Yamaha TW 125 Service Manual - 1999

EAS00002

NOTICE This manual was produced produc ed by the Yamaha Motor Company primarily for f or 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 perf orm 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 str iving to improve all its models. Modifications Modification s and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. EAS00004

IMPORTANT INFORMA INFOR MATION TION Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

EAS00007

HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, installati on, removal, disassembly, assembly, repair and inspection procedures procedur es are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter. Refer to “SYMBOLS” on the following page. 2 Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“Periodic Inspections and Adjustments”), where the sub-section title(-s) appear. (In Chapter 3, “Periodic Inspections and Adjustments”, the sub-section title appears at the top of each page, instead of the section title.) 3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify cl arify procedure steps, st eps, there are exploded diagrams diag rams at the start of each

removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step. 6 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”). 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

EAS00009

1

SYMBOLS

2

GEN INFO 3

SPEC 4

CHK ADJ 5

The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information

ENG 6

2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetor(-s)

CARB

CHAS

6 Chassis 7 Electrical system

7

8

ELEC

TRBL SHTG

9

10

8 Troubleshooting

Symbols 9 to 16 indicate the following. 9 Serviceable with engine mounted 10 Filling fluid 11 Lubricant

INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL

GEN INFO

1

SPEC

2

CHK ADJ

3

ENG

4

CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1–2 REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . 1–2 LOCK WASHERS / PLATES AND COTTER PINS . . . . . . . . . . . . . . . . 1–3 BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3 CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–5

MOTORCYCLE IDENTIFICA I DENTIFICATION TION

GEN INFO

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GENERAL INFORMATION MOTORCYCLE IDENTIFICA ID ENTIFICATION TION EAS00017

VEHICLE IDENTIFICATION NUMBER The vehicle identificatio identification n number 1 is stamped into the right side of the steering head.

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MODEL CODE The model code label 1 is affixed to the frame. f rame. This information will be needed to order spare parts.

IMPORTANT INFORMATION

GEN INFO

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IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal removal and disassembl disassembly y, remove all dirt, mud, dust and foreign material. 2. Use only only the proper proper tools tools and cleanin cleaning g equipment. Refer to the “SPECIAL TOOLS” section. 3. When disass disassembl embling, ing, always always keep mated 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 repl aced as an assembly. 4. During disassembly disassembly,, clean all all of the 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. 5. Keep all all parts away from any source source of fire.

IMPORTANT INFORMATION

GEN INFO

EAS00023

OR

LOCK WASHERS/PLATES AND COTTER PINS 1. After remova removal, l, replace replace all lock lock washwashers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

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BEARINGS AND OIL SEALS 1. Insta Installll bearings bearings and and oil seals seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coat of lithium soap base grease onto the oil seal lips. Oil bearings liberally when installing, if appropriate appropriate.. 1 Oil seal

CAUTION: Do not spin the bearing with compressed air because this will damage the bearing sur-

CHECKING THE CONNECTIONS

GEN INFO

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CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Di Disc scon onne nect ct:: lead coupler connector 2. Check ck:: lead coupler connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect several times. 3. Check ck:: all connections Loose connection ! Connect properly. S S S

S S S

S

NOTE: If the pin 1 on the terminal is flattened, bend it up. 4. Conn Connec ect: t: lead

SPECIAL TOOLS

GEN INFO

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SPECIAL TOOLS The following special tools are necessary nece ssary for complete and accurate accur ate tune-up and assembly. Use only the appropriate special tools; tool s; 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 90890 -04052

Tool name / Usage Rotor puller Attachment These tools are used when removing the generator rotor.

90890-01083 90890-01084 90890 -01084

Rocker arm shaft puller bolt Weight These tools are used when removing or installing the rocker arm shafts.

9089 890 0-0 -01 126 268 8

Ringn gnu ut wre ren nch This tool is used to loosen and tighten the exhaust and steering ringnut.

90890-01294

Damper rod holder

Illustration

SPECIAL TOOLS Tool No. 9089 890 0-0 -03 307 079 9

Tool name / Usage Thi hick ckne ness ss gau aug ge This tool is used to measure the valve clearance.

90890-03081 90890-04082 90890 -04082

Compression gauge Adaptor These tools are used to measure the engine compression.

90890-03112

Pocket tes tester These instruments are invaluable for checking the electrical system.

9089 890 0-0 -03 3113

Engi gin ne ta tach cho omet ete er

This tool is needed for detecting engine rpm. 90890-03141

Timing lilight

GEN INFO Illustration

SPECIAL TOOLS Tool No. 9089 90 8900-04 0410 101 1

Tool name / Usage Val alve ve lap lappe perr

This tool is is used for lapping the valve. 9089 90 8900-06 0675 754 4

Igni Ig niti tion on ch chec ecke kerr

This instrument is necessary for checking the ignition system components. 9089 90 8900-85 8550 505 5

Yam amah aha a bond bond No. No.12 1215 15

This sealant (bond) is used for crankcase mating surface, etc.

GEN INFO Illustration

GEN INFO

CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 LUBRICATION POINT AND GRADE OF LUBRICANT . . . . . . . . . . . . . 2-15 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS GENERAL SPECIFICATIONS Model

TW125

Model code:

5EK1 / 5EK2

Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius

2,140 mm ,810 mm 1,120 mm ,805 mm 1,330 mm ,260 mm 2,100 mm

Basic weight: With oil and full fuel tank

125 kg

Engine: Engine type Cylinder arrangement Displacement Bore  stroke Compression ratio Compression pressure (STD)

Air-cooled 4-stroke, SOHC Forward-inclined single cylinder 0.124 L (124 cm3) 57.0  48.8 mm 10.0 : 1 1,200 1,20 0 kPa (12.0 kg/ cm2, 12.0 bar) at 1,000 r/min

GENERAL SPECIFICATIONS Model

TW125

Carburetor: Type/quantity Manufacturer

Y24P/1 TEIKEI

Spark plug: Type Manufacturer Spark plug gap

DR8EA NGK 0.6 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 74/ 20 (3.700 (3.700)) Chain drive 50/ 14 (3.571 (3.571)) Constant mesh 5 speed Left foot operation 36/ 16 (2.250 (2.250)) 31/ 21 (1.476 (1.476)) 27/ 24 (1.125 (1.125)) 25/ 27 (0.926 (0.926)) 23/ 29 (0.793 (0.793))

Chassis: Frame type

Diamond

X

SPEC

GENERAL SPECIFICATIONS Model

TW125

Brake: Fron Fr ontt bra brake ke type type operation Rear brake type operation

Single disc brake Right hand operation Drum brake Right foot operation

Suspension: Front suspension Rear suspension

Telescopic fork Swingarm (Monocross)

Shock absorber: Front shock absorber Rear shock absorber

Coil spring/Oil damper Coil gas spring/Oil damper

Wheel travel: Front wheel travel Rear wheel travel

160 mm 150 mm

Electrical: Ignition system Generator system Battery type Battery capacity

C.D.I. C.D.I. magneto GM 7CZ-3D 12 V 7 AH

Headlight type:

Bulb type

Bulb wattage  quantity:

SPEC

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS ENGINE Item

Standard

Limit

Cylinder head: Warp limit

SSS

0.05 mm

Cylinder: Bore size Taper limit Out of runout limit Camshaft: Cam dimensions Intake “A” “B” “C” Exhaust “A” “B” “C” Camshaft runout limit Cam chain: Cam chain type/No. of links Cam chain adjustment Rocker arm/rocker armshaft:

57.00

X

57.02 mm

SSS SSS

36.54 36.64 mm 30.13 30.23 mm 6.59 mm 36.58 36.68 mm 30.21 30.31 mm 6.63 mm X

X

X

X

SSS

DID 25SH/104 EDESOLES Automatic

57.1 mm 0.05 mm 0.01 mm

36.45 mm 30.05 mm SSS

36.49 mm 30.13 mm SSS

0.03 mm SSS SSS

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

IN EX IN EX

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

6.042 mm 6.042 mm 0.08 mm 0.10 mm 0.03 mm 1.6 mm 1.6 mm

SSS

IN EX

SPEC

0.9 X 1.1 mm 0.9 X 1.1 mm

IN / EX 35.5 mm IN / EX 37.2 mm

33.5 mm 35.2 mm

IN / EX 30.5 mm IN / EX 32.0 mm

SSS

IN / EX IN / EX IN / EX IN / EX IN// EX IN IN / EX

8.4 X 10.2kg 16.6 X 20.4 kg

SSS

SSS

2.5_ /1.5 mm 2.5_ /1.6 mm

SSS

SSS

SSS

Clockwise Counterclockwise

SSS

0.035 X 0.055 mm

SSS

SSS

MAINTENANCE SPECIFICATIONS Item Crankshaft:

Crank width “A” Runout limit “C” Big end side clearance “D” Big end radial clearance Small end free play “F”

F

SPEC

Standard

Limit

55.95

SSS

´

X

56.00 mm

SSS

0.35 0.65 mm 0.010 0.025 mm 0.8 1.0 mm X

X

X

Clutch: Friction plate thickness Quantity Clutch plate thickness Quantity Clutch spring free length Quantity Push rod bending limit

2.9 3.1 mm 4 pcs. 1.6 mm 3 pcs. 34.9 mm 4 pcs.

Transmission: Main axle runout limit Drive axle runout limit

SSS

X

SSS

0.03 mm 1.0 mm SSS SSS

2.7 mm SSS

0.05 mm SSS

33.9 mm SSS

0.2 mm 0.08 mm 0.08 mm


SPEC

TIGHTENING TORQUES ENGINE Part to be tightened Cylinder head blind plug Cylinder head and cylinder Cylinder head (Timing chain side) Cam sprocket cover Valve cover Camshaft retainer Spark plug Cylinder Balancer driven gear C.D.I. magneto Valve adjuster locknut Cam sprocket Timing chain tensioner Timing chain guide (intake) Oil pump Oil pump and crankcase Drain plug

Part name

rea re a

Q’ty

Tightening torque Nm

m kg S

Screw Bolt Bolt

M6 M8 M8

2 4 2

7 22 20

0.7 2.2 2.0

Screw Bolt Bolt — Bolt Nut Bolt Nut Bolt Bolt Bolt Screw Screw Bolt

M6 M6 M6 M12 M6 M14 M10 M6 M10 M6 M6 M6 M6 M35

2 5 2 1 2 1 1 2 1 2 2 2 3 1

7 10 8 18 10 50 50 14 60 10 8 7 7 43

0.7 1.0 0.8 1.8 1.0 5.0 5.0 1.4 6.0 1.0 0.8 0.7 0.7 4.3

Remarks

MAINTENANCE SPECIFICATIONS Ite m Tightening sequence Cylinder head

Crankcase

Standard

SPEC Li mi t


SPEC

CHASSIS Item

Standard

Steering system: Steering bearing type (upper) (lower) No.// size of steel balls (upper) No.

Ball bearings Angular ball bearing 22 pcs. 0.1875 in

Front suspension: Front fork travel Fork spring free length Fitting length Spring rate (K1) Stroke (K1) Oil capacity Oil level Oil grade Inner tube vend limit Rear suspension: Shock absorber stroke Spring free length Fitting length Spring rate (K1) Stroke (K1) Front wheel:

160 mm 342 mm 337 mm 4.4 N / mm (0.44 (0.44 kg kg / mm) 0 X 160 mm 0.243 L (243 cm3) 135 mm Fork oil 10 WT or equivalent SSS

48 mm 193 mm 185 mm 100 N/mm (10.0 kg/mm) 0 X 48 mm

Limit SSS SSS SSS

SSS

338 mm SSS SSS SSS SSS SSS SSS

0.2 mm SSS

173 mm SSS SSS SSS

MAINTENANCE SPECIFICATIONS Item

Standard

Rear brake: Type Drum inside diameter Shoe thickness Shoe spring free length

Leading, trailing 110 mm 4 mm 50.5 mm

Brake lever: Brake lever free play (at lever end)

2

Brake pedal: Brake pedal free play Brake pedal position

20 30 mm 30 mm

Clutch lever: Clutch lever free play (at lever end)

10

Throttle cable free play

3

X

5 mm

X

X

X

15 mm

5 mm

SPEC Limit SSS

111 mm 2 mm SSS

SSS

SSS SSS

SSS

SSS

SPEC

MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Part to be tightened Handle crown and front fork Handle crown and steering shaft Handlebar holder (under and upper) Steering ring nut Master cylinder (front brake) Brake hose union bolt (front brake) 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 frame Swingarm pivot shaft Rear shock absorber and frame Chain guide and swingarm Sidestand Footrest (left) Footrest (right)

Thread size M8 M14 M8 M25 M6 M10 M10 M8 M8 M8 M8 M8 M12 M10 M5 M10 M12 M10

Tightening torque Nm

m kg

23 90 20 18 7 26 30 33 33 33 33 33 80 56 5 40 60 45

2.3 9.0 2.0 1.8 0.7 2.6 3.0 3.3 3.3 3.3 3.3 3.3 8.0 5.6 0.5 4.0 6.0 4.5

Remarks

S

Refer to NOTE


SPEC

ELECTRICAL Item

Standard

Limit

Ignition timing: Ignition timing (B.T.D.C.) Advanced timing Advanced type

9_ at 1,500 r/min 30_ at 5,000 5,000 r/ min Digital type

SSS

656 984 Ω at 20_C / Red – White 624 936 Ω at 20_C / Brown – Green 5EK/YAMAHA

SSS

Ignition coil: Modell / manu Mode manufactu facturer rer Minimum spark gap Primary winding resistance Secondary winding resistance

2JN/YAMAHA 6 mm 0.18 0.28 Ω at 20_C 6.32 9.48 kΩ at 20_C

SSS

Spark plug cap: Type Resistance

Resin type 10 kΩ

SSS

Charging system: Type

C.D.I. magneto

SSS

C.D.I.: Pickup coil resistance/color Source coil resistance/color C.D.I. unit model/manufacturer

X

X

X

X

SSS SSS

SSS

SSS

SSS SSS SSS

SSS


SPEC

Item

Standard

Limit

Starter relay: Model/manufacturer Amperage rating Coil winding resistance

MS5F/JIDECO 100 A 4.2 X 4.6 Ω at 20_C

SSS

Horn: Model/manufacturer Maximum amperage

YF-12/NIKKO 3A

SSS

Flasher relay: Type Model/manufacturer Flasher frequency

Full transistor type FE 246 BH/ DEN DENSO SO 85 cycle/min

SSS

Circuit breaker: Type Main Reserve

Fuse 20 A  1 pcs. 20 A  1 pcs.

SSS

SSS SSS

SSS

SSS SSS

SSS SSS

CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS

GEN INFO

EAS00028

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

mSkg mSkg cmSkg cmSkg

7.233 86.794 0.0723 0.8679

ftSlb inSlb ftSlb inSlb

Weight

kg g

2.205 0.03527

lb oz

km/hr km m m cm

0.6214 0.6214 3.281 1.094 0.3937

mph mi ft yd in

Distance

LUBRICATION POINT AND GRADE OF LUBRICANT

SPEC

LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE Lubrication Point Oil seal lips (all) Bearing retainer (all) Bolt (cylinder head) Crank pin Connecting rod (big end) Piston pin Piston/ Pist on/ pist piston on ring Buffer boss Valve stem/ valve guide (IN, EX) Valve stem end (IN, EX) Rocker arm shaft Cam and bearing (camshaft)

Symbol

LUBRICATION POINT AND GRADE OF LUBRICANT

SPEC

CHASSIS Lubrication Point Steering head pipe pipe bearing (upper/ lower) Front wheel oil seal lips (left/right) Rear wheel oil seal lips (left/right) Rear brake shoe plate, camshaft and pivoting pin Pivoting points (brake pedal shaft and frame) Sidestand sliding sliding surface/ mounting bolt Tube guide (throttle grip) inner surface Brake lever bolt/ master cylinder sliding sliding surface Clutch lever bolt/collar/cable sliding surface Brake pedal shaft surface Gear unit (speedometer) Swigarm insert surface/ bush bush// thrust cover Pivot shaft surface

Symbol

LUBRICATION DIAGRAM LUBRICATION DIAGRAM 1 2 3 4 5 6

Rocker Rock er ar arm m (IN (IN)) Rock Ro cker er sh shaf aftt Rock Ro cker er ar arm m (EX (EX)) Cams Ca msha haft ft Oil pump Pus Pu sh lev lever er

SPEC

LUBRICATION DIAGRAM 1 2 3 4 5 6

Oil pump Oill fil Oi filte terr Cran Cr anks ksha haft ft Main Ma in ax axlle Driv Dr ive e axl axle e Oill str Oi strai aine nerr

SPEC

CABLE ROUTING

SPEC

CABLE ROUTING 1 2 3 4 5 6 7 8 9

Brake Brak e hos hose e Throt Th rottl tle e ca cabl ble e Frontt brake Fron brake swi switch tch lea lead d Handle Han dlebar bar switc switch h lead (righ (right) t) Handle Han dlebar bar switc switch h lead (lef (left) t) Clut Cl utch ch ca cabl ble e Clut Cl utch ch swi switc tch h lead lead Main Ma in swi switc tch h lea lead d Spee Sp eedo dome mete terr cable cable 10 Starter cable 11 Indicator light lead

12 13 14 15 16

Meter lead A Fast Fasten en the handl handleba ebarr switch switch Headlight coupler lead, front brake switch lead and Wireharness clutch switch lead to the handleFront turn signal light (right) bar with a plastic clamp. Front turn signal light lead (right) B The end end of the plastic plastic locki locking ng tie must face down ward. C To headl headlig ight ht

CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13

Battery Batter y posi positiv tive e lead lead Star St arte terr rela relay y Star St arte terr moto motorr lead lead Cl a m p Frontt brake Fron brake swi switch tch lea lead d Handle Han dlebar bar switc switch h lead (righ (right) t) Igni Ig niti tion on coi coill Horn Ho rn le lead ad High Hi gh ten tensi sion on cab cable le Flasher relay Rear brake switch lead Neutral relay CDI unit

A The end of the plasti plastic c locking locking tie tie must face down ward. B Fas Fasten ten the the wire harn harness ess,, handlebar switch lead (right), front brake switch lead, throttle cable, starter cable, clutch switch lead and main switch lead to the frame with steel clamp. C Route the wire wire harness harness,, handlehandlebar switch (right) and front brake switch lead through the cable guide. D Route the battery breath breather er hose hose through the cable guide.

SPEC

E Route the battery battery breathe breatherr hose hose through the hole of air cleaner case. F Fas Fasten ten the the rear rear brake brake swit switch ch lead couplers and carburetor heater lead to the frame with a plastic locking tie. The end of the plastic locking tie must face front side.

CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13

Starte Star terr cabl cable e Throt Th rottl tle e ca cabl ble e Clut Cl utch ch swi switc tch h lead lead Main Ma in swi switc tch h lea lead d Therm Th ermo o swit switch ch lead lead Sidest Sid estand and swi switch tch lea lead d Carbur Car buretor etor ove overr flow flow hose hose Carbur Car buretor etor air ven ventt hose hose Clut Cl utch ch ca cabl ble e Brake hose Speedometer cable CDI magneto leads Neutral switch lead

A Fasten Fasten the CDI CDI magneto magneto leads leads,, starter motor lead, neutral switch lead and ground lead to the frame stay. The end of plastic locking tie must face down ward. B Fas Fasten ten the the side stan stand d switch switch lead with the steel clamp. C Fasten the carburet carburetor or air air vent vent hose, carburetor over flow hose and starter motor lead with a plastic clamp. D Route the side side stand stand switch switch lead through the guide.

SPEC

E Route Route the carbur carbureto etorr air vent vent hose and carburetor over flow hose between the engine and swingar swingarm. m. F Rou Route te the star starter ter motor motor lead lead bebetween the engine and swing arm.

CABLE ROUTING G Route Route the carbur carburetor etor air air vent hose and carburetor over flow hose through the guide. H Rou Route te the clutc clutch h cable cable through through the cable guide. I Ro Rout ute e the brak brake e hose hose and spee speeddometer cable through the cable guide. J Fas Fasten ten the the brake brake hose hose and and speespeedometer cable to the front fork outer tube with a cable holder.

SPEC

CABLE ROUTING 1 2 3 4 5 6 7 8 9

Clutch Clut ch swit switch ch lea lead d Main Ma in sw swit itch ch le lead ad Star St arte terr moto motorr lead lead CDII mag CD magne neto to le lead ad Batter Bat tery y posi positiv tive e lead lead Wire Wi re ha harn rnes ess s Therm Th ermo o swit switch ch lead lead Sidest Sid estand and swi switch tch lea lead d Batter Bat tery y nega negativ tive e lead lead 10 Rectifier/Regulator 11 Ground lead

A Fasten Fasten the the wire wire harness harness with with steel clamp. B Fasten the wire wire harness harness and rear rear turn signal light lead to the frame with a plastic locking tie. The end of plastic locking tie must face in side. C Route the rear rear turn turn signal signal light light lead inside of hose. D Fasten the wire wire harness harness and rear rear turn signal light (right) with a steel clamp.

SPEC

E Route the rear rear turn turn signal signal light light lead (right) between the frame and license bracket. F Rou Route te the rear rear turn turn signal signal light light lead (left) between the frame and license bracket.

CABLE ROUTING G Fasten the rear rear turn signal light (left) to the frame with a plastic locking tie. The end of plastic locking tie must face rear ward. H Fasten the thermo thermo switc switch h lead lead connectors to the frame with a plastic locking tie. The end of plastic locking tie must face inside.

SPEC

CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 PERIODIC MAINTENAN MAINTENANCE CE// LUBRICA LUBRICATION TION INTERV INTERVALS ALS . . . . . . . . . . . 3-1 SEAT,, FUEL SEAT FUE L TANK AND SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . 3-4 ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . 3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . 3-7 CHECKING THE SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-10 CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . 3-14 CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . 3-15 CHECKING THE THE CARBURETOR CARBURETOR JOINT JOINT AND INTAKE INTAKE MANIFOLD MANIFOLD 3-16 CHECKING THE FUEL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS

CHK ADJ

EAS00036

PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, procedur es, 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 servi ce as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. EAS00037

PERIODIC MAINTENANCE/LUBRICATION INTERVALS No

1

*

2 3

ITEM

Fuel line

Spark plugs

*

4

Valves Air filter

ROUTINE

S

S

*

Battery

Check fuel hoses for cracks or damage. Replace if necessary.

6,000 km 12,000 km or or 6 months 12 months √

√

Check condition. Clean, regap or replace if necessary.

√

√

√

Check valve clearance. Adjust if necessary.

√

√

√

S

S

Clean or replace if necessary.

√

√

Check electrolyte level and specific gravity. Correct or recharge if necessary.

√

√

S

S

S

S

5

IN 1,000 KM

EVERY

PERIODIC MAINTENACE/LUBRICATION INTERVALS

CHK ADJ EVERY

NO.

15

*

16

ITEM

Chassis fasteners

Sidestand

17

*

Sidestand switch

18

*

Front fork

19

*

Rear shock absorber assembly pivoting points

20

*

Carburetor

ROUTINE

S

S

S

S

S

S

S

S

S

S

23

*

√

√

Check operation. Lubricate and repair if necessary.

√

√

√

√

Check operation and for oil leakage. Correct accordingly.

√

√

Check operation. Lubricate with lithium soap base grease every 24,000 km or 24 months (whichever comes first).

√

√

Check operation. Replace if necessary.

√

√

√

√

√

√

√

S

Check oil level and vehicle for oil leakage. Correct if necessary. Change. (Warm engine before draining.)

Engine oil filter element

S


√

√

Engine oil strainer

S


√

√

Engine oil

22

Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary.

Check engine idling speed and starter operation. Adjust if necessary.

S

S

S

21

BRAKE-IN 6,000 km 12,000 km 1,000 KM or or 6 months 12 months

S

*: Since these items items require special special tools, date date and technical technical skills,they should be serviced serviced by a YaYamaha dealer.

SEAT SEA T, FUEL FUE L TANK AND SIDE COVER SEAT, FUEL TANK AND SIDE COVER

CHK ADJ

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

EAS00049

ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. S

S

1. Remo Remove ve:: seat side cover (left and right) fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVER”. 2. Re Remo move ve:: spark plug cap 1 spark plug valve cover (intake side) 2 valve cover (exhaust side) 3 3. Re Remo move ve:: S S S

S S S S

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

5. Adju Adjust st:: valve clearance S

a. Loose Loosen n the lockn locknut ut 1 . b. Inse Insert rt a thick thickness ness gau gauge ge 2 between the end of the adjusting screw and the valve tip. c. Tu Turn rn the the adjusti adjusting ng screw screw 3 in direction a or b until the specified valve clearance is obtained. Direction a

!

Direction b

!

Valve clearance is increased. Valve clearance is decreased.

Valve adjusting tool 90890-01311 d. Hold the the adjustin adjusting g screw to preve prevent nt it from moving and tighten the locknut to specification. Locknut 14 Nm (1.4 m kg)

ADJUSTING THE ENGINE IDLING SPEED

CHK ADJ

EAS00054

ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. In Inst stal all: l: engine tachometer (to the spark plug lead) S

Engine tachometer 90890-03113 3. Meas Measur ure: e: engine idling speed Out of specification ! Adjust. S

Engine idling speed 1,300 1,500 r/min X

4. Ad Adju just st

ADJUSTING THE THROTTLE CABLE FREE PLAY

CHK ADJ

EAS00058

ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle throt tle cable free play, the engine idling speed should be adjusted. 1. Check ck:: throttle cable free play a Out of specification ! Adjust. S

Throttle cable free play (at the flange of the throttle grip) 3 5 mm X

2. Adju Adjust st:: throttle cable free play S

Carburetor side a. Lo Loose osen n the lockn locknut ut 1 on the throttle cable. b. Tu Turn rn the the adjustin adjusting g nut nut 2 in direction a or b until the specified throttle cable free play is obtained. Direction

Throttle cable free play is

ADJUSTING THE THROTTLE CABLE FREE PLA PLAY Y/ CHECKING THE SPARK PLUG

CHK ADJ

WARNING After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. EAS00060

CHECKING THE SPARK PLUG 1. Di Disc scon onne nect ct:: spark plug cap 2. Re Remo move ve:: spark plug S

S

CAUTION: Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 3. Check ck:: spark plug type Incorrect ! Change. S

CHECKING THE SPARK SPARK PLUG/ PLUG / CHECKING THE IGNITION TIMING

CHK ADJ

7. Inst Instal alll: spark plug S

Spark plug 18 Nm (1.8 m kg) S

NOTE: Before installing the spark plug, clean the spark plug and gasket surface. Finger-tighten 1 the spark plug before torquing to specification 2 . S

S

8. Con onne nec ct: spark plug cap S

EAS00064

CHECKING THE IGNITION TIMING

NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion. 1. Rem emov ove: e: timing check plug 2. In Inst stal alll: timing light 1 S

MEASURING THE COMPRESSION PRESSURE

CHK ADJ

EAS00067

MEASURING THE COMPRESSIONPRESSURE NOTE: Insufficient compression compression pressure will result in a loss of performance. 1. Check ck:: valve clearance Out of specification ! Adjust Refer to “ADJUSTING “ADJUS TING THE VALVE VALVE CLEARANCE ”. 2. Start the engine, warm it up for several several minminutes, and then turn it off. 3. Di Disc scon onne nect ct:: spark plug cap 4. Re Remo move ve:: spark plug S

S

S

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.

MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL

CHK ADJ

Compression pressure (at sea level) Standard: 1,200 kPa (12.0 kg/cm 2, 12 bar) Minimum: 1,100 kPa (11,0 kg/cm2, 11 bar) a. Turn Turn the main main switch switch to “ON”. “ON”. b. With the throttle wide wide open, open, crank the the engine engine until the reading on the compression gauge stabilizes.

WARNING To prevent sparking, ground the spark plug lead before cranking the engine.

7. Inst Instal all: l: spark plug 8. Co Conn nnec ect: t: spark plug cap S

18 Nm (1.8 m kg)

S

EAS00069

CHECKING THE ENGINE OIL LEVEL

S

CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL

CHK ADJ

CAUTION: S

S

Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled “ENERGY CONSERVING II” b or higher. Do not allow foreign materials to enter the crankcase.

4. Start the engine, warm it up for several several minminutes, and then turn it off. 5. Che Check ck the engine engine oil oil level level again. again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. EAS00076

CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several several minminutes, and then turn it off.

CHANGING THE ENGINE OIL

CHK ADJ

8. Fill: crankcase (with the specified amount of the recommended engine oil) S

Quantity Total amount 1.3 L Without oil filter element replacement 1.0 L With oil filter element replacement 1.1 L 9. Inst Instal all: l: engine oil filler cap 10. Start the engine, engine, warm it up for several several minutes, and then turn it off. 11. Ch Chec eck: k: engine (for engine oil leaks) 12.. Ch 12 Chec eck: k: engine oil level Refer to “CHECKING THE ENGINE OIL S

S

S

ADJUSTING THE CLUTCH CABLE FREE PLAY

CHK ADJ

EAS00078

ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check ck:: clutch cable free play a Out of specification ! Adjust. S

Clutch cable free play (at the end of the clutch lever) 10 15 mm X

2. Adju Adjust st:: clutch cable free play S

Handlebar side a. Lo Loose osen n the lockn locknut ut 1 . b. Tu Turn rn the the adjusti adjusting ng screw screw 2 in direction a or b until the specified clutch cable free play is obtained. Direction a

!

Direction b

!

Clutch cable free play is increased. Clutch cable free play is decreased.

CLEANING THE AIR FILTER ELEMENT

CHK ADJ

EAS00090

CLEANING THE AIR FILTER ELEMENT 1. Re Remo move ve:: side cover (left) air filter case cover 1 S S

2. Remo Remove ve:: air filter element 1 3. Clea ean n: air filter element (with solvent) S

S

NOTE: After cleaning, carefully pat the air filter element on a clean cloth to remove the excess oil.

4. Check ck:: air filter element Damage ! Replace. S

CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINT AND INT INTAKE AKE MANIFOLD/ CHECKING THE FUEL HOSES

CHK ADJ

NOTE: Make sure that the air filter element is properly installed in the air filter case. The air filter screen fits into the slots 2 in the air filter case. S

S

7. Inst Instal all: l: side cover (left) S

EAS00094

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Re Remo move ve:: seat side cover fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVER”. 2. Check ck:: carburetor joint 1 intake manifold 2 Cracks/damage ! Replace. Refer to “CARBURETOR” in chapter 5. S S S

S S

CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM

CHK ADJ

EAS00098

CHECKING THE CRANKCASE BREATHER HOSE 1. Re Remo move ve:: seat side cover fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVER”. S S S

2. Check ck:: crankcase breather hose 1 Cracks/damage ! Replace. Loose connection ! Connect properly. S

CAUTION: Make sure that the crankcase breather hose is routed correctly.

3. Inst Instal all: l: fuel tank side cover S S

CHK ADJ

CHECKING THE EXHAUST SYSTEM 3. Check ck:: tightening torque S

Exhaust pipe 4 12 Nm (1.2 m kg) Exhaust pipe and muffler bolt 5 20 Nm (2.0 m kg) Muffler and muffler bracket bolt 6 20 Nm (2.7 m kg) Muffler and muffler bracket bolt 7 27 Nm (2.7 m kg) S

S

S

S

4. Inst Instal all: l: side cover (right) rear cowling seat S S S

ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE

CHK ADJ

EAS00108

CHASSIS ADJUSTING THE FRONT BRAKE 1. Check ck:: brake lever free play a Out of specification ! Adjust. S

Brake lever free play (at the end of the brake lever): 2 5 mm X

2. Adju Adjust st:: brake lever free play S

a Loos Loosen en th the e loc lockn knut ut 1 . b Tu Turn rn the adj adjust usting ing bol boltt 2 in direction b or c until the specified free play is obtained. Direction b

!

Direction c

!

Brake lever free play is increased. Brake lever free play is decreased.

c Tig ight hten en th the e loc lockn knut ut..

WARNING

ADJUSTING THE REAR BRAKE

CHK ADJ

2. Adju Adjust st:: brake pedal position S

a. Loose Loosen n the lockn locknut ut 1 . b. Tu Turn rn the the adjustin adjusting g bolt bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a

!

Brake pedal is raised.

Direction b

!

Brake pedal is lowered.

c. Ti Tighte ghten n the locknut locknut to specificat specification. ion.

3. Meas Measur ure: e: brake pedal free play a Out of specification ! Adjust. S

CHECKING THE BRAKE FLUID LEVEL

CHK ADJ

EAS00115

CHECKING THE BRAKE FLUID LEVEL 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface. NOTE: Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. S S

2. Check ck:: brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. S

Recommended brake fluid Recommended DOT 4

WARNING S

Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor

CHECKING THE BRAKE PADS/CHECKING THE BRAKE SHOES/ ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHK ADJ

EAS00117

CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Ope Operat rate e the brak brake. e. 2. Check ck:: brake pad Wear indicators 1 almost touch the brake disc ! Replace the brake pads as a set. Refer to “FRONT BRAKE” in chapter 7. S

EAS00126

CHECKING THE BRAKE SHOES 1. Ope Operat rate e the brak brake. e. 2. Check ck:: wear indicator 1 Reaches the wear limit line 2 ! Replace the brake shoes as a set. Refer to “REAR WHEEL” in chapter 7. S

EAS00128

ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHECKING THE BRAKE HOSE/ BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK ADJ

EAS00129

CHECKING THE BRAKE HOSE 1. Check ck:: brake hose 1 Cracks/damage/wear ! Replace. 2. Check ck:: brake hose clamp Loose connection ! Tighten. 3. Hold the the motorcycle motorcycle upright upright and apply apply the front or rear brake. 4. Check ck:: brake hose Activate the brake several times. Brake fluid leakage ! Replace the damaged hose. Refer to “FRONT BRAKE” in chapter 6. S

S

S

EAS00133

BLEEDING THE HYDRAULIC BRAKE SYSTEM

BLEEDING THE HYDRAULIC HYDRAULIC BRAKE SYSTEM/ SYSTEM / ADJUSTING THE DRIVE CHAIN SLACK

CHK ADJ

1. Ble lee ed: hydraulic brake system S

a. Add the recomm recommende ended d brake fluid fluid to the proper level. b. Install the the brake master cylinder cylinder reservoir reservoir diaphragm. c. Con Connect nect a clear clear plasti plastic c hose hose 1 tightly to the bleed screw 2 . d. Plac Place e the other other end of the hose hose into into a container. e. Slow Slowly ly squeeze squeeze the brake brake lever lever several several times. f. Full Fully y squeeze squeeze the brake brake lever lever with without out releas releas-ing it. g. Loos Loosen en the blee bleed d screw screw.. This will release the tension and cause the brake lever to contact the throttle grip. h. Tighte Tighten n the bleed screw screw and then release release the brake lever. i. Rep Repeat eat steps steps (e) to to (h) unti untill all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Ti Tighte ghten n the blee bleed d screw screw to to specific specificatio ation. n.

ADJUSTING THE DRIVE CHAIN SLACK

CHK ADJ

1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Rotate Rotate the rear wheel wheel several several times times and check the drive chain to locate its tightest point. 3. Me Meas asur ure: e: drive chain slack Out of specification ! Adjust. S

Drive chain slack 35 60 mm X

4. Adju Adjust st:: drive chain slack S

LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD

CHK ADJ

EAS00143

LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. areas . Use only kerosine to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for non-Oring chains. Recommended lubricant Recommended Engine oil or chain lubricant suitable for non-O-ring chains EAS00146

CHECKING AND ADJUSTING THE STEERING HEAD 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over.

CHK ADJ

CHECKING AND ADJUSTING THE STEERING HEAD

b. Loosen Loosen the the lower lower ring ring nut nut 4 and then tighten it to specification with a ring nut wrench 5 . NOTE: Set the torque wrench at a right angle to the ring nut wrench. Ring nut wrench 90890-01403 Lower ring nut (initial tightening torque) 38 Nm (3.8 m kg) S

c. Loosen the lower lower ring nut completely completely,, then tighten it to specificatio specification. n.

WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 Nm (1.8 m kg) S

CHECKING THE FRONT FORK CHECKING THE TIRES

CHK ADJ

EAS00149

CHECKING THE FRONT FORK 1. Stan Stand d the motorcycle motorcycle on on a level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Check ck:: inner tube Damage/scratches ! Replace. oil seal Oil leakage ! Replace. 3. Hold the the motorcycle motorcycle upright upright and apply apply the front brake. S

S

4. Check ck:: operation Push down hard on the handlebar several S

CHECKING THE TIRES

CHK ADJ

Basic weight (with oil and a full fuel tank)

125 kg

Maximum load*

180 kg

Cold tire pressure Up to 80 kg load*

Front tire

Rear tire

150 kPa

150 kPa

(1.50kgf/cm2,

(1.50kgf/cm2, 1.5 bar)

1.5 bar)

80 kg maximum load* X

Off road riding

150 kPa

175 kPa

(1.50 kgf/cm2, 1.5 bar)

(1.75 kgf/cm2, 1.75 bar)

125 kPa

125kPa

kgf/cm2,

(1.25 1.25 bar)

(1.25 kgf/cm2, 1.25 bar)

*: total of cargo, rider, passenger and accesso ries

WARNING It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check ck:: tire surfaces S

CHECKING THE TIRES S

CHK ADJ

After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle.

Front tire Manufacturer

Type

Size

BRIDGESTONE

TW31

130/8 0/80 0-18 66P

Manufacturer

Type

Size

BRIDGESTONE

TW34

180/80-14 M/ C 78P 78P

Rear tire

WARNING S

After mounting a new tire, ride conservatively for a while to become accustomed to

CHECKING AND TIGHTENING THE SPOKES/ CHECKING AND LUBRICATING THE CABLES

CHK ADJ

EAS00169

CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1. Check ck:: spoke 1 Bends/damage ! Replace. Loose ! Tighten. Tap the spokes with a screwdriver. S

NOTE: A tight spoke will emit a clear, ringing tone; a loose spoke will sound flat. 2. Tig ight hten en:: spoke (with a spoke wrench 2 ) S

NOTE: Be sure to tighten the spokes before and after break-in. Spoke nipple 2 Nm (0.2 m kg) S

LUBRICATING THE LEVERS AND PEDALS /LUBRICA LUBRICATING /LUBRICATING TING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION

CHK ADJ

EAS00171

LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Recommended Engine oil EAS00172

LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Recommended Engine oil EAS00174

LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Recommended Molybdenum disulfide oil

CHECKING THE BATTERY

CHK ADJ

EAS00176

ELECTRICAL SYSTEM CHECKING THE BATTERY

WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries. Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. First aid in case of bodily contact: S

S S

S

S

S

CHECKING THE BATTERY

CHK ADJ

4. Check ck:: S electrolyte level The electrolyte level should be between the minimum level mark 1 and the maximum level mark 2 . Below the minimum level mark ! Add distilled water to the proper level.

CAUTION: Add only distilled water. Tap water contains minerals which are harmful to the battery. 5. Check ck:: S specific gravity Less than 1.280 ! Recharge the battery. Specific gravity 1.280 at 20_C 6. Char Charge ge:: S battery Battery charging amperage and time 0.7 amps/ amps/ 10 hrs

CHECKING THE BATTERY S

S

S

CHK ADJ

Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode!

NOTE: Replace the battery whenever: battery voltage does not rise to specification or bubbles fail to rise during charging, sulphation of one or more battery cells occurs (as indicated by the battery plates turning white or material accumulating in the bottom of the battery cell), specific gravity readings after a long, slow S

S

S

CHECKING THE BATTERY/ BATTERY/CHECKING CHECKING THE FUSES

CHK ADJ

10.. Ch 10 Chec eck: k: battery terminals Dirt ! Clean with a wire brush. Loose connection ! Connect properly. 11. Con Connec nect: t: battery leads (to the battery terminals) S

S

CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 12. Lub Lubric ricate ate:: battery terminals S

Recommended lubricant Recommended Dielectric grease 13. Ins Instal tall: l: side cover (right) seat S S

CHECKING THE FUSE/ REPLACING THE HEADLIGHT BULB

CHK ADJ

3. Repl Replac ace: e: blown fuse a. Turn Turn off off the igni ignition. tion. b. Insta Installll a new fuse of the correc correctt amperage amperage rating. c. Turn on the switches to verify if the electrical circuit is operationa operational. l. d. If the fuse immediat immediately ely blows blows again, again, check the electrical circuit.

WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Inst Instal all: l: side cover (right) seat S S

REPLACING THE HEADLIGHT HEADLIGHT BULB/ BULB / ADJUSTING THE HEADLIGHT BEAM

CHK ADJ

3. Remo Remove ve:: headlight bulb holder 1 headlight bulb 2 S S

WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Inst Instal all: l: headlight bulb (New) Secure the new headlight bulb with the headlight bulb holder. S

CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. thinner.

ADJUSTING THE HEADLIGHT BEAM

CHK ADJ

2. Adju Adjust st:: headlight beam (horizontally) S

a. Turn Turn the the adjustin adjusting g knob knob 2 in direction a or b. Direction a

!

Direction b

!

Headlight beammoves to the right. Headlight beammoves to the left.

CHK ADJ

CHAPTER 4. OVERHAULING THE ENGINE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 LEAD AND EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 CARBURETOR AND DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . 4-2 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 CAMSHAFT SPROCKET COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . 4-8 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 INSTALLING THE CAMSHAFT SPROCKET . . . . . . . . . . . . . . . . . . . . 4-9 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 REMOVING THE ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . 4-13

INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 INSTALLING THE SEGMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42 REMOVING THE PROMARY GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 INSTALLING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . 4-46 BALANCER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47 REMOVING THE BALANCER DRIVEN GEAR . . . . . . . . . . . . . . . . . . 4-48 CHECKING THE BALANCER DRIVE GEAR . . . . . . . . . . . . . . . . . . . 4-48 ASSEMBLING THE BALANCER DRIVE GEAR . . . . . . . . . . . . . . . . . 4-48 INSTALLING THE BALANCER DRIVEN GEAR . . . . . . . . . . . . . . . . . 4-49 STARTER CLUTCH AND GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 GENERATOR COVER 4 50

CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 INSTALLING THE TRANSMISSION, SHIFT FORKS AND SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

ENGINE

ENG

EAS00188

OVERHAULING THE ENGINE ENGINE LEAD AND EXHAUST PIPE

12 Nm (1.2 m kg) S

20 Nm (2.0 m kg) S

ENGINE

ENG

EAS00189

CARBURETOR AND DRIVE SPROCKET

7 Nm (0.7 m kg) S

ENGINE

ENG

EAS00192

ENGINE

33 Nm (3.3 m kg) S

33 Nm (3.3 m kg) S

80 Nm (8.0 m kg) S

33 Nm (3.3 m kg) S

ENG

ENGINE EAS00192

INSTALLING THE ENGINE 1. In Inst stal all: l: pivot shaft 1 engine mount bolt (rear) 2 engine mount bolt (front) 3 engine mount bolt (front) 4 engine mount bolt (top) 5 engine bracket bolt (front) 6 engine bracket bolt (front) 7 engien bracket bolt (top) 8 engine bracket bolt (top) 9 S S S S S S S S S

NOTE: Do not fully tighten the bolts. 2. Tighte Tighten n the bolts bolts in the following following order. order. Pivot shaft 1 80 Nm (8.0 m kg) Engine mount bolt (rear) 2 33 Nm (3.3 m kg) Engine mount bolt (front) 3 33 Nm (3.3 m kg) Engine mount bolt (front) 4 33 Nm (3.3 m kg) S

S

S

ENG

CYLINDER HEAD CYLINDER HEAD CAMSHAFT SPROCKET COVER

18 Nm (1.8 m kg) S

10 Nm (1.0 m kg) S

7 Nm (0.7 m kg) S

10 NM (1.0 m kg)

CYLINDER HEAD

ENG

EAS00221

CYLINDER HEAD 22 Nm (2.2 m kg) S

20 Nm (2.0 m kg) S

60 Nm (6.0 m kg) S

10 Nm (1.0 m kg) S

CYLINDR HEAD

ENG

EAS00225

REMOVING THE CYLINDER HEAD 1. Ali lig gn: “I” mark a on the generator rotor (with the stationary pointer b on the crankcase cover) S

a. Turn the primary primary pulley pulley counterclockw counterclockwise. ise. b. When th the e piston piston is at TDC on the the comprescompression stroke, align the “I” mark c on the camshaft sprocket with the mark d on the cylinder head.

2. Loos Loosen en:: bolt 1

CYLINDER HEAD

ENG

4. Remo Remove ve:: cylinder head S

NOTE: Loosen the nuts in the proper sequence. Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. S S

EAS00227

CHECKING THE CYLINDER HEAD 1. El Elim imin inat ate: e: combustion chamber carbon deposits (with a rounded scraper) S

NOTE: Do not use a sharp instrument to avoid damaging or scratching: spark plug threads valve seats S S

2. Check ck:: cylinder head Damage/scratches ! Replace. S

CYLINDER HEAD

ENG

EAS00216

CHECKING THE TIMING CHAIN TENSIONER 1. Check ck:: timing chain tensioner Cracks/damage ! Replace. S

EAS00212

CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER The following procedure applies to both of the tappet covers and O-rings. 1. Check ck:: tappet cover camshaft sprocket cover O-ring Damage/wear ! Replace the defective part(-s). S S S

EAS00233

INSTALLING THE CYLINDER HEAD 1. In Inst stal all: l:

CYLINDER HEAD

ENG

EAS00213

INSTALLING THE CAMSHAFT SPROCKET 1. Ali lig gn: “I” mark on the generator rotor (with the mark on the generator rotor cover) S

a. Turn Turn the cran cranksha kshaft ft counterclock counterclockwise wise.. b. When the the piston piston is at TDC on the the comprescompression stroke, align the “I” mark a on the generator rotor with the mark b on the generator rotor cover. NOTE: Be sure to keep the timing chain cha in as tight as possible.

2. Inst Instal all: l: timing chain (onto the camshaft sprocket) S

ENG

CYLINDER HEAD 5. Inst Instal all: l: timing chain tensioner S

a. While lightly pressing pressing the timing timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . b. with the timing timing chain chain tensioner tensioner rod turned turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed),install the gasket and the timing chain tensioner 2 onto the cylinder block.

WARNING Always use a new gasket. c. Tighte Tighten n the timing timing chain tensio tensioner ner bolts bolts to the specified torque. Timing chain tensioner bolt 10 Nm (1,0 m kg) S

d. Remove the screwdriver screwdriver,, make sure that the timing chain tensioner rod releases, and then tighten the cap bolt 3 to the specified

CAMSHAFT EAS00195

CAMSHAFT 14 Nm (1.4 m kg) S

14 Nm (1.4 m kg) S

ENG

CAMSHAFT

ENG

EAS00202

REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Lo Loos osen en:: locknuts 1 adjusting screws 2 S S

2. Remo Remove ve:: bolt 1 lock washer 2 camshaft retainer 3 S S S

3. Remo Remove ve:: camshaft 1 camshaft bushing 2 S

CAMSHAFT

ENG

3. Meas Measur ure: e: camshaft lobe dimensions A and B Out of specification ! Replace the camshaft. S

A

Camshaft lobe dimension limit Intake A 36.45 mm B 30.05 mm Exhaust A 36.49 mm B 30.13 mm

B

4. Check ck:: camshaft oil passage Obstruction ! Blow out with compressed compress ed air. S

EAS00206

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS

CAMSHAFT

ENG

6. Calc Calcul ulat ate: e: rocker-arm-to-rocker-arm-s rocker-arm-to -rocker-arm-shaft haft clearance S

NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Out of specificatio specification n ! Replace the defective part(-s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 0.033 mm X

INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lu Lubr bric icat ate: e: rocker arm shaft S

Recommended lubricant Recommended Molybdenum disulfide oil 2. Inst Instal all: l: exhaust rocker arm

CAMSHAFT 5. Inst Instal all: l: camshaft retainer 1 Lock washer 2 New Bolt 3

ENG

S S S

8 Nm (0.8 m kg) S

NOTE: Bend the lock washer tab along a flat side of the bolt 3 .

VALVES AND VALVE SPRINGS EAS00236

VALVES AND VALVE SPRINGS

ENG


ENG

EAS00238

REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal.

1. Check ck:: valve sealing Leakage at the valve seat ! Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS”. S

a. Pour Pour a clean clean solven solventt a into the intake and exhaust ports. b. Che Check ck that the valve valves s properly properly seal. seal. There should be no leakage at the valve seat 1. 2. Remo Remove ve:: valve cotters 1

ENG

VALVES AND VALVE SPRINGS EAS00239

CHECKING THE VALVES VALVES AND VAL VALVE VE GUIDES GUIDE S The following procedure applies to all of the valves and valve guides. 1. Me Meas asur ure: e: S valve-stem-to valve-stem-to-valve-guid -valve-guide e clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a – Valve stem diameter b Out of specification guide.

!

Replace the valve

Valve-stem-to-valve-guide Valve-stem-to-v alve-guide clearance Intake 0.010 0.037 mm Limit: 0.08 mm Exhaust 0.025 0.052 mm Limit: 0.10 mm X

X

2. Repl Replac ace: e: S valve guide


ENG

3. Elim Elimin inat ate: e: carbon deposits (from the valve face and valve seat) 4. Check ck:: valve face Pitting/wear ! Grind the valve face. valve stem end Mushroom shape or diameter larger than the body of the valve stem ! Replace the valve. S

S

S

5. Meas Measur ure: e: valve margin thickness a Out of specification ! Replace the valve. S

Valve margin thickness 0.8 1.2 mm X

6. Meas Measur ure: e: valve stem runout Out of specification ! Replace the valve. S


ENG

a. Apply Mechanic’ Mechanic’s s blueing blueing dye dye (Dykem) (Dykem) 1 onto the valve face. b. Insta Installll the valve valve into the cylinde cylinderr head. c. Pres Press s the valve valve through through the the valve guide guide and and onto the valve seat to make a clear pattern. d. Meas Measure ure the valve valve seat seat width. width. Where the the valve seat and valve face contacted one another, the blueing will have been removed. 4. Lap: valve face valve seat S S

NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

a. Apply Apply a coarse coarse lapping lapping compou compound nd a to the valve face.


ENG

e. Apply a fine lapping lapping compound compound to the valve face and repeat the above steps. f. After ever every y lapping lapping proc procedur edure, e, be sure to clean off all of the lapping compound from the valve face and valve seat. g. Apply Mechanic’ Mechanic’s s blueing blueing dye dye (Dykem) (Dykem) b onto the valve face. h. Insta Installll the valve valve into the cylinde cylinderr head. i. Pres Press s the valv valve e throug through h the valv valve e guide guide and onto the valve seat to make a clear impression. j. Me Measu asure re the the val valve ve seat seat wi width dth c again. If the valve seat width is out of specification specification,, reface and lap the valve seat.

EAS00241

CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Me Meas asur ure: e: S valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length (intake


ENG

EAS00246

INSTALLING THE T HE VALVES VALVES The following procedure applies to all of the valves and related components. 1. De Debu burr rr:: valve stem end (with an oil stone) S

2. Lubr Lubric icat ate: e: valve stem oil seal (with the recommended lubricant) S S

Recommended lubricant Recommended Molybdenum disulfide oil 3. Inst Instal all: l: valve 1 lower spring seat 2 oil seal 3 valve springs 4 upper spring seat 5 S S S S S

CYLINDER AND PISTON EAS00265

CYLINDER AND PISTON

ENG

CYLINDER AND PISTON

ENG

YP******

REMOVING THE PISTON AND PISTON RINGS 1. Re Remo move ve:: piston pin circlip 1 piston pin 2 piston 3 S S S

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. Remo Remove ve:: top ring 2nd ring oil ring S S S

NOTE: When removing the piston ring, open the end gap of the ring by fingers, and push up the other side of the ring. EAS00255

CYLINDER AND PISTON

ENG

b. If out of specificat specification, ion, rebore rebore or replac replace e the cylinder, and replace the piston and piston rings as a set. c. Meas Measure ure piston piston skirt skirt diameter diameter “P” “P” with the micrometer. 1 7.0 mm from the bottom edge of the piston.

Piston size “P” Standard

56.960

X

56.975 mm

Oversize 2

57.25 mm

Oversize 4

57.50 mm

d. If out of specification, specification, replace replace the piston and piston rings as a set. e. Calculate the piston-to-cyli piston-to-cylinder nder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.035 0.055 mm X

ENG

CYLINDER AND PISTON 2. Inst Instal all: l: piston ring (into the cylinder) S

NOTE: Level the piston ring in the cylinder with the piston crown as shown. a 5.0 mm

3. Meas Measur ure: e: piston ring end gap Out of specification ring. S

!

Replace the piston

NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. Piston ring end gap Top ring 0.15 0.35 mm X

CYLINDER AND PISTON

ENG

Piston-pin-to-piston clearance = Piston pin bore size b – Piston pin outside diameter a Piston-pin-to-piston clearance 0.010 0.026 mm X

EAS00267

INSTALLING THE PISTON AND CYLINDER 1. In Inst stal all: l: top ring 1 2nd ring 2 lower oil ring rail 3 upper oil ring rail 4 oil ring expander 5 S S S S S

NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.

CYLINDER AND PISTON

ENG

5. Offs Offset et:: piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring S

6. Inst Instal all: l: cylinder 1 S

NOTE: While compressing the piston rings with one hand, install the cylinder with the other hand. Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity. S

S

CLUTCH EAS00273

CLUTCH CLUTCH COVER

ENG

CLUTCH

ENG

EAS00274

CLUTCH 70 Nm (7.0 m kg) S

8 Nm (0.8 m kg) S

12 Nm (1.2 m kg) S

CLUTCH

ENG

70 Nm (7.0 m kg) S

8 Nm (0.8 m kg) S

12 Nm (1.2 m kg) S

CLUTCH

ENG

EAS00277

REMOVING THE CLUTCH 1. Stra Straighte ighten n the lock lock washer washer tab tab 1 . 2. Lo Loos osen en:: clutch boss nut 2 S

NOTE: While holding the clutch boss 3 with the universal clutch holder 4 , loosen the clutch boss nut. Universal clutch holder 90890-04086 3. Remo Remove ve:: clutch boss nut 1 lock washer 2 clutch boss 3 thrust washer 4 clutch housing 5 S S S S S

EAS00280

CHECKING THE FRICTION PLATES The following procedure applies applies to all of the fric-

CLUTCH

ENG

2. Meas Measur ure: e: clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification ! Replace the clutch plates as a set. S

Clutch plate warpage limit Less than 0.05 mm

EAS00282

CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check ck:: clutch spring Damage ! Replace the clutch springs as a set. S

2. Meas Measur ure: e: clutch spring free length Out of specification ! Replace the clutch S

CLUTCH

ENG

EAS00288

CHECKING THE CLUTCH PUSH RODS 1. Check ck:: O-ring 1 short clutch push rod 2 long clutch push rod 3 ball 4 Cracks/damage/wear ! Replace the defective part(-s). 2. Me Meas asur ure: e: long clutch push rod bending limit Out of specification ! Replace the long clutch push rod. S S S S

S

Long clutch push rod bending limit 0.2 mm

EAS00298

INSTALLING THE CLUTCH 1. In Inst stal all: l: clutch housing 1 S

CLUTCH

ENG

5. In Inst stal all: l: friction plates clutch plates S S

NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate. 6. In Inst stal all: l: long clutch push rod ball 7. In Inst stal all: l: short clutch push rod 1 O-ring 2 New push plate 3 washer 4 nut 5 S S

S S S S S

8. In Inst stal all: l: pressure plate 1 clutch springs 2 S

ENG

CLUTCH CAUTION:

Do not overtighten the locknut since this will remove the free play between both push rods. Push lever lock nut 8Nm (0.8m kg) S

11. Ins Instal tall: l: clutch cover 1 S

7 Nm (0.7 m kg) S

NOTE: Tighten the clutch cover bolts in stages sta ges and in a crisscross pattern.

SHIFT SHAFT AND STOPPER LEVER EAS00327

SHIFT SHAFT AND STOPPER LEVER

12 Nm (1.2 m kg) S

ENG


12 Nm (1.2 m kg) S

ENG


ENG

EAS00328

CHECKING THE SHIFT SHAFT 1. Check ck:: shift shaft 1 shift lever 2 Bends/damage/wear ! Replace. S S

S

shift lever spring Damage/wear ! Replace.

EAS00330

CHECKING THE STOPPER LEVER 1 Check ck::


ENG

INSTALLING THE SHIFT SHAFT 1. In Inst stal all: l: shift shaft assembly S

a. Set the stopper stopper lever lever and return spring spring to the shift shaft. b. Mesh the stop stopper per leve leverr 1 with the shift cam segment. c. Ins Instal talll the shift shift lever lever 2 to the shift cam segment. d. After installing installing the shift shift shaft, check the the shift cam for smooth operation by turning the shift shaft with your hand.

2. Check ck:: shift lever 1 position Gaps a and b are not equal S

Replace the

OIL PUMP EAS00357

OIL PUMP

50 Nm (5.0 m kg) S

ENG

OIL PUMP EAS00360

ENG

OIL PUMP

ENG

REMOVING THE PRIMARY DRIVE GEAR 1. Stra Straighte ighten n the lock lock washer washer tab. tab. 2. Re Remo move ve:: nut (primary drive gear) 1 lock washer 2 primary drive gear 3 S S S

NOTE: Place a folded aluminium plate or copper washer a between the teeth of the balancer drive gear 4 and balancer driven gear 5 . EAS00364

CHECKING THE OIL PUMP 1. Check ck:: primary drive gear 1 oil pump driven gear 2 oil pump housing 3 oil pump housing cover 4 Cracks/damage/wear ! Replace the defective part(-s). 2. Me Meas asur ure: e: inner-rotor-to-outer-rotor-ti inner-rotorto-outer-rotor-tip p clearance A outer-rotor-to-oil-pump-housing clearance B S S S S

S S

OIL PUMP

ENG

EAS411701

ASSEMBLING THE OIL PUMP 1. Lu Lubr bric icat ate: e: inner rotor outer rotor oil pump shaft (with the recommended lubricant) S S S

Recommended lubricant Recommended Engine oil 2. Inst Instal all: l: oil pump shaft 1 (to the oil pump cover 2 ) pin 3 inner rotor 4 outer rotor 5 pin 6 oil pump housing 7 screw 8 7 Nm (0.7 m kg) S

S S S S S S

S

NOTE: When installing the inner rotor, align the pin 3 in the oil pump shaft with the groove a on the

OIL PUMP

ENG

EAS00302

INSTALLING THE PRIMARY DRIVE GEAR 1. In Inst stal all: l: primary drive gear 1 lock washer 2 New primary drive gear nut 3 S S S

50 Nm (5.0 m kg) S

NOTE: Place a folded aluminum plate a or copper washer between the teeth of the balancer drive gear 4 and the balancer driven gear 5 in order to lock them. Do not damage the balancer drive and balancbalanc er driven gear’s teeth. S

S

2. Bend the lock washer washer tab along a flat side of the nut.

BALANCER GEAR BALANCER GEAR

ENG

BALANCER GEAR

ENG

SR******

REMOVING THE BALANCER DRIVEN GEAR 1. Stra Straighte ighten n the lock lock washer washer tab. tab. 2. Re Remo move ve:: nut (balancer driven gear) 1 lock washer 2 balancer driven gear 3 S S S

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******

CHECKING THE BALANCER DRIVE GEAR 1. In Insp spec ect: t:

BALANCER GEAR

ENG

SR******

INSTALLING THE BALANCER GEAR 1. In Inst stal all: l: balancer driven gear 1

DRIVEN

S

NOTE: Install the balancer driven gear, then mesh the balancer driven gear match mark a and balancer drive gear assembly match mark b . 2. Inst Instal all: l: lock washer 1 New nut (balancer drive gear) 2 S S

50 Nm (5.0 m kg) S

NOTE: Place a folded aluminium plate or copper washer a between the teeth of the balancer drive gear 3 and balancer driven gear 4 . S

3. Bend the the lock washer washer tab, tab, after tighten tighten the the nut flats.

STARTER CLUTCH AND GENERATOR STARTER CLUTCH AND GENERATOR GENERATOR COVER

ENG

STARTER CLUTCH AND GENERATOR EAS00341

STATOR COIL

3 Nm (0.3 m kg) S

7 Nm (0.7 m kg)

ENG

STARTER CLUTCH AND GENERATOR EAS00343

STARTER CLUTCH AND GENERATOR ROTOR

ENG

STARTER CLUTCH AND GENERATOR

ENG

REMOVING THE GENERATOR ROTOR 1. Re Remo move ve:: bolt 1 (magneto) plain washer 2 S S

NOTE: Loosen the bolt (generator rotor) 1 while holding the rotor with a sheave holder 3 . Do not allow the sheave holder to touch the projection on the rotor. S

S

Sheave holder: 90890-01701 2. Remo Remove ve:: generator rotor 1 woodruff key S S

NOTE: Remove the rotor using sheave holder 2 , rotor puller 3 and rotor puller attachment 4 . Rotor puller: 90890-01080


ENG

b. When turning turning the starter starter clutch clutch gear clockclockwise a , the starter clutch and the starter clutch gear should engage. If the starter clutch gear and starter clutch do not engage, the starter clutch is faulty and must be replaced. c. When turnin turning g the starter starter clutch gear gear countercounterclockwise b , it should turn freely. If the starter clutch gear does not turn freely, the starter clutch is faulty and must be replaced. 3. Insp Inspec ect: t: dowel pins 1 compression springs 2 spring caps 3 Wear/Damage ! Replace. S S S

4. Insp Inspec ect: t: starter wheel gear (contacting surface) S


ENG

INSTALLING THE GENERATOR ROTOR 1. In Inst stal all: l: shim 1 starter wheel gear 2 woodruff key 3 S S S

2. Inst Instal all: l: generator rotor 1 S

NOTE: Clean the tapered portion of the crankshaft and the rotor hub. When installing the rotor, make sure the woodruff key is properly seated in the key way of the crankshaft and turning the starter wheel gear 2 clockwise. S

S

3. Tig ight hten en:: generator rotor 1 S

CRANKSHAFT

ENG

CRANKSHAFT CRANKCASE

8 Nm (0.8 m kg) S

CRANKSHAFT

ENG

8 Nm (0.8 m kg) S

CRANKSHAFT CRANKSHAFT AND BALANCER WEIGHT

ENG

CRANKSHAFT

ENG

EAS00386

DISASSEMBLING THE CRANKCASE 1. Re Remo move ve:: crankcase bolts S

NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully f ully loosened, remove them. Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration) illustration).. The numbers embossed on the crankcase indicate the crankcase tightening sequence. S

S

S

2. Remo Remove ve:: right crankcase S

CRANKSHAFT

ENG

EAS00394

CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Me Meas asur ure: e: crankshaft runout Out of specification ! Replace the crankshaft, bearing or both. S

NOTE: Turn the crankshaft slowly. Crankshaft runout Less than 0.03 mm 2. Meas Measur ure: e: big end axial clearance Out of specification ! Replace the big end bearing, crankshaft pin, or connecting rod. S

Big end axial clearance 0.35 0.65 mm Limit 1.0 mm X

3. Meas Measur ure: e: crankshaft width S

CRANKSHAFT

ENG

EAS00401

CHECKING THE BEARINGS AND OIL SEALS 1. Check ck:: bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement ! Replace. 2. Check ck:: oil seals Damage/wear ! Replace. S

S

EAS00207

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET, AND TIMING CHAIN GUIDES 1. Check ck:: timing chain Damage/stiffness ! Replace the timing chain and camshaft sprocket as a set. S

2. Check ck:: camshaft sprocket More than than 1/ 4 tooth a S

Replace the

CRANKSHAFT

ENG

EAS00408

INSTALLING THE CRANKSHAFT 1. In Inst stal all: l: crankshaft assembly 1 balancer weight assembly 2 S S

CAUTION: To avoid scratching the crankshaft and to ease the installation procedure, apply grease onto the oil seal lips and apply engine oil onto each bearing. EAS00418

ASSEMBLING THE CRANKCASE 1. Thor Thorough oughly ly clean all the gasket gasket mating mating surfaces and crankcase mating surfaces. 2. App pplly: sealant (onto the crankcase mating surfaces) S

Yamaha bond No. 1215 90890-85505 NOTE:

TRANSMISSION TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS

ENG

TRANSMISSION DRIVE AXLE AND MAIN AXLE

ENG

TRANSMISSION

ENG

EAS00420

REMOVING THE TRANSMISSION 1. Re Remo move ve:: Drive axle assembly 1 Main axle assembly 2 Remove them at same the time. S S

EAS00421

CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related componen components. ts. 1. Check ck:: shift fork cam follower 1 shift fork pawl 2 Bends/damage/scoring/wear ! Replace the shift fork. S S

2. Check ck:: shift fork guide bar Roll the shift fork guide bar on a flat surface. S

TRANSMISSION

ENG

EAS00424

CHECKING THE TRANSMISSION 1. Me Meas asur ure: e: main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main axle. S

Main axle runout limit 0.08 mm 2. Meas Measur ure: e: drive axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the drive axle. S

Drive axle runout limit 0.08 mm

3. Check ck:: transmission gears Blue discoloration/pitting/wear S

!

Replace

ENG

TRANSMISSION EAS00426

INSTALLING THE TRANSMISSION, SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1. In Inst stal all: l: 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) S

S

S

S S

NOTE: Install the shift forks with the embossed mark to the right and in sequence (R, C, L) beginning from the right.

2. Check ck:: shift cam operation Unsmoothy operation S

!

Repair.

ENG

CHAPTER 5. CARBURETOR CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 CHECKING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 INSTALLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . 5-7 CHECKING THE FUEL COCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 CHECKING THE FUEL COCK OPERATION . . . . . . . . . . . . . . . . . . . 5-8

CARBURETOR EAS00480

CARBURETOR CARBURETOR

CARB

CARBURETOR EAS00483

CARB

CARBURETOR

CARB

CARBURETOR

CARB

EAS00485

CHECKING THE CARBURETOR 1. Check ck:: carburetor body float chamber jet housing Cracks/damage ! Replace. 2. Check ck:: fuel passages Obstruction ! Clean. S S S

S

a. Wash the carburetor carburetor in a petroleum-based petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out out all of the passag passages es and jets jets with compressed air.

3. Check ck:: float chamber body Dirt Clean. S

CARBURETOR

CARB

8. Check ck:: piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness ! Replace the piston valve. S

9. Check ck:: starter plunger 1 starter plunger spring 2 Bends/cracks/damage ! Replace. S S

10.. Ch 10 Chec eck: k: hose joints Cracks/damage S

Replace.

CARBURETOR

CARB

2. Inst Instal all: l: needle valve seat 1 S

3. Inst Instal all: l: float 1 needle valve float pin 2 S S S

NOTE: Install the float pin from the side opposite the arrow.

4. Inst Instal all: l: float chamber 1 pilot screw 2 S

CARBURETOR

CARB

EAS00492

INSTALLING THE CARBURETOR 1. Ad Adju just st:: engine idling speed S

Engine idling speed 1,300 1,500 r/min X

Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 2. Ad Adju just st:: throttle cable free play S

Throttle cable free play (at the flange of the throttle grip) 3 5 mm X

Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.

EAS00498

MEASURING AND ADJUSTING THE FUEL LEVEL

CARBURETOR

CARB

2. Adju Adjust st:: fuel level S

a. Remove Remove the the carburet carburetor or.. b. Che Check ck the needle needle valve valve seat and and needle needle valve. c. If either either is worn, worn, replac replace e them as as a set. d. If both are fine, adjust the the float level by slightly bending the float tang 1 . e. Insta Installll the the carbure carburetor tor.. f. Me Measu asure re the the fuel fuel lev level el aga again. in. g. Repeat steps steps (a) to (f) until the fuel level is within specification.

EAS00505

CHECKING THE FUEL COCK 1 Check ck::

CHAPTER 6. CHASSIS FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 CHECKING THE BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . . 6-8 REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 REAR BRAKE AND REAR WHEEL SPROCKET . . . . . . . . . . . . . . . . 6-12 REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 CHECK CH ECKING ING AND RE REPLA PLACIN CING G THE THE REAR REAR WHE WHEEL EL SPR SPROCK OCKET ET . 6-1 6-16 6 CHECKING THE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 ASSEMBLING THE BRAKE SHOE PLATE . . . . . . . . . . . . . . . . . . . . . 6-17 INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . . 6-18 FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . 6-51 HANDLING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . 6-52 DISPOSING OF A REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . 6-52 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . 6-53 REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53 REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . 6-55 CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55 CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56 INSTALLING TH THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . 6-57 INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

FRONT WHEEL AND BRAKE DISC

CHAS

EAS00512

CHASSIS FRONT WHEEL AND BRAKE DISC

90 Nm (9.0 m kg) S

13 Nm (1.3 m kg) S


CHAS


CHAS

EAS00519

REMOVING THE FRONT WHEEL 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remo Remove ve:: speedometer cable 1 brake caliper 2 wheel axle 3 S S S

NOTE: Do not squeeze the brake lever when removing the brake caliper. 3. Elev Elevat ate: e: front wheel S


CHAS

3. Check ck:: spokes Bends/damage ! Replace. Loose ! Tighten. Tap the spokes with a screwdriver. S

NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat.

4. Tig ight hten en:: spokes S

2 Nm (0.2 m kg) S

NOTE: After tightening the spokes, measure the front wheel runout.

5. Meas Measur ure: e: front wheel radial runout a


CHAS

7. Check ck:: wheel bearings Front wheel turns roughly or is loose ! Replace the wheel bearings. oil seals Damage/wear ! Replace. S

S

8. Repl Replac ace: e: wheel bearings (New) oil seals (New) S S

a. Clean Clean the outside outside of the the front wheel wheel hub. hub. b. Rem Remove ove the oil seal seals s 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. c. Rem Remove ove the the whee wheell bearin bearings gs 1 with a gener-


CHAS

EAS00527

CHECKING THE BRAKE DISC 1. Check ck:: brake disc Damage/galling ! Replace. 2. Me Meas asur ure: e: brake disc deflection 1 Out of specification ! Correct the brake disc deflection or replace the brake disc. S

S

Brake disc deflection limit (maximum) 0.15 mm a. Place the motorcycle on a suitable suitable stand so that the front wheel is elevated. b. Befo Before re measurin measuring g the front brake brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary. c. Rem Remove ove the the brake brake caliper caliper.. d. Hold the the dial gauge at a right right angle against the brake disc surface. e. Meas Measure ure the the deflect deflection ion 2 3 mm below the edge of the brake disc. X


CHAS

d. Measure Measure the brake brake disc disc deflecti deflection. on. e. If out of specification, specification, repeat the the adjustment adjustment steps until the brake disc deflection is within specification. f. If the brak brake e disc disc deflectio deflection n cannot cannot be be brought brought within specification, replace the brake disc. EAS00542

INSTALLING THE FRONT WHEEL 1. Lu Lubr bric icat ate: e: wheel axle wheel bearings oil seal lips speedometer drive gear speedometer driven gear S S S S S

Recommended lubricant Recommended Lithium soap base grease 2. Inst Instal all: l: speedometer gear unit 1 S

NOTE: Make sure that the speedometer gear unit and the wheel hub are installed with the three pro-


CHAS

EAS00548

ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the front wheel static balance should be adjusted. S Adjust the front wheel static balance with the brake disc installed.

1. Remo Remove ve:: S balancing weight(-s) 1 NOTE: Place the front wheel on a suitable balancing stand.

2. Find: S front wheel’s heavy spot


CHAS

b. Turn Turn the the front front wheel wheel 90_ so that the heavy spot is positioned as shown. c. If the heavy heavy spot spot does not not stay in that that posiposition, install a heavier weight. d. Repeat steps steps (b) and and (c) until until the front front wheel is balanced.

4. Check ck:: S front wheel static balance a. Turn the front wheel wheel and and make sure sure that it stays at each position shown. b. If the front wheel wheel does does not remain stationary at all of the positions, rebalance it.

REAR WHEEL AND REAR BRAKE REAR WHEEL AND REAR BRAKE REAR WHEEL

90 Nm (9.0 m kg) S

CHAS

REAR WHEEL AND REAR BRAKE

90 Nm (9.0 m kg) S

CHAS


CHAS

REAR BRAKE AND REAR WHEEL SPROCKET

35 Nm (3.5 m kg) S


CHAS


9 Nm (0.9 m kg) S

CHAS


CHAS

EAS00563

REMOVING THE REAR WHEEL 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remo Remove ve:: wheel axle 1 rear wheel S S

NOTE: Push the rear wheel forward and remove the drive chain from the rear wheel sprocket. 3. Remo Remove ve:: brake shoe plate 4. Re Remo move ve:: brake shoes 1 S

S


CHAS

EAS00568

CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check ck:: rear wheel sprocket More than than 1/ 4 tooth a wear ! Replace the rear wheel sprocket. Bent teeth ! Replace the rear wheel sprocket. S

b Correct 1 Drive chain roller 2 Rear wheel sprocket

2. Repl Replac ace: e: rear wheel sprocket S

a. Remove Remove the self-loc self-locking king nuts nuts and the rear wheel sprocket. b. Clean the the rear wheel drive drive hub with a clean cloth, especially the surfaces that contact the t he sprocket. c. Insta Installll the new new rear rear wheel wheel sprocket sprocket.. Rear wheel sprocket self-locking nut


CHAS

WARNING Do not allow oil or grease to contact the brake shoes. NOTE: Replace the brake shoes as a set, if either is worn to the wear limit.

3. Meas Measur ure: e: brake drum inside diameter a Out of specification ! Replace the wheel. S

Brake drum inside diameter limit (maximum) 111 mm 4. Check ck:: brake drum inner surface Oil deposits ! Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches ! Repair. S


CHAS

EAS00571

INSTALLING THE REAR WHEEL 1. Lu Lubr bric icat ate: e: wheel axle wheel bearings oil seal lips S S S

Recommended lubricant Recommended Lithium soap base grease 2. Adju Adjust st:: drive chain slack S


Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 3. Tig ight hten en:: wheel axle nut 90 Nm (9.0 m kg) S

S

WARNING Make sure that the brake hose is routed properly.

FRONT BRAKE FRONT BRAKE FRONT BRAKE PADS

CHAS

FRONT BRAKE

CHAS

EAS00579

CAUTION: Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Never use solvents on internal brake components. Use only clean or new brake fluid for cleaning brake components. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt fluid immediately. immediately. Avoid brake fluid coming into contact with the eyes as it can cause serious injury. First aid for brake fluid entering the eyes: Flush with water for 15 minutes and get imS

S

S

S

S

S

FRONT BRAKE

CHAS

4. Meas Measur ure: e: brake pad wear limit a Out of specification ! Replace the brake pads as a set. S

Brake pad wear limit 0.8 mm

5. Inst Instal all: l: brake pads 1 brake pad spring 2 S S

NOTE: Always install new brake pads and a new brake pad spring as a set.

a. Connect Connect a clear clear plasti plastic c hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed bleed screw and push push the brake caliper pistons into the brake caliper with

FRONT BRAKE 7. Inst Instal all: l: brake caliper brake pad bolt

CHAS

S S

27 Nm (2.7 m kg) S

8. Check ck:: brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 9. Check ck:: brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. S

S

FRONT BRAKE

CHAS

FRONT BRAKE MASTER CYLINDER

2 Nm (0.2 m kg) S

7 Nm (0.7 m kg) S

FRONT BRAKE

CHAS

FRONT BRAKE

CHAS

EAS00588

DISASSEMBLING THE MASTER CYLINDER

FRONT

BRAKE

NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disc Discon onne nect ct:: brake switch 1 2. Re Remo move ve:: union bolt 1 copper washers 2 brake hose 3 S

S S S

NOTE: To collect any remaining brake fluid, place a container under the master cylinder cyl inder and the end of the brake hose.

EAS00590

CHECKING THE FRONT BRAKE MASTER CYLINDER

CHAS

FRONT BRAKE 4. Check ck:: brake hose 1 Cracks/damage/wear S

!

Replace.

EAS00598

ASSEMBLING AND INSTALLING FRONT BRAKE MASTER CYLINDER

THE

WARNING S

S

Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components. Recommended brake fluid Recommended DOT 4

1. Inst Instal all: l: brake master cylinder 1 S

7 Nm (0.7 m kg) S

NOTE: Install the brake master cylinder holder with the “UP” mark 2 facing up. First, tighten the upper bolt, then the lower S

FRONT BRAKE

CHAS

NOTE: Turn the handlebar to the left and to the right to make sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. 3. Fill: brake master cylinder reservoir (with the specified amount of the recommended brake fluid) S

Recommended brake fluid Recommended DOT 4

WARNING S

S

Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor-

FRONT BRAKE

CHAS

FRONT BRAKE CALIPER

30 Nm (3.0 m kg) S

26 Nm (2.6 m kg) S

FRONT BRAKE

6 Nm (0.6 m kg) S

CHAS

FRONT BRAKE

CHAS

EAS00619

DISASSEMBLI NG THE FRONT BRAKE CALDISASSEMBLING IPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system.

1. Remo Remove ve:: union bolt 1 copper washers 2 brake hose S S S

NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

2. Remo Remove ve:: brake caliper pistons 1 brake caliper piston seals 2 S S

FRONT BRAKE

CHAS

1. Check ck:: brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper. brake caliper cylinders 2 Scratches/wear ! Replace the brake caliper. brake caliper body 3 Cracks/damage ! Replace the brake caliper. brake fluid delivery passages (brake caliper body) Obstruction ! Blow out with compressed compress ed air. S

S

S

S

WARNING Whenever a brake caliper is disassembled, replace the piston seals.

2. Check ck:: brake caliper bracket 1 Cracks/damage Replace. S

FRONT BRAKE

CHAS

WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”.

CAUTION: When installing the brake hose onto the brake caliper 1 , make sure that the brake pipe a touches the projection b on the brake caliper. 2. Remo Remove ve:: brake caliper 3. In Inst stal all: l: brake pads brake pad springs brake caliper retaining bolt S

S S S

27 Nm (2.7 m kg) S

S

brake caliper bracket 30 Nm (3.0 m kg) S

S

brake hose holder Refer to “REPLACING THE BRAKE PADS”.

FRONT BRAKE

CHAS

CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Ble lee ed: brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. S

6. Check ck:: brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check ck:: brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. S

S

FRONT FORK

CHAS

FRONT FORK

5

23 Nm (2.3 m kg) S

23 Nm (2.3 m kg) S

23 Nm (2.3 m kg) S

FRONT FORK

23 Nm (2.3 m kg) S

CHAS

FRONT FORK

CHAS

EAS00649

REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stan Stand d the motorcycle motorcycle on on a level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Loos Loosen en:: upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolt 3 S S S

WARNING Before loosening the upper and lower bracket pinch bolts, support the front fork leg.

FRONT FORK

CHAS

3. Remo Remove ve:: damper rod bolt copper washer S S

NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 , loosen the damper rod bolt. Damper rod holder 90890-01294 T-handle 90890-01326 4. Remo Remove ve:: inner tube S

EAS00657

CHECKING THE FRONT FORK LEGS The following procedure applies to both of the

FRONT FORK

CHAS

CAUTION: S

S

The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.

4. Check ck:: cap bolt O-ring Damage/wear ! Replace. S

EAS00659

ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the

FRONT FORK

CHAS

2. Lubr Lubric icat ate: e: inner tube’s outer surface S

Recommended lubricant Recommended Fork oil 10W or equivalent 3. Tig ight hten en:: damper rod bolt S

27 Nm (2.7 m kg) S

NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 , tighten the damper rod bolt. Damper rod holder 90890-01294 T-handle 90890-01326

4. Inst Instal all: l: outer tube bushing 1 (with the fork seal driver weight and adapter) S

FRONT FORK

CHAS

6. Inst Instal all: l: oil seal clip 1 S

NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove.

7. Inst Instal all: l: boot 1 S

8. Fill: front fork leg (with the specified amount of the recomS

FRONT FORK

CHAS

EAS00662

INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. In Inst stal all: l: front fork leg Temporarily tighten the upper and lower bracket pinch bolts. S

NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder. 2. Tig ight hten en:: lower bracket pinch bolt 1 S

30 Nm (3.0 m kg) S

S S

23 Nm (2.3 m kg) cap bolt 2 upper bracket pinch bolt 3 S

23 Nm (2.3 m kg) S

WARNING Make sure that the brake hoses are routed properly.

HANDLEBAR HANDLEBAR

20 Nm (2.0 m kg) S

CHAS

HANDLEBAR

20 Nm (2.0 m kg) S

CHAS

HANDLEBAR

CHAS

EAS00666

REMOVING THE HANDLEBAR 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remo Remove ve:: throttle cable housing 1 throttle grip 2 S S

3. Remo Remove ve:: handlebar grip (left) 1 S

NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

EAS00668

CHECKING THE HANDLEBAR 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

HANDLEBAR

CHAS

WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried. EB704700

INSTALLING THE HANDLEBAR 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Inst Instal all: l: handlebar 1 upper handlebar holders 2 S S

20 Nm (2.0 m kg) S

CAUTION: S

S

First, tighten the bolts on the front side of the handlebar holder, holder, then on the rear side. Turn the handlebar all the way to the left and right. If there is any contact with the

HANDLEBAR

CHAS

5. Inst Instal all: l: left handkbar switch S

NOTE: Align the tab a on the plate with the slot b on the handkbar switch/

6. Inst Instal all: l: clutch cable 7. Co Conn nnec ect: t: clutch switch coupler S

S

NOTE: Apply a thin coat of litium soap base grease onto the end of the clutch cable. 8. Adju Adjust st:: clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. S

STEERING HEAD

CHAS

STEERING HEAD

90 Nm (9.0 m kg) S

5

1st 38 Nm (3.8m kg) 2nd 18 Nm (1.8 m kg) S

S

STEERING HEAD

CHAS

90 Nm (9.0 m kg) S

5

1st 38 Nm (3.8m kg) 2nd 18 Nm (1.8 m kg) S

S

STEERING HEAD

CHAS

EAS00679

REMOVING THE LOWER BRACKET 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over.

2. Remo Remove ve:: upper ring nut rubber washer lower ring nut 1 S S S

NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, then remove the upper ring nut with the ring nut wrench. Exhaust and steering nut wrench 2 90897-01268

STEERING HEAD

CHAS

b. Remove Remove the bearin bearing g race from from the lower lower bracket with a floor chisel 2 and hammer. c. Insta Installll a new dust dust seal and and new beari bearing ng races.

CAUTION: If the bearing race is not installed properly, properly, the steering head pipe could be damaged. NOTE: Always replace the bearing balls and bearing races as a set. Whenever the steering head is disassembled, replace the dust seal. S

S

4. Check ck:: upper bracket lower bracket (along with the steering stem) Bends/cracks/damage ! Replace. S S

EAS00683

INSTALLING THE STEERING HEAD

REAR SHOCK ABSORBER AND SWINGARM

CHAS


56 Nm (5.6 m kg) S


CHAS

EAS00687

HANDLING THE REAR SHOCK ABSORBER

WARNING This rear shock absorber contain highly compressed nitrogen gas. Before handling the rear shock absorber, absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. Do not tamper or attempt to open the rear shock absorber. Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. Do not deform or damage the rear shock absorber in any way. If the rear shock absorber or both are damaged, damping performance will suffer. S

S

S


CHAS

EAS00694

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remo Remove ve:: rear shock absorber assembly lower pin 1 S

NOTE: While removing the rear shock absorber assembly lower pin, hold the swingarm so that it does not drop down. 3. Remo Remove ve:: rear shock absorber assembly upper bolt 1 rear shock absorber assembly S S


CHAS

EAS00703

REMOVING THE SWINGARM 1. Stan Stand d the motorcycle motorcycle on a level level surface. surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remo Remove ve:: rear shock absorber assembly lower pin 1 S

NOTE: When removing the rear shock absorber assembly lower pin, hold the swingarm so that it does not drop down. 3. Check ck:: swingarm side play A swingarm vertical movement B S S


CHAS

EAS00696

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check ck:: rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly. rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly. spring Damage/wear ! Replace the rear shock absorber assembly. bushings Damage/wear ! Replace. dust seals Damage/wear ! Replace. bolts Bends/damage/wear ! Replace. S

S

S

S

S

S

EAS00707

CHECKING THE SWINGARM 1 Check ck::


CHAS

4. Check ck:: dust covers 1 spacer 2 oil seals 3 Damage/wear ! Replace. bearings Damage/pitting ! Replace. S S S

S

EAS00710

CHECKING THE DRIVE CHAIN 1. Me Meas asur ure: e: 10-link section a of the drive chain Out of specification ! Replace the drive chain. S

10-link drive chain section limit (maximum) 121.4 mm NOTE: While measuring the 10-link section, push down on the drive chain to increase its tension. Measure the length between drive chain roller S


CHAS

4. Check ck:: drive chain rollers 1 Damage/wear ! Replace the drive chain. drive chain side plates 2 Damage/wear ! Replace the drive chain. Cracks ! Replace the drive chain and make sure that the battery breather hose is properly routed away from the drive chain and below the swingarm. 5. Lu Lubr bric icat ate: e: drive chain S

S

S

Recommended lubricant Recommended Engine oil or chain lubricant suitable for non-O-ring chains

6. Check ck:: drive sprocket rear wheel sprocket S


CHAS

EAS00711

INSTALLING THE SWINGARM 1. Lu Lubr bric icat ate: e: bearings spacers dust covers pivot shaft S S S S

Recommended lubricant Recommended Molybdenum disulfide grease 2. Inst Instal all: l: Swingarm 80 Nm (8.0 m kg) 3. In Inst stal alll rear shock absorber assembly rear wheel Refer to “INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY” and ”REAR WHEEL”. 4. Ad Adju just st:: drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. S

S

S S

S


EAS00714

INSTALLING THE DRIVE CHAIN 1. Lu Lubr bric icat ate: e:


CHAS

CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits.

CHAS

CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHECKING THE BULBS AND BULB SOKETS . . . . . . . . . . . . . . . . . . . . 7-4 TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . 7-4 CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . 7-6 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 STARTING CIRCUIT CUTOFF SYSTEM OPERATION . . . . . . . . . . . 7-13

ELECTRICAL COMPONENTS EAS00729

ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7

Horn Flasher relay Main switch Fuse holder assembly Starter relay Rectifier/Regulator Battery

8 9 10 11 12 13 14

Neutral relay Thermo switch Sidestand switch Rear brake switch Neutral switch Spark plug cap Ignition coil

15 C.D.I. unit

ELEC

SWITCHES

ELEC

EAS00730

SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.

CAUTION: Never insert the tester probes into the coupler terminal slots 1 . Always insert the probes from the opposite end of the coupler coupler,, taking care not to loosen or damage the leads. Pocket tester 90890-03112 NOTE: Before checking for continuity, set the pocket tester to “0” and to the “Ω  1” range. When checking for continuity, continuit y, switch back and forth between the switch positions a few times. S

S

SWITCH INSPECTION

ELEC

EAS00731

SWITCH CONTINUITY INSPECTION Check each switch for damage or wear, wear, proper connections, and also for continuity between betwee n the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace the switch. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. ³

³

³

CHECKING THE BULBS AND BULB SOCKETS

ELEC

EAS00732

CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! Properly connect. Incorrect continuity reading ! Repair or replace the bulb, bulb socket or both.

TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left.


ELEC

WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

CAUTION: S

S

Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler. Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. thinner.

2. Check ck:: bult (for continuity) (with the pocket tester) S


ELEC

CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check ck:: bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. S

Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following.

a. Install Install a good bulb bulb into into the bulb bulb socket. socket. b. Con Connect nect the pocke pockett tester probe probes s to the respective leads of the bulb socket. c. Che Check ck the bulb socket socket for continu continuity ity.. If any of the readings indicate no continuity, replace the bulb socket.

IGNITION SYSTEM EAS00734

IGNITION SYSTEM CIRCUIT DIAGRAM

ELEC


TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Check: 1. spa spark rk plu plug g 2. igni ignition tion spar spark k gap 3. spar spark k plug cap cap resistanc resistance e 4. ign igniti ition on coil coil 5. pick pickup up coil coil resistanc resistance e 6. sour source ce coil coil resistan resistance ce 7. ma main in swit switch ch 8. engi engine ne stop stop switch switch 9. side sidestand stand swit switch ch 10. neut neutral ral rela relay y 11. neut neutral ral swit switch ch 12.. di 12 diod ode e 13. wiri wiring ng conne connection ction (entire ignition system) NOTE: Before troubleshooting, remove the following part(-s): 1) side cover covers s (left (left and right) right) 2) seat 3) fu fuel el ta tank nk

ELEC

EAS00742

2. Ignit Ignition ion spark spark gap S

S

S S S

Disconnect the spark plug cap from the spark plug. Connect the ignition checker 1 as shown. 2 Spark plug cap Turn the main switch to ”ON”. Measure the ignition spark gap a . Check the spark by pushing the starter switch, and gradually increase the spark gap until a misfire occurs.

S

Min. ignition spark gap 6 mm

ELEC

IGNITION SYSTEM Spark plug cap resistance 10 kΩ at 20_C S

Secondary coil resistance 6.32 X 9.48 kΩ at 20_C

Is the spark plug cap OK? YES

S

Is the ignition coil OK?

NO

YES

Replace the spark plug cap. EAS00746

NO Replace the ignition coil.

EAS00748

4. Ignition coil resistance

5. Pickup coil resistance

Disconnect the ignition coil lead from the wireharness. S Connect the pocket tester ( Ω  1) to the ignition coil as shown.

S

S

Tester positive probe ! orange Tester negative probe ! ground

1 2

Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester (Ω  100) to the pickup coil terminal as shown. Tester positive probe ! red 1 Tester negative probe ! white 2


6. Sour Source ce coil resistanc resistance e

8. Engi Engine ne stop switc switch h

Disconnect the source coil coupler from the wireharness. S Connect the pocket tester (Ω  100) to the charging coil terminal as shown. S

Tester positive probe ! brown Tester negative probe ! green

ELEC

Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? S

YES

1 2

NO Replace the right handlebar switch.

EAS00752

9. Side Sidestan stand d switch switch Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the sidestand switch OK? S

S

Measure the source coil resistance. Source coil resistance resistance:: 624 X 936 Ω (20_C) (between brown and green) Is the source coil OK?

YES

NO Replace the stand switch.

side-


12.. Dio 12 iode de S S

S

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13.. Wi 13 Wiri ring ng

Disconnect the diode from the coupler. Connect the pocket tester (Ω  1) to the diode terminals as shown. Measure the diode for continuity as follows.

Tester positive probe ! blue/white 1 Tester negative probe ! blue/black 2

Continuity

Tester positive probe ! blue/black 1 Tester negative probe ! blue/white 2

No continuity

S

S

Check the entire ignition system’s wiring. Refer to ”CIRCUIT DIAGRAM”. Is the ignition system’s wiring properly connected and without defects? NO

Properly connect or repair the ignition system’s wiring.

YES Replace the CDI unit.

ELECTRIC STARTING SYSTEM EAS00755

ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM

ELEC

ELECTRIC STARTING SYSTEM

ELEC

EAS00756

STARTING CIRCUIT CUTOFF SYSTEM OPERATION If th the e eng engin ine e sto stop p swi switc tch h is is set set to “ ” and and th the e main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand sidestan d is up (the sidestand switch is closed). The neutral relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the neutral relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the neutral relay is closed close d and the engine can be started by pressing the start switch. S

S

WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO

ELEC


TROUBLESHOOTING The starter motor fails to turn. Check: 1. fu fuse se 2. ba batte ttery ry 3. sta starte rterr motor motor 4. ne neutr utral al relay relay 5. sta starte rterr relay relay 6. ma main in swit switch ch 7. engi engine ne stop stop switch switch 8. ne neutr utral al switch switch 9. side sidestand stand swit switch ch 10.. clu 10 clutch tch switch switch 11. sta start rt switc switch h 12.. wi 12 wiri ring ng (of the entire starting system) NOTE: S Before, troubleshooting, remove the following part(-s): 1) side cover covers s (left (left and right) right) 2) seat 3) fu fuel el ta tank nk

2. Bat Batter tery y S

Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Specific gravity: 1.280 at 20_C

S

Is the battery OK? YES

NO Refill the battery fluid. S Clean the battery terminals. S Recharge or replace the battery. S

EAS00758

3. Start Starter er moto motorr S

Connect the battery positive terminal 1 and starter motor lead 2 with jumper lead 3


ELEC

4. Neut Neutral ral rela relay y S S

Disconnect the relay unit from the coupler. Connect the pocket tester (Ω  1) and battery (12 V) to the relay unit terminals as shown.

R Br

R/W

Battery positive terminal ! brown 1 Battery negative terminal ! sky blue 2 Tester positive probe ! blue/white 3 Tester negative probe ! black/white 4

S

Does the starter relay have continuity between red and check? YES

NO Replace the starter relay.

EAS00749

6. Main swit switch ch S

Does the starting circuit cutoff relay have continuity between black/white and blue/white?

S

S

Check the main switch for continuity. Refer to ”CHECKING THE SWITCHES”. Is the main switch OK?


EAS00766

8. Neut Neutral ral switc switch h S

S

12.. Wi 12 Wiri ring ng

Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the neutral switch OK? YES

S

S

Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the starting system’s wiring properly connected and without defects?

NO NO Replace the neutral switch.

EAS00752

9. Side Sidestan stand d switch switch S

S

ELEC

Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the sidestand switch OK? YES

NO Replace the stand switch.

side-

Properly connect or repair the starting system’s wiring.

YES The starting system circuit is OK.

ELECTRIC STARTING SYSTEM STARTER MOTOR

ELEC


ELEC

EAS00769

Checking the starter motor 1. Check ck:: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Me Meas asur ure: e: S commutator diameter a Out of specification ! Replace the starter motor. Min. commutator diameter 21 mm 3. Meas Measur ure: e: S mica undercut a Out of specificatio specification n ! Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutacommut ator. Mica undercut 1.5 mm NOTE: The mica must be undercut to ensure proper


ELEC

5. Meas Measur ure: e: brush length a Out of specification ! Replace the brushes as a set. S

Min. brush length 3.5 mm

6. Meas Measur ure: e: brush spring free length (Compressed spring) a Out of specification ! Replace the brush springs as a set. S

Brush spring 14.5 mm

7. Check ck:: gear teeth Damage/wear S

Replace the gear.

CHARGING SYSTEM YP804000

CHARGING SYSTEM CIRCUIT DIAGRAM

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CHARGING SYSTEM EAS00774

TROUBLESHOOTING The battery is not being charged. Check: 1. fuse 2. ba batt tter ery y 3. cha chargi rging ng volta voltage ge 4. stato statorr coil assemb assembly ly resistan resistance ce 5. wir irin ing g (of the entire charging system) NOTA: S Before troubleshooting, remove the following part(-s): 1) side cover covers s (left (left and right) right) 2) seat S Troubleshoot with the following special tool(-s). Engine tachometer 90890-03113 Pocket tester 90890-03112 EAS00738

ELEC

EAS00775

3. Char Charging ging voltag voltage e Connect the engine tachometer to the spark plug lead. S Connect the pocket tester (DC 20 V) to the battery as shown. S

Tester positive probe ! battery positive terminal Tester negative probe ! battery negative terminal

Start the engine and let it run at approximate approximate-ly 5,000 5,000 r/ min. S Measure the charging voltage. S

CHARGING SYSTEM EB804401

4. Stator coil coil assembly assembly resistance resistance Disconnect the starter coil coupler from the wire harness. S Connect the pocket tester ( Ω  1) to the stator coil assembly coupler as shown. S

Tester positive probe ! white 1 Tester negative probe ! white 2 Tester positive probe ! white 1 Tester negative probe ! white 3

S

Measure the stator coil assembly resistances.

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LIGHTING SYSTEM EB804000

LIGHTING SYSTEM CIRCUIT DIAGRAM

ELEC

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LIGHTING SYSTEM EAS00781

TROUBLESHOOTING Any of the following fail to light: head light, high beam indicator light, taillight, auxiliary light or meter light. Check: 1. fuse 2. ba batt tter ery y 3. ma main in swi switc tch h 4. lig lights hts sw switc itch h 5. dim dimmer mer swi switch tch 6. wir irin ing g (of the entire charging system) NOTE: S Before troubleshooting, remove the following part(-s): 1) side cover covers s (left (left and right) right) 2) seat 3) fu fuel el ta tank nk S Troubleshoot with the following special tool(-s).

2. Bat Batter tery y S

Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Specific gravity 1.280 at 20 _C

S



EAS00749


Check the main switch for continuity.


EAS00788

5. Dimm Dimmer er switch switch S

S

ELEC

Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the dimmer switch OK? YES

NO The dimmer switch is faulty. Replace the left handlebar switch.

CHECKING THE LIGHTING SYSTEM 1. The headlight headlight and the high beam beam indicator indicator light fail to come on. 1. Headligh Headlightt bulb and socket socket S

S

Check the headlight bulb and socket for f or continuity. Refer to ”CHECKING THE BULBS AND BULB SOCKETS”. Are the headlight bulb and socket OK? YES

NO

EAS00787

7. Wi Wiri ring ng S

S

Replace the headlight bulb, socket or both.

Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the lighting system’s wiring properly connected and without defects? 2. Volt oltage age YES

Check the condition

NO Properly connect or

S

Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown.

LIGHTING SYSTEM Headlight Tester positive probe ! yellow 1 or green 2 Tester negative probe ! black 3 High beam indicator light Tester positive probe ! yellow 4 Tester negative probe ! black 5

S S S S

S

Set the main switch to “ON”. Set th the lilight sw switch to “ ”. Set the dimmer switch to “ ” or “ ”. Measure the voltage (12 V) of yellow (green) 2 on the headlight coupler (headlight side). Is the voltage within specification?

ELEC

2. Volt oltage age S

Connect the pocket tester (20 V) to t o the meter assembly coupler (wire harness side) as shown.

Tester positive probe ! blue 1 Tester negative probe ! black 2

S S S

S

Set the main switch to “ON”. Set the light switch to “ ” or “ ”. Measure the voltage (12 V) of blue 1 on the meter assembly coupler (wire harness side). Is the voltage within specification? YES

NO


EAS00791

3. A tail tail / brak brake e light light fails fails to come come on. on.

4. The auxilia auxiliary ry light light fails to come come on.

1. Tail ail// brake light light bulb bulb and socket S

S

1. Auxiliary light light bulb and and socket

Check the tail/ brake light bulb bulb and socket for continuity. Refer to ”CHECKING THE BULBS AND BULB SOCKETS”. Are the tail/brake light bulb and socket OK? YES

ELEC

S

S

Check the auxiliary light bulb and socket for continuity. Refer to ”CHECKING THE BULBS AND BULB SOCKETS”. Are the auxiliary light bulb and socket OK?

NO

YES

Replace the tail/brake light bulb, socket or both.

NO Replace the auxiliary light bulb, socket or both.

2. Vol oltag tage e S

Connect the pocket tester (DC 20 V) to the tail// brake light coupler tail coupler (wire harness side) as shown.

Tester positive probe ! blue 1 Tester negative probe ! black 2


Connect the pocket tester (DC 20 V) to the auxiliary light couplers (wire harness side) as shown.

Tester positive probe ! blue/red 1 Tester negative probe ! black 2

SIGNAL SYSTEM EB806000

SIGNAL SYSTEM CIRCUIT DIAGRAM

ELEC

ELEC

SIGNAL SYSTEM EAS00794

TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light or an indicator light. S The horn fails to sound. S

Check: 1. fuse 2. ba batt tter ery y 3. ma main in swi switc tch h 4. wir irin ing g (of the entire signaling system)

2. Ba Batte ttery ry S

Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. Specific gravity 1.280 at 20_C

S


NOTE: S Before troubleshooting, remove the following part(-s): 1) side cover covers s (left (left and right) right) 2) seat 3) fu fuel el ta tank nk S Troubleshoot with the following special tool(-s).


EAS00749

Pocket tester 90890-03112


Check the main switch for continuity.

SIGNAL SYSTEM

ELEC

EAS00796

CHECKING THE SIGNALING SYSTEM 1. The horn horn fails fails to sound. sound. 1. Horn swit switch ch S

S

3. Ho Horn rn S

S

Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the horn switch OK?

S S S

YES

NO

Disconnect the pink connector at the horn terminal. Connect a jumper lead 1 to the horn terminal and ground the jumper lead. Set the main switch to “ON”. Push the horn switch. Does the horn sound?

Replace the left handlebar switch.

2. Vol oltag tage e S

Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown.

Tester positive probe ! brown 1 Tester negative probe ! ground

NO

YES The horn is OK.

SIGNAL SYSTEM

ELEC

EAS00797

2. A tail tail / brak brake e light light fails fails to come come on. on.

S S

1. Tail ail// brake light light bulb bulb and socket S

S

Check the tail/ brake light bulb bulb and socket for continuity. Refer to ”CHECKING THE BULBS AND BULB SOCKETS”. Are the tail/brake light bulb and socket OK? YES

NO

S

S

Set the main switch to “ON”. Pull in the brake lever or push down on the brake pedal. Measure the voltage (12 V) of yellow at the tail// brake light coupler tail coupler (wire harness side). side). Is the voltage within specification? YES

This circuit is OK.

Replace the tail/brake light bulb, socket or both.

NO The wiring circuit from the main switch to the tail/ brake light light coupler is faulty and must be repaired.

2. Brak Brake e light switche switches s S

S

Check the brake light switches for continuity. Refer to “CHECKING THE SWITCHES”. Is the brake light switch OK? YES

NO

EAS00799

3. A turn signal light, light, turn signal indicator light or both fail to blink. 1. Turn signal signal light bulb bulb and socket

ELEC

SIGNAL SYSTEM 4. Vol oltag tage e S

S

Connect the pocket tester (DC V 20) to the flasher relay coupler (wire harness side) as shown.

S

S

Set the main switch to “ON”. Measure the voltage (12 V) on brown/white at the flasher relay coupler (wire harness side). Is the voltage within specification?

Tester positive proble ! brown 1 Tester negative proble ! ground

YES

NO The flasher relay is faulty and must be replaced.


S S

S

Set the main switch to ”ON”. Measure the voltage (12 V) of brown 1 at the flasher relay coupler (wire harness side). Is the voltage within specification? YES

NO The wiring circuit from

Connect the pocket tester (DC 20 V) to the turn signal light connectors or the meter assembly coupler (wire harness side) as shown.

A Turn signal light B Turn signal indicator light

Left turn signal light Tester positive probe ! chocolate (orange)

1

SIGNAL SYSTEM S S S

S

Set the main switch to “ON”. Set the turn switch to “ ” or “ ”. Measure the voltage (12 V) of chocolate (orange) 1 or dark green 2 at the turn signal light connector (wire harness side). Is the voltage within specification? YES

This circuit is OK.

NO

ELEC


Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown.

Tester positive probe ! brown 1 Tester negative probe ! sky blue 2

The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.

EAS00800

4. The neutral neutral indicator indicator light fails to come on. on. 1. Neutral indicator indicator light light bulb and socket S

S

Check the neutral indicator light bulb and socket for continuity. Are the neutral indicator light bulb and socket OK?

S S

S

Set the main switch to “ON”. Measure the voltage (12 V) of brown 1 and sky blue 2 at the meter assembly coupler. Is the voltage within specification? YES

NO

SIGNAL SYSTEM

ELEC

!

S

Measure the carburetor heater resistance. Carburetor heating element resistance: 6 X 12 Ω (20_C)

S

Is the carburetor heating element element OK? YES

S

Check the thermo switch for continuity at the temperatures indicated below.

8_C " 4_C

A COOL DOWN

19_C " 3_C

This circuit is OK.

NO Replace the carburetor heater element.

CHAPTER 8. TROUBLESHOOTING STARTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 8-2 FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 FAULTY FAUL TY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 FAULTY FRONT LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 FAULTY LIGHTING AND SIGNALING SYSTEMS . . . . . . . . . . . . . . . . . . 8-5

STARTING PROBLEMS

TRBL SHTG

EAS00844

TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. troubleshoot ing. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.

STARTING PROBLEMS ENGINE Cylinders and cylinder head(-s) Loose spark plug Loose cylinder head Damaged cylinder head gasket Worn or damaged cylinder Incorrect valve clearance Incorrectly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timing Faulty valve spring Seized valve Pistons and piston rings Incorrectly installed piston ring Damaged, worn or fatigued piston ring Seized piston ring S S S S S S S S S S

S S S

FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel filter Clogged fuel tank breather hole Deteriorated or contaminated fuel Fuel cock Clogged or damaged fuel hose Carburetors Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked-in air Damaged float Worn needle valve Incorrectly installed needle valve seat S S S S

S

S S S S S S S

INCORRECT EN INCORR EN GINE IDLING IDLING SPEE SPEED / POOR M EDIUM AN ANDDHIGH-SPEED HIGH-SPEE D PERF PERFORM ORMAN ANCE/ CE/ FAU AUL LTY GEAR SHIFTING

TRBL SHTG

EAS00846

INCORRECT ENGINE IDLING SPEED ENGINE Cylinders and cylinder head Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element S S

S

ELECTRICAL SYSTEMS Battery Faulty battery Discharged battery Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap Ignition coil Broken or shorted primary or secondary coils Faulty spark plug lead Damaged ignition coil Ignition system Faulty CDI unit Faulty pickup coil S S

S S

FUEL SYSTEM Carburetor Faulty starter plunger Loose or clogged pilot jet Loose or clogged pilot air jet Damaged or loose carburetor joint Incorrectly adjusted engine idling speed (throttle stop screw) Incorrect throttle cable free play Flooded carburetor S S S S S

S S

S S S S

S S S

S S

EAS00848

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”.

FAU AUL LTY CLU CLU TCH/ OV OVER ERHEA HEATIN TING G

TRBL SHTG

EAS00851

FAULTY CLUTCH CLUTCH SLIPS Clutch Incorrectly assembled clutch Incorrectly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate Engine oil Incorrect oil level Incorrect oil viscosity (low) Deteriorated oil S S S S S

S S S

CLUTCH DRAGS Clutch Unevenly tensioned clutch spring Warped pressure plate Bent clutch plate Swollen friction plate Bent clutch push rod Damaged clutch boss Burnt primary driven gear bushing Match marks not aligned Engine oil Incorrect oil level Incorrect oil viscosity (high) Deteriorated Deteriorate d oil S S S S S S S S

S S S

EAS00854

OVERHEATING ENGINE Cylinder head(-s) and piston(-s) Heavy carbon buildup Engine oil Incorrect oil level Incorrect oil viscosity S

S S

CHASSIS Brakes Dragging brake S

ELECTRICAL SYSTEMS Spark plugs

POOR BRAK BRAKIN ING G PERFOR PERFORM M AN ANCE/ CE/ FAU AUL LTY FRONT FOR FORK K LEGS/ UN ST STAB ABL LE HANDLING

TRBL SHTG

EAS00859

POOR BRAKING PERFORMANCE Front brake Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper piston seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level S S S S S S S S S S

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 S S S S S S S S S S

EAS00861

FAULTY FRONT FORK LEGS LEAKING OIL Bent, damaged or rusty inner tube Damaged outer tube Incorrectly installed oil seal Damaged oil seal lip Incorrect oil level (high) Loose damper rod assembly bolt Damaged damper rod assembly, bolt, or copper washer S S S S S S S

MALFUNCTION Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube busing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level S S S S S S S

FAUL AULTY TY LIGHTING AN D SIGN AL ALING ING SYSTE SYSTEM MS

TRBL SHTG

EAS00866

FAUL AULTY TY LIGHTING LIG HTING AND AN D SIGNALING SYSTEMS HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Incorrectly grounded circuit Poor contacts (main or light switch) Burnt-out headlight bulb S S S S

TURN SIGNAL BLINKS SLOWLY Faulty flasher relay Faulty main switch Faulty turn signal switch Wrong turn signal bulb S S S S

S S S

TURN SIGNAL REMAINS LIT Faulty flasher relay Burnt-out-turn signal bulb S S

HEADLIGHT BULB BURNT OUT Wrong headlight bulb Faulty battery Faulty rectifier/regulator Incorrectly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired S S S S

TURN SIGNAL BLINKS QUICKLY Incorrect turn signal bulb Faulty flasher relay Burnt-out turn signal bulb S S S

S S S

HORN DOES NOT SOUND Incorrectly adjusted horn Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery S S

TAIL AIL// BRAKE LIGHT DOES NOT LIGHT Wrong tail/brake light bulb Too may electrical accessories S S

S S

TRBL SHTG

TW125 ’99 WIRING DIAGRAM

1 2 3 4 5 6 7 8 9 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 40 41 42

COLOR CODE B ..... Br . . . . Ch . . . Dg . . . G .... L ..... O ....

Black Brown Chocolate Dark green Green Blue Orange

Sb . . . . P ..... R ..... Y ..... W .... B /R /R . . . B/W . .

Sky blue Pink Red Yellow White Black /R /Red Black / Wh White

Br / L . . Br / W . G /R /R . . G/W. . G/Y . . L /B /B . . . L /R . . .

Brown / Bl Blue Br ow ow n/ n/ Wh Wh ite Green /R /Red Green / Wh White Green / Yellow Blue /B /Black Blue / Red

L /W /W . . L /Y /Y . . . R/L . . . R /W /W . . W/B . . W /L /L . . W /R /R . .

Blu e/ e/ Wh White Blue /Y /Yellow Red / Blue Red /W /White White / Bl Black White /B /Blue White /R /Red

C.D.I. magneto Neutral switch Rectifier/Regulator Battery Starter relay Fuse Starting motor Handlebar switches (right) Start switch Engine stop switch Main switch Clutch switch Diode C.D.I. unit Ignition coil Spark plug Thermo switch Carbuletor heater Horn Flasher relay Sidestand switch Neutral relay Speedometer Reed switch (for D[5EK2]) Meter light Neutral indicator light Turn signal indicator light Hi-beam indicator light Handlebar switches (left) Horn switch Turn switch Lights switch Dimmer switch Front brake switch Rear brake switch Rear turn signal light (right) Front turn signal light (right) Front turn signal light (left) Rear turn signal light (left) Headlight Auxiliary light Tail/ l/ Brake light

Yamaha TW 125 Service Manual - 1999

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