM
21s)
Cylinder Comp
;
2.3 Kg.m, (17 Ft.Lb)
2.
INSTALL:
.
Oil SeaL @ with Special Service Tool EStVt 275 €).
.
Clip Oil Seal
3. INSTALL:
.
13
Front Fork Spring @ Seat @
. spring
'11
'
. .
4.
Spacer @ Boit Cap @ Dust Cap @
FILL:
.
Each Fork Leg 175 r 3cc SERVO TELESHOCAB
otL
Front Fork Oil
5. INSTALL
. .
'. t il
I
Front Fork Assembly LH & RH. Tighten the Bolt Cap. Pinch Bolt upper and lower Cap Front Fork
t6\ \ \
cap Bolr: 2.3 Kg.m, (17 Fr.Lb) Pinch Bolt: Upper: 1.5 Kg.m, (11 Ft.Lb) Lower : 3.0 Kg.m, (22 Ft.Lb
e11
€tz
eP
E0
kis?
l-/P
g F
L-
COVEB UPPER RIGHT COVER UPPER LEFT COVER OUTER RIGHT COVER OUTER LEFT EMBLEM UNDER BRACKET LOWER RACE BALL 1 BALL 19 NOS LOWER RACE BALL . 2
UPPER RACEBALL - 2 BALL (22 NOS) UPPER RACE BALL - 1 COVER BALL RACE NUT CROWN HANDLE HOLDER HANDLE UPPER BOLT CROWN
10. 11.
14.
17.
REMOVAL
1
. REMOVE:
.
Front Wheel as per instructions on page
.
Front Forks as per instructtons on page 5-6. Headlight Bezel Assy. O
.
2
DLSCONNECT: All Electrical lead wires @ (in the Headlight Case)
.
13
e14 ^_5 rz
s,9 .d:
g" 16
COVER UPPER RIGHT COVER UPPER LEFT COVER OUTER RIGHT COVER OUTER LEFT EMBLEIiI UNDER BRACKET LOWER RACE BALL 1 BALL 19 NOS LOWER HACE BALL . 2
'1
UPPER RACEBALL . 2 BALL (22 NOS) UPPER RACE BALL - 1 COVER BALL RACE NUT CROWN HANDLE HOLDER HANDLE UPPER BOLT CROWN
0.
1',t.
12.
14.
17.
REMOVAL
I
REMOVE: trrolt Wheel as per rlsl.uctro'rs on page
.
2
.
tr'o1t Forks as per Insl.lrctions or pagc
.
Headlight Bezel Assy. O
DISCONNECT: A I E ectrical lead wires @ (in the Headlight Case)
.
s-12
3, REMOVE:
.
Cover Crown O Bolt Crown @ bY using socket No 17
.
. Crown Head assembly @ . Headlight Stays (LH & RH) @
4. DISCONNECT:
.
Brake Cable @ {rom the Brake Lever @) clutch cable (0 from the clutch Lever @
.
5, REMOVE: lnigil 1t 13
6
'14
t5 t6
.
Fork stem Nut @ using Special Service Tool @ ESM 221 . Cover Ball Race @ . Race Ball 1 @ . Top Balls @ (22 nos ) . Bottom Balls q9 (19 nos ) . Under bracket @
6, FIEMOVE
. .
Race Ball 2 (Lower @ and Upper @) Using a long rod. Race Ball 1 @ (Lower) Using a cold chisel.
T CHA a
INSPECTION
@"@
--: ::::: :_:
2 \,s:::.:
oqr. ^
'.EW
=
Sals in pekol.
-:r ::_rage Then Replace.
:-:;
tarage Then
Replace.
INSTALLATION
J \S-ALL . Fa.e Ba
T (bottom) €Jon the under cra:K:l ano race ball 2 bottorn Oand upcer ,2 insrde the head tube of the
frarne uslng punch l.Grease the Balls and Baces
2, INSTALL
. . . .
Under Bracket @ Race ball 1 upper Beaflng uover a Ring Nut lO
3. TIGHTENi
.
Ring Nut @ with Specia Service Too ESM 221 t-' (So that a I play is taken up, but the DracKel can still pivot freely.) INSTALL: Handle Crown w th Head ght stays Crown Bolt Front Forks LH and RH as per nslruc tions on page 5-8
CHAS
@q$roo
f\\Cr-;3
\
,iu 5, BRACKET UPPER 6. COVER OUTER 7. SPRING 8. SEAT SPRING 9. DAIVPER ASSY
1. SHAFT PIVOT
2. BUSH 3.
REAR ARM COMPLETE
SHOCK
ABSOFIBE R
ASSY REAR
REMOVAL REMOVE:
. .
. .
Chain Case Drive Chain Dfiven Sprocket Chain Case
REMOVE:
. .
Shock Absorber Mount Bolts@ Shock Absorbers
REMOVE:
el
.
Pivot Shalt Nut O
. Pivot Shatt
. I
Sw)ng arm
0
t\
CHAS
INSPECTION t.....:''':'
lhen Beplace
2 '.s;:a.
S,',
-l a'-
'.,'i- :.a
s!','ng arm Installed gfasp the ar.n enC to check forfree play- Free p ay rc: .ed Replace bushes.
sl., .;
Swing arm Free Play
)o
Limit:
2.0 mm
3. INSPECT:
.
P vot Shaft 2
Rusvd rty Clean or Replace. Bent - Replace
INSTALLATION . GREASE THE BUSHES AND PIVOT SHAFT. 1
2INSTALL:
.
.
Swlng arm P vot Shaft
Kgm (43 Ft. Lb)
Always adjust both the right and left shock absorbers to the same posit on.
5-16
ELEU
t2!
5/2tW
a.s
o
ls I
Ei
Jl ]HTET
F
-u
ql
- M-
si
\*s
t
z E9* 6
I
r"l
E
-E
-
= =
IT
o (l
4 I
I 6+ .o
e t-l;" s:E?lsa
dts
-a
rt"'lr
s;:869s
ft
IE
-:HE
ecFii?
z
. -li O6dEt;
FLASHEFLIOHI
12V.1Cr'
LGI]I 12V.3lW
HEAD
12VN4W
]21J-3 4W
L]6
-
12V.35r3!rr
_:-_ : :r'
I
t SOURCE COIL IGNITION COIL
,,i----\ 'i
@o-
cotL
FIG 2 tr{!,}
ffi vi
il
E)
T
0
FUNCTION CHARGING . As tt-te fotor turns, cufienl ls produced in 'ie so- ce.oil a1d then storpo il rl^e.g1. t on condenser. (Fig. 1) TR GGER NG
. Att
e same time.The pickup coil sends a pulse s gna I to activate the thyristor (Fig. 2)
SPARKING
' --:. the gnilion condenser discharges :-: :iored current rapidly. This induces a - l- c tage n the lgnition coil and a stronc
:::
.
< s oroduced.(Fig.
3)
t
TROUBLESHOOTING CHART
.
All wires Conneclion must be checked in advance. Pick Up Coil
Spark Gap Test
1
. Ground the Spark Plug to
the Cylinder
.
Head and Kick the Starter No Spark or Weak Spark
"^+
+
5
Hold the lgnition Lead 5 mm from the Cylnder Head No Spark
.
|
*o+
SoLrrce Coil Check
Check up source coil resistance
*+
o*+
check the Plug Cap
Replace the Source Coil
and Spark Plug 3
Coil Resistance
Replace the Pick Up Coil
rk Gao Test
.
Check the Pickup
6
rk Gap Test
|
lqnition Coil Check
OPRM
'"6 .
Disconnect the Main Switch Coupler and kick the Sta er. No Spark
I\,/
Check Main Switch
5parK
.
o
L
6_J:!qqn
t--tnl t . t-- -rtl
HY
Check the resistance of the primary and
*"+
secondary coil winding.
"^+ Rep ace the CDI Ljnit
Replace the lgn tion Coil
RECTIFIER/ REGULATOR
--.--\
FUSE
CHARGING
corL
;-
.i
,i
BATTERY
l..Charging Voltaqe Test . Connect the lester leads with battery terminals as shown.Start the engine and check voltage.
2. Charging Coil Besistance
Dlsconnect the generator leads an: check charging coil winding resistanc€
iHAFG NG COIL RES STANCE : .q olll,,4s r l0?" (Wlrrle/B ack)
CHARG NG VOLTAGE
14.5i05Vai5000FPNj
_!
lf out of speciiications checK Char,o coil windlngs reslstance Ata ' ff :'a than 12V replace the Rectre"Fe!-:' 10r
:
-: :: soec l cation,
reP ace charglng
.-
rllGH BEArli NDtCaTOF LtcFT
neoo.,cr-,
il
).
\" I ll e.+" l J
L?'TI r*-l,
AUXTL|ARY
LIGI,]T
i
,rrrr^-
LIGHT
*
LIGHTING SWITCH
f'l)l
Yl
| o,0;";*"t BECTIFIEF BEGULATOF
LroHlruc
=
l.Lighting Voltage Test t:e headl;ght reads and connecl I:To'1e Ine lester leads as shown St:ri rh. -^^; ard .necF rr^e uoi,uj"" "*" " = - tgrn"
YELLOW
ll:n.:'::J ;":t j ";:;,,;1:1". ."
2.Lighting Coil Reststance
coti
H GH BEAM IND CATOF
LIGH'
LIGHTING SWITCH
HEADLIGHT
,ti
/:4.
r\14*Fr
FIECTIF ER
LIGHTING COIL
REGULATOF
l.Lighting Voltage Test Remove the Headlight leads and connect the lester leads as shown.Start the engine and check the voltage.
L G]]TING VOLTAGE 13.5!0 5V AT 5000 BPl",l (Yel ow /Black or Grcen/Back)
lf o.rl o' spec:'icatio Ihe.( | rgl^lng coil resislance and Rectif ler/Regu ator.
2.Lighting Coil Resistance
L GHTING CO L FES STANCE 0.55 OHNIS r0% Yellow Red/Bla
r
--I
HLGH BEAM INDICATOF
LIGI]T
LIGHTING SWITCH
HEADLIGHT
L GHT
METEFI L
GIIT
MAIN SWITCH
L GHT
L GHTING COIL
BECTIFIEB REGULATOR
=T
---L-
l.Lighting Volage Test Remove the Headlight leads and connect the lester leads as shown.Start the engine and check the voltage.
LIGHTING VOLTAGE l3 5!0.5V AT 5000 RPM (Ye low iB ack
or GreedBlack)
li out of specification, check L ghting Coil resistance and Rectif ier/Regulator-
2.Lighting Coil Resistance
LIGHTING CO L RESISTANCE 0.55 Ol'llr4s i 10%
r
Briw
Br
FLASHEF
LGHT(FF)
.i
swtTct
I
FLASHEF
\
tt:
i:sw Tcfl
FLASIIEF IND L GHT (B)
+
SHIFT
LGHT (L.F
l
LGHT(LFl
BATTERY
FLASI]EF N: L GHT (L) BRAKE LIGHT
MAIN SWITCH SWITCH INSPECTION
B/W
oFs G
o
Br
R
G.
oNo
(:rc
LIGHT SWITCH L
o (oscoNTlNrlED)
6-6
{coNTrNUEo)
-{f
PO
G
ON
o-
o
o -o
I,IMER SWITCH
BRAKE SWITCH
\JS
ASHER SWITCH
qN SWITCH
G
-o
-..-
DIMMEF SWITCH
BBAKE SWITCH G
H'
ro
o
Qt
ci
o
\JS
o
--o
FLASHER SWITCH B/w
D9
oN
o-
-o
HORN SWITCH
i :l
--o
O
--o
DIMMER SWITCH
BRAKE SWITCH
\J>
G
\Js
G_
ci
LO
o- --o
FLASHER SWITCH Br/w
Dg
oN
-o
HORN SWITCH 7777
I rl
o
o
t
o
I
delivelr
crank veniilarcn
hoso
calbu1610r br€atherhose
STARTING TROUBLE POSSIBLE CAUSES FUEL SYSTEM No
luelln Tank
BefrtJfuelrn Tank
Fuel Coch cjosed
ri'"",'"",',iti
:?11 fl:?
Turn Fuet Coctco ,ON,
ll
.,,":fiJ'
Air veni
hole n FuelTanf Crp Choked FueICock
"log;;
Carbureitor llooded
c";"
Fuer
3:Tlr:,i:ilank,
Foitroi
F*il;""d
Clean Fuel Tank Cap Get Fuet Cock cteaned T,,rn F,,-i
^-^,-. ,;";::::1,:,y.' .pos,uon. oDer rre rhro re ;;;;ff il:j :"^ ifj i'; :rar.airer unscrewns spark --;;;il'Jil
l;1g T:,t :g:'ln:l'" "'u,,,. He'lt upark plug and k,cx start
Chocked Fuel Filter
Switch OFF,
Spart eiug Otrty
or.
Turn key to ON'positio;
OriOg;;y
s;;
H. T. tead toose/broken.
lnsulatton of Spark plug cracked Elecl ron ic
i
g ni
tion
: :['Jl i.g,"s
Get Fuel Fjller cleaned
IGNITION f"1arn
rne
system;f e;;
cl""n,
"t,""t
uno
uo;rs
Frt propertyheptace
rnu
$rkEfEE[IZ"p
H.TIeJ
Replace Spark pjug. Check ior ioose conneclions-
POOR PICK UP POSSIBLE CAUSES \4|rfJier ouIet chokecJ Ar
F[ler choked or drrly
!g1Oer Carluretror aCtustme,,rt Cylinder Head Loose C utch stipping
irenorQuality ol Fuel 3rake(s) b ndrng ?islon Fing worn out
Clean Ihe t!,lulfter Clean Air Filler/Beplace najL,sr tne Carburettor
sen-inii
f'On'"n CV""O", Uo"o
t,r"
AdJUst Cturch
se
rng
,o
*"a,t,J,o,G
.-,,r1,"1 cn"1!115g11a111.0^"[osoodquJ. Adjust Brake(s) Replace pisron Fings as
a;
STARTING TROUBLE POSSIBLE CAUSES
REMEDIES
FUEL SYSTEM No
fuel n Tank
Retilfuel
n Tank
FLre Cock closed
Turn Fuel Cock to ON' position
lmproper iue supp y due to sed ment orwater n fuelor alr lock in iuel line.
Clean Fuel fank, Fuel Cock, Fuel Line and Carbureitor.
Air vent hole in Fuel Tank Cap clogged
C ean FuelTank C_ap
Choked Fuel Cock
Get Fuel Cock cleaned
Carbureltor floo.led
Turn Fuel Cock to OFF'position. Open the Throttle and endeavour lo kick slad after unscrewing Spark Plug and plugging the Spark Plug hote with a clean c oll . Refil Soark P Lg and k'ck start rhe Engine.
Chocked Fuel F lter
Gel Fue Fiter c eaned
IGNITION Ma n Swilch OFF-'
Turn key to 'ON' posilion
Spark P ug diriy or brdged by soot or
Clean, check and adjust the Spark ptug Electrode cap
H. T. lead loose broken
Fit properly/rep ace H.T. lead
Insulation of Spark Plug cracked
Replace Spark Plug.
Eleclronrc rgn 1on system delect ve.
Check lor loose connect ons
POOR PICK UP POSSIBLE CAUSES
REMEDIES
I\,4uifief out et choked
Clean the IVluttler
A r F terchoked or dirly
Lrean A r
lmproper carbure or adj!stmenl
Adj,r.l th" C"rb,""1i",
Cylnder Head Loose
I sh"l]?4d"'. j""gli"lIp"Il"d
C utch s rpp
-:.
Adjust Clutch
Inlerior Oua fy ol FLrel Brake(s\ hind\ng
se
*til"S"
t"!*
ing.
Check and replace with specfied good qualty fue.
\ olt
_---
Tel/Hep ace
-
rg
Piston R ng v/orn
I
NNs\B\ake\s\ Rep ace Piston Fings as a set.
ENGINE GETS OVER HEATED BE|llEDIES
POSSIBLE CAUSES Fue -Arr L4i^ture ean
Adlusl Carburellor Selt ng
Air F lter choked by dirl
C ean Replrce Arr F Ter
I\,4uil
Clean the lMutiler
er outlel choked
Carbon depost n lhe Engine
Decarbonise lhe Cy inder Head
Spark Plug ol Incorreci Heai Range
Repla' e rrt_ Sp.
r
Dr ro
ol Co_e.lHe.L qdnge
POOR BRAKING REMEDIES
POSSIBLE CAUSES Brake(s) not propery adlusted
Adj!st Brake(s) propeny
Lin ng of Brake Shoe worn out
Replace Brake Shoes(s)
Brake Drum worn oul or scored
Rep ace Brake Drum
Brake no sy
Gr nd Brake Shoe surlace propeny
MOTOCYCLE WOBBLING REIMEDIES
POSSIBLE CAUSES R m Run Oul
orwobb e Trghten tenlace Spol'e(s)
Loose/Broken Spokels) ncoffect F trnenl of Tyre (s)
Rel I Tyre propery
Worn oul Whee Bearing(s)
Rep ace Wheel Bearingls)
Rear arnr Bush(es) worn oul
Replac€ Birsh(es) Replace Reaf Sw Inflale T!reisi
Tyre Pressure loo low
l.
{ rg Fofk
Iifcoer press!re
KNOCKING IN THE FRAME HEAD POSSIBLE CAUSES
Ba
Races Loose/ptted
R EI\,'I E
Ber.... :_:
a:
DIES
I rtes
DRIVE CHAIN NOISE POSSIBLE CAUSES Cha
n
oose
REIVEDIES
:-E: led s ac[ lm L
BULBS DO NOT GLOW POSSIBLE CAUSES No Fuse in lhe c rcu I or defective
Flse
Rep ace/assemb e Fuse assy.
Battery D scharged
Check electolyle eveland reptenish wilh dislj ed water. Check battery leads ior proper contact . Check Recl lier/Regulator un t.
Handle Bar Sw tch defecUve
Repa r/ Feplace Handte Bar Switch.
Bulb(s) Fused
Replace bulb(s)
mproper Earthing
Chech earthinq connecttons and clean lhem.
Loose or improper connections
Checl, and
recify connectons.
HORN DOES NOT BLOW POSSIBLE CAUSES Battery Discharged
Check electolyte level and repten sh with d stileo water. Check battery teads for proper contact . Check Rectif ierlRegulalof Unil.
Horn Defective
Feplace Horn
Horn Sw tch detecltve
Replace Horn Swtch
INDICATORS NOT WORKING POSSIALE CAUSES F!sed Bu bs
Rep ace Bu bs
mproper connect ons
Make proper connect ons
Indicator S!./ilch defect ve
Rep ace Ind cator Switch
Flasher Un t defectrve
Feplace Flasher unrt.
rmproper earllr ng
Check earthing connections and rectify thenr.
BRAKE LIGHT NOT WORKING POSSIBLE CAUSES
REMEDIES
rmproper adluslment ol Rear Brake Light Swtch.
Adjust the Erake Light Switch
Slicky Front Brak," Llght Sw tch
Clean/Replace ihe Switch
_
Fused Bulb.
_
R"pb"" B,rb
A\ Seat Height Wheel Base Minimum Ground Clearance l\y'inimum Turning Radius WEIGHT Dry CLUTCH Type Clutch Plate Friction Plate Lining of Friciion Plate TRANSMISSION Primary Reduction System Primary Reduction Ratio Secondary Reduction Systm Secondary Reduction Ratio Transmission Type Operatjon
765 1245
145
2100
mm mm mm mm
103 Kgs
Wet l\.4ultiple Disc 5 Nos 6 Nos Rubberised Cork Working in Oil HELICAL GEAR 71/22 \3.227) CHAIN DRIVE 37115 (2.460) CONSTANT MESH, 4-SPEED Through Foot Operated Lever, Mouni.: on LH Side of Gear Box with Neutra Gea. Positron Belween Frrsl Speed Second Speed
GEAR RATIO 'I
2nd 3rd
(35/11) (30/15) (26/19)
41h
(23/23)
St
3.182:1 2.000.1 1 .368:1 1 .000r'l
CHASSIS: Type Construction Castor Angle Traii TYRE Size (Front) Size (Rea0
2.50x1 8-4PFl-Nylon'Ribbed 2 75x18 4PR-Ny on-Universal
TYRE PRESSURE Front (Solo/Double) Rear - Solo - Double
22 PSI 2a PSI 32 PSI
Double Cradle Duplex, l\,4ade of Tubular Section 27.54
90 mm
t
Aq BRAKE Fronl Brake Type Operation Rear Brake Type Operation SUSPENSION Front Suspension Rear Suspension
.
Drum Brake (130 O), Intemally Expanding Right Hand Operation Drum Brake (130 O), Intemally Expanding Right Foot Operation CerianiType, Telescopic Fork, Oil Damped Swing Arm (Adjustable 5 Positions), Coil Spring, Oil Damped.
WHEEL TRAVEL Front Wheel Travel Rear Wheel Travel ELECTRICAL
lgnition System Generator System lgnition Timing :
SYSTEM Head Light Tail/Brake Light Flasher Light Park Light Neutral lndicator High beam Indicator Turn lndicators N/leter Light HO rn
110mm 75 mm
cDl Flywheel Magneto 15 a 3 at 1300 R.PM. BTDC '19 r 3 at 6000 R.PM. BTDC 12 VOLT 12V- 35W35W 12V- 5W/10W 12V- 10W(x4) 12V- 3AW 12V- 3.4W '12V- 3.4W
12V- 3.4W(x2) 12V- 3.4W '12V- 1.sAmp
BATTERY Rating Charging Current Charging Time Specific Gravity
12V-2.5 AH 0.25 Amp '15
Hrs (Approximate)
'1.240 (Fully charged)
RESISTANCE SPECIFICATIONS Pick up Coil resistance SoUrce Coil resistance lgnition Coil resistance Primary Coil Secondary Coil . Lighting Coil resistance Charging coil resistance
80 o a20% (MFIL) 230 or20% (MFIL)
o r 10% 6.6 Ko r 10% 0.55 o r20%(MFIL) 0.80 o r 10% (MFIL) 1.6
MAINTENANCE SPECIFICATIONS CYLINDER HEAD (Warp Limit)
<0.03 mm Lines Indicate Straight Edge l\,4easurenre.: l
CYLINDER Bore Size Taper Limit Out of Round Limit PISTON Piston Clearance (C)
58.00 - 58.02 mm in 4 Grades <0.004 mm <0.004 mm
:
34-39 l\4icrons (0.034 mm - 0.039 mm, Cylinder Piston Red
Orange Green
c
Pu rple
D
B
c=A_B SIZE (STANDARD)
57.967- 57.982 mm in 4 Grades
srzE iovERSrzE) First Oversize Second Oversize
58.25 mm 58.50 mm
I
A\ PISTON RINGS SECTIONAL SKETCH
I
--'-----)'
T
tl
f-r-] Top Ring
Key Stone B=1.2 mm f=2.2 mm Key Stone B=1.2 mm T=2.0 mm
2nd Ring
END GAP
Top Ring 2nd Ring Service Limit SIDE CLEARANCE
0.25-0.45 mm 0.25-0.45 mm 0.60 mm
Top Ring 2nd Ring
0.03-0.05 mm 0.03-0.05 mm
CRANK SHAFT
;a^ ,:r l1I
l-<
I
Crank Width 'A' Runout Limit 'C' Con. Rod Big End side clearance'D Small end Free Play Limit'F
55.9+0oshm
<0.02 mm 0.20-0.70 mm <0.03-0.18 mm
A\ CLUTCH Friction Plate Thickness/Quantit, Service Limit Clutch Plate Thickness/Quantity Service Limit (Warp) Clutch Spring Free Length/Quantity Clutch Spring lvlinimum Length Clutch Release l\,4ethod Push Rod Bending Limit TRANSMISSION Main Axle Deflection Limit (Run Out) Drive Axle Deflection Limit (Run Out) SHIFTER Shifting Type Guide Bar Bending Limit KICK STARTEH TYPe
Kick Clip Friction Force (lvl in - N4 ax) Air Filter Element CARBURETTOH TYPe
lvlanufacturer lvlain Jet Jet Needle-Clip Position Pilot Jet Starter jet Pilot Air Screw Setting Float Height Engine ldling Speed (On warm Engine) LUBRICATION l\y'inimum Stroke l\,4aximum Stroke Pulley Adjusting Mark Ai ldle
3.0mmx6 <0.02 mm '1.05-1.35 mm (x 5) <0.05 mm 34.5 mm x 4 <33.2 mm Inner Push, Screw Push <0.15 mm 0.1 mm 0.1 mm
Guide Bar <0.05 mm Kick and Mesh Type P=1.0 Kg. (0.8-1.2 Ks) 2T oilof Superior Grade Qualily
vM22 I\,4IKUNI
#
165
3rd Groove From TOP # 17.5
#20 1.5a0.5 Turns-(Adj. at max. r.p.m. position)
22.50+1 mm (As reference) 150011m pm (After running in of 1000 kms) '700:'00 'om lupto 'u.-ing in or 1000 k.ns/ 0.20-0.25 mm 1.95-2 05 mm
i
SE RV
INFO
A
Gr
CHASSIS STEERING SYSTEM Steering Bearing Type Number of Balls/Size of Steel Balls Upper Lower FBONT SUSPENSION Front Fork travel Spring Free lenght Spring l\.4inimum Length Oil Capacity (New Fill) Oil Capacity (For Replacement) Grade REAR SUSPENSION Shock Absorber Travel Rear Swing Fork Swingarm Free Play Limit End (Skew) Side WHEEL Front & Rear Wheel Type Front & Rear Rim Size/lvlaterial Rim Run Out Limit Venicai Lateral DRIVE CHAIN No. ol Links Chain Slackness
BaLl Bear ng
22 Nos (3/16') 19 Nos (1/4') 110 mm 296.5 mm 291.5 mm 17
5!3cc
158a3cc Special Yamaha Oil
70 mm
<2.0 mm < 2.0 mm Spoke Wheel 1.50x18/Steel <2.0 <2.0 mm 110
20-30 mm
DRUM BRAKE Type Drum lnside Dia Service Limit Lining Thickness Service Limit
BRAKE LEVER & BBAKE PEDAL Brake Lever Free Play/ At Lever Point Brake Pedal Free Play CLUTCH LEVER Free Play/At Lever Point Free Play At Tappel Rod
Internally Expanding, Leading & 130 mm <131 mm 5.0 mm <2.0 mm 5'B mm ( nd an l\,4arket) 2.5'3 5 mm (Other N/arket)
20'30.nm 2-3 mnl r. Turn oose (Anti Clock Wise) B-7
A\ TIGHTENING TOROUE
THREAD SIZE
QTY
Lb"Ft.
Kg.M
ENGINE Oll Pump
lvl5
2
3.60
0.50
Drain Plug
t\r12
'I
'14.00
2.00
Cylinder Head
t\.48
4
18.00
2.50
Cylinde r
l\i11
4
25.00
3.50
Spark Plug
t\,414
1
14.00
2.00
Intake Manifold
M6
4
5.70
0.80
Primary Drive Gear
M12
1
40.00
5.50
Clulch Boss
t\,412
l
31.00
4.30
Clutch Spring
tvl5
4
4.30
0.60
Drive Sprocket
l\.416
1
40.00
5.50
Neutral Point
l\.414
1
14.00
2.OA
Neutral Switch
l\,1r
2
2.go
0.40
Cam Stopper
l\,11
4
14.00
2.00
10.0
1
4A
1
.00
Shift Cam Stopper Lever
0
-
M6
l
t\,16
l
7.00
Change Shalt Adluster
t\,18
Oil Seal Retainer
IV]B
1.60
Flywheel lvlagneto
tvl12
7.04
22.40
3.00
TIGHTENING TOROUE
THREA
OTY
Lb.Ft.
Kg.M
slzE CHASSIS Front Axle Shaft
t\,110
1
31.00
4.30
Crown Handle-lnner Tube
t\,18
2
1
1.00
1.50
1
29.00
4.00
Crown Handle-Steering Shaft
l\41
Handle crown-Handle Holder
M8
4
13.00
'1
Under Bracket-lnner Tube
tvt10
2
22.00
3.00
Pivot Shaft
M12
'1
43.00
6.00
Tension Bar
l\,18
2
13.00
1
Sprocket Bear
M8
4
18.00
2.60
Camshaft Lever
M6
2
6.50
0.90
Flear Axie Shaft
l\i]14
1
66.00
9.20
Sprocket Shaft Nut
t\,120
'1
66.00
9.20
Shock Absorber
l\41
2
29.00
4.00
Front Engine Mtg. Bolt
t!18
1
22.OO
3.00
Rear Upper Engine Niltg. Bolt
M10
1
43.00
6.00
0
1
43.00
6.00
Rear Lower Engine Mtg. Bolt
t\41
0
0
.90
.90
Foolrest Frame
[,48
4
17.00
2.30
Cap Bolt Front Fork
l\i]25
2
'1
7.00
2.30
j
't
I
'6
I'
ESGORTS YAMAHA MOTOR LIMITED 19/6, Mathura Road, Faridabad 121 006 (lNDlA)
