Yamaha Libero Workshop Manual
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Yamaha Libero Workshop Manual

Yamaha Libero Workshop Manual

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  • Page 1 WORKSHOP MANUAL...
  • Page 2 FOREWORD This Workshop Manual has been prepared for use by the Yamaha Motor India Private Ltd. Authorised Dealerships and their service personnel to attend to servicing of Crux Motorcycles. It is not possible to include entire service education into this Manual. It is assumed that persons using this book to...

  • Page 3: How To Use This Manual

    HOW TO USE THIS MANUAL MANUAL ORGANISATION EXPLODED DIAGRAMS ENGINE ASSEMBLY AND ADJUSTMENTS ENGINE ASSEMBLY PISTON RING, PISTON AND CYLINDER NOTE : • Make sure to install the Piston Rings so that the GTP TOP1/GTP-TOP 2 marks are lo- cated on the upper side of the 2nd Ring/Top Ring •...
  • Page 4 ILLUSTRATED SYMBOLS SPEC INFO INSP CHAS CARB TRBL ELEC SHTG Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text. Clearance Voltage, Current Illustrated symbols 16 to 21 in the exploded diagrams indicate the types of lubricants and lubrication points.

  • Page 5: General Information

    INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION INSP AND ADJUSTMENTS ENGINE CARBURETION CARB CHASSIS CHAS ELECTRICAL ELEC TROUBLE SHOOTING TRBL SHTG...

  • Page 6: Table Of Contents

    CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER ............1-1 ENGINE SERIAL NUMBER ............1-1 IMPORTANT INFORMATION PREPARATION FOR DISASSEMBLY ........1-2 ALL REPLACEMENT PARTS ........... 1-3 GASKETS, OIL SEALS, AND O-RINGS ........1-3 LOCK WASHERS/PLATES AND COTTER PINS ..... 1-3 BEARINGS AND OIL SEALS ............

  • Page 7: Motorcycle Identification

    INFO MOTORCYCLE IDENTIFICATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER XXXXXX MODEL YEAR OF MONTH UNIT PRODUCTION CODE PRODUCTION CODE NUMBER Year of Production 2 Digits standing for last two digits of year Eg. 0 0 - 2000, 0 1 - 2001 ..Month Code One alphabet standing for Month Eg.

  • Page 8: Important Information

    INFO IMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR DISASSEMBLY 1. Remove all dirt, mud, dust and foreign ma- terial before disassembly. 2. Use proper Tools and Cleaning Equipment. Refer to “SPECIAL SERVICE TOOLS”. 3. When disassembling the Motorcycle, keep mated parts together. This includes gears, Cylinder, Piston and other mated parts that have been “mated”...

  • Page 9: Bearings And Oil Seals

    INFO IMPORTANT INFORMATION BEARINGS AND OIL SEALS CAUTION: WARNING Do not use compressed air to spin the Bearings dry. This causes damage to the Bearing surfaces. CIRCLIPS WARNING If the Circlip is fitted the wrong way it would cause it to jump off its groove and damage related components.

  • Page 10: Special Tools

    INFO SPECIAL SERVICE TOOLS SPECIAL TOOLS SPECIAL SERVICE TOOLS The appropriate Special Service Tools are necessary for proper maintenance of the Motorcycle. Using the correct Special Service Tool will help to prevent damage caused by the use of improper tools or improvised techniques. The following is the detailed list of all Special Service Tools with their application.
  • Page 11 L-10 INFO SPECIAL SERVICE TOOLS 9. Crank Shaft Removal Tool. 13. Torx Bit (T - 30) YSST - 265 YSST - 611 This tool is used to loosen or tighten the This tool is used to remove the Crank Shaft Cam Shifter Segment Screw.
  • Page 12 R-11 INFO SPECIAL SERVICE TOOLS 22. Engine Stand 17. Rear Shock Absorber Adjuster YSST 221 This fixture is used to hold the Engine This tool is used to adjust spring preload for its disassembly and assembly. of Rear Shock Absorbers. 18.

  • Page 13: Service Instruments

    L-12 INFO SERVICE INSTRUMENTS SERVICE INSTRUMENTS The following Service Instruments are necessary for complete and accurate tune up of Motorcycle 5. Vernier Calliper 1. Tachometer YSST - 613 (150 mm) This Instrument is used for checking the This instrument is used for measuring Engine RPM length, width &...

  • Page 14: Special Service Materials

    This instrument is used to check clear- intake vaccum. ance/ gaps between parts. SPECIAL SERVICE MATERIAL The following Service material are necessary to use at the time of assembly of various parts. 1. YAMAHA Bond 2. LOCTITE TG-1215 Three Bond 1322 YAMAHA BOND...
  • Page 15 CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ............2-1 MAINTENANCE SPECIFICATIONS ENGINE ..................2-4 CHASSIS ..................2-10 ELECTRICAL ................2-13 GENERAL TORQUE SPECIFICATIONS ........2-15 LUBRICATION POINTS AND LUBRICANT TYPE ENGINE ..................2-16 CHASSIS ..................2-17 ENGINE LUBRICATION ROUTE ............. 2-18 ENGINE BEARINGS ................ 2-20 CABLE ROUTING ................2-21...

  • Page 16: Specifications

    R-15 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS DESCRIPTION SPECIFICATION Model : CRUX Model Code : 5KA1 Engine model code: DIMENSIONS: Overall length 1997 Overall width Overall height 1055 Seat height Wheelbase 1247 Minimum ground clearance Minimum turning radius 2000 Dry weight : 105.5 kg Basic weight : (With Oil and full Fuel Tank)
  • Page 17 L-16 SPEC GENERAL SPECIFICATIONS DESCRIPTION SPECIFICATION Clutch type : Wet, Multiple disc Transmission : Primary reduction system Helical gear Primary reduction ratio 68/18 (3.778 : 1) Secondary reduction system Chain drive Secondary reduction ratio 42/14 (3.00 : 1) Transmission type Constant mesh 4-speed Operation Left foot operation...
  • Page 18 R-17 SPEC GENERAL SPECIFICATIONS DESCRIPTION SPECIFICATION Brake : Front brake Type Drum Brake (Dia 130 mm) Operation Right hand operation Rear brake Type Drum brake (Dia 130 mm) Operation Right foot operation Suspension : Front suspension Telescopic fork Rear suspension Swingarm Shock absorbser : Front shock absorber...

  • Page 19: Maintenance Specifications

    L-18 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE DESCRIPTION SPECIFICATION Cylinder : Bore size 49.000 ~ 49.020 mm (in five grades) Piston : Piston to Cylinder Clearance 0.017 ~ 0.021 mm <0.12mm> Piston size “D” 48.962 ~ 48.981 mm Cylinder Piston Grading (in five grades) Matching of Grades Piston...
  • Page 20 R-19 SPEC MAINTENANCE SPECIFICATIONS DESCRIPTION SPECIFICATION Cylinder head : <0.03 mm (0.0012 in)> Lines indicate straightedge measurement. Camshaft : Drive method Chain Drive Cam dimensions Intake “ A ” 25.356 ~ 25.456 mm <25.326 mm> “ B “ 20.989 ~ 21.089 mm ...
  • Page 21 L-20 SPEC MAINTENANCE SPECIFICATIONS DESCRIPTION SPECIFICATION Stem outside diameter 4.975 ~ 4.990 mm 4.960 ~ 4.975 mm <4.950 mm> <4.935 mm> Guide inside diameter 5.000 ~ 5.012 mm 5.000 ~ 5.012 mm <5.035 mm> <5.035 mm> Stem to guide clearance 0.005 ~0.0325 mm 0.0125 ~ 0.026 mm ...
  • Page 22 R-21 SPEC MAINTENANCE SPECIFICATIONS DESCRIPTION SPECIFICATION Clutch : Friction plate thickness 2.90 ~ 3.10 mm Quantity 5 pcs. <2.80 mm> Clutch Plate thickness 1.05 ~ 1.35 mm Quantity 4 pcs. 0.05 mm Clutch Spring free length 33 mm Quantity 4 pcs.
  • Page 23 L-22 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE (ENGINE) Tightening torque Remark Parts Thread Part to be tightened Q'ty name size m.kg ft.lb Cylinder Head Bolt Bolt Spark Plug 17.5 1.75 12.6 Cylinder Head Side Cover Bolt Valve Cover 17.5 1.75 CDI Magneto Rotor Bolt Stopper Guide Bolt...
  • Page 24 R-23 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE (ENGINE) Tightening sequence Cylinder Head Tightening torque Remark Parts Thread Part to be tightened Q'ty name size m.kg ft.lb Shift Pedal Bolt Segment Screw Torx Bolt Stopper lever Bolt Sensor Assembly Bolt Neutral Switch Assembly Crankcase Left - hand Right - hand...

  • Page 25: Chassis

    7.4 N/mm (K2) 13.2 N/mm Stroke (K1) 0 ~ 28 mm (K2) 28 ~ 110mm Oil grade Special YAMAHA oil. Rear suspension : Shock Absorber travel 70 mm Spring free length 205.4 mm Fitting length 197.4 mm Spring rate (K1) 18.6 N/mm...
  • Page 26 R-25 SPEC MAINTENANCE SPECIFICATIONS DESCRIPTION SPECIFICATION Front Drum Brake : Type Leading, Trailing Brake Drum inside diameter 130mm <131> Lining Thickness 4.0 mm <2 mm> Shoe Spring free length 36.5mm Rear drum brake : Type Leading, Trailing Brake Drum inside diameter 130mm ...
  • Page 27 L-26 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE (CHASSIS) Note : 1. First tighten the Ring Nut approximately 45.5 Nm (4.55 m.kg 32.3 ft.lb) by using the torque wrench then loosen the Ring Nut one turn. 2. Retighten the Ring Nut to specifications 2-12...

  • Page 28: Electrical

    R-27 SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL DESCRIPTION SPECIFICATION Voltage : Ignition system : Ignition timing (B.T. D. C) 7º at 1400 r/min Advancer Type Electrical type CDI : Digitally Controlled Magneto model/manufacturer 5KA/DENSO 240 Ω ± 20% Sensor Coil (Color) CDI Unit Model/manufacturer 5KA/ Denso (Japan) IgnitionCoil : Model/Manufacturer...
  • Page 29 L-28 SPEC MAINTENANCE SPECIFICATIONS Circuit Breaker : Type Fuse Amperage for individual circuit X quantity : Main 10A X 1pc. Reserve 10A X 1pc. 2-14...

  • Page 30: General Torque Specifications

    R-29 SPEC GENERAL TORQUE SPECIFICATION GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque speci- fication for special components or assemblies are included in applicable section of this book. To avoid warpage, tighten multi-fastener assemblied in a criss-cross fashion, in progressive stages, until full torque is reached.

  • Page 31: Lubrication Points And Lubricant Type

    Rotary Filter and Oil Pump Sliding Gear (Transmission) Kick Axle Shaft Axle Drive Shift Fork and Guide Bar Shift Cam and Bearing (shift cam) Crankcase Mating Surfaces Yamaha bond No. 1215 Crankcase Cover 1 and Grommet Yamaha bond No. 1215 2-16...

  • Page 32: Chassis

    R-31 SPEC LUBRICATION POINTS AND LUBRICANT TYPE CHASSIS Lubrication points (part name) Lubricant type Gear Unit (Gear Meter and Drive) Oil Seal Lips (all) Pivot Shaft (Swingarm) Pivoting Points (Brake Pedal Shaft and Frame) Ball and Ball Race (Steering Head) Tube Guide (Right Grip) Pivoting points (Brake Lever and Clutch Lever) Pivoting Point (Brake Shoe Plate)

  • Page 33: Engine Lubrication Route

    L-32 SPEC ENGINE LUBRICATION ROUTE Engine Lubrication route CAUTION: WARNING DO NOT DAMAGE CRANK CASE SURFACES, OTHERWISE OIL LEAKAGE WILL START 2-18...
  • Page 34 R-33 SPEC ENGINE LUBRICATION ROUTE Engine Lubrication route CAUTION: WARNING FOR IMPROVED PERFORMANCE, ALWAYS USE YAMALUBE OIL 2-19...

  • Page 35: Engine Bearings

    L-34 SPEC ENGINE BEARINGS ENGINE BEARINGS 2-20...

  • Page 36: Cable Routing

    R-35 SPEC CABLE ROUTING CABLE ROUTING É Flasher light lead (left) of the right side. ¿ Handlebar switch (left) Ê Horn C Pass the Meter Cable Ç and À Clutch cable Ë Flasher light lead (right) the Brake Cable through the Á...
  • Page 37 L-36 SPEC CABLE ROUTING ¿ Headlight assembly Î Over flow hose upper left side of the en- À Handlebar switch lead Ï Crankcase breather hose gine bracket. Á Speedometer cable Ð Brake cable F Pass the battery breather  Cable guide A Pass wireharness hose,...
  • Page 38 R-37 SPEC CABLE ROUTING ¿ Throttle cable A Pass the high tension cord À through the À High tension cord cable guide to the inside of throttle cable ¿ Á Ignition Coil and the clutch cable Æ. Â Band B Tighten the ground lead and ignition coil to- Ã...
  • Page 39 L-38 SPEC CABLE ROUTING ¿ Clamp à Stop/tail light lead À Rectifier regulator Ä Wireharness Á Flasher relay Å Battery  Flasher light lead Æ CDI unit assy. A Clamp the battery positive (+) lead to the batterybox. B Insert hose Air Bent to holder of frame. À...

  • Page 40: Periodic Inspection

    R-39 CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENTS PERIODIC MAINTENANCE / LUBRICATION INTERVALS ..3-1 SIDE COVER, SEAT AND FUEL TANK REMOVAL ...................3-3 INSTALLATION ................3-5 ENGINE VALVE CLEARANCE CHECKING ADJUSTMENT ....3-6 IDLING CO MEASUREMENT, AND ADJUSTMENT ....3-8 THROTTLE CABLE ADJUSTMENT SPARK PLUG INSPECTION AND ADJUSTMENT....3-10 IGNITION TIMING CHECK ............3-11 COMPRESSION PRESSURE MEASUREMENT ......

  • Page 41: Periodic Maintenance/Lubrication Intervals

    L-40 INSP INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable Motorcycle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to Motorcycles already in service as well as to new Motorcycles that are being prepared for sale.
  • Page 42 Check operation, free play, Cable damage CONTROL CABLES, Readjust or replace as required - THROTTLE - CLUTCH - FRONT BRAKE It is recommended that above be authorised YAMAHA MOTOR INDIA PRIVATE LIMITED dealer. * Service more frequently when the vehicle is driven in dusty areas.

  • Page 43: Side Cover, Seat And Fuel Tank

    L-42 INSP SIDE COVERS, SEAT AND FUEL TANK SIDE COVERS, SEAT AND FUEL TANK REMOVAL SIDE COVER (LH) 1. Remove • Side Cover (LH) ææææææææææææææææææææææææææææææææææ Removal steps : • Open the Lock ¿ using Main Switch Key. • Pull the Lug À towards you to remove it from the Fuel Tank.
  • Page 44 R-43 INSP SIDE COVERS, SEAT AND FUEL TANK REMOVAL SEAT 1. Remove • Side Cover LH and RH • Bolts 2 Nos • Seat ææææææææææææææææææææææææææææææææææ Removal steps : • Open bolts ¿ and À inside the side covers. • Lift the front of the Seat and slide it forward. REMOVAL FUEL TANK 1.

  • Page 45: Installation

    L-44 INSP SIDE COVERS, SEAT AND FUEL TANK INSTALLATION Reverse the REMOVAL procedure. Note the following points. 1. Install • Fuel Tank ¿ • Damper Rubber À • Plate Á • Bolt  • Fuel Hose à Bolt (fuel tank) 20 Nm (2.0 mkg;...

  • Page 46: Engine

    R-45 INSP VALVE CLEARANCE CHECKING AND ADJUSTMENT ENGINE VALVE CLEARANCE CHECKING AND ADJUSTMENT NOTE : Valve clearance checking and adjustment should be made with the Engine in cold condi- tion, at room temperature. When the Valve clearance is to be measured or adjusted, the Piston must be at Top Dead Cen- ter (T.D.C.) on the compression stroke and marking on Cam Sprocket should be aligned...
  • Page 47 L-46 INSP VALVE CLEARANCE CHECKING AND ADJUSTMENT ææææææææææææææææææææææææææææææææææ Checking steps : Measurement steps : • Rotate the Crankshaft anticlockwise to align the slit ç third mark on the rotor with the sta- tionary pointer è on the Crankcase Cover LH when the Piston is at Top Dead Center (T.D.C.) and in compression stroke.

  • Page 48: Idling Co Measurement, And Adjustment

    R-47 INSP IDLING CO. MEASUREMENT AND ADJUSTMENT 7. Install • Valve Covers (with O-ring) ¿ • Spark Plug • Cylinder Head Side Cover À Valve cover (intake and exhaust) : 17.5 Nm (1.75 m kg, 13 ft-lb) Bolts (cylinder head side cover) : 10 Nm (1.0 m kg, 7.2 ft-lb) 8.

  • Page 49: Throttle Cable Adjustment

    L-48 INSP IDLING ‘CO’ MEASUREMENT AND ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT 5. Adjust : • ‘CO’ concentration ææææææææææææææææææææææææææææææææææ Adjustment steps : • Turn the pilot screw ¿ in or out until the speci- fied ‘CO’ concentration is obtained. Turning in ” ‘CO’ concentratin decreases Turning out ”...
  • Page 50 R-49 INSP THROTTLE CABLE ADJUSTMENT/ SPARK PLUG INSPECTION • Loosen the Locknut ¿ on the Throttle Cable. • Turn the Adjuster À in or out until the specified free play is obtained. Turning IN ç Ÿ Free play is increased. Turning OUT è...

  • Page 51: Ignition Timing Check

    L-50 INSP SPARK PLUG INSPECTION/ IGNITION TIMING CHECKING PROCEDURE 6. Install : • Spark Plug Spark Plug : 17.5 Nm (1.75 mkg, 12.6 ftlb) NOTE : • Before installing a Spark Plug, clean the Gas- ket surface and Plug surface. •...
  • Page 52 R-51 INSP IGNITION TIMING CHECKING PROCEDURE 3. Check : • Ignition timing ********************************************* Checking steps : • Start the Engine and let it warm up for sev- eral minutes or run the Motorcycle for approx. 4 kms. • Maintain the Engine idling speed Engine idling speed : 1,300 ~ 1,500 r/min •...

  • Page 53: Compression Pressure Measurement

    L-52 INSP COMPRESSION PRESSURE MEASUREMENT COMPRESSION PRESSURE MEASUREMENT NOTE : Insufficient compression pressure will result in performance loss. 1. Check : • Valve clearance Out of specification Ÿ Adjust. Refer “VALVE CLEARANCE ADJUSTMENT” section. Page no 3-6 2. Start the Engine and let it warm up for sev- eral minutes.

  • Page 54: Engine Oil Level Inspection

    R-53 INSP ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT 8. Install : • Fuel tank • Seat • Side covers Refer to “SIDE COVERS, SEAT AND FUEL TANK” section Page no 3-3 ENGINE OIL LEVEL INSPECTION 1. Stand the Motorcycle on a level surface us- ing the Center Stand.
  • Page 55 L-54 INSP ENGINE OIL REPLACEMENT/ EXHAUST SYSTEM INSPECTION 4. Install : • Drain plug ¿ with Washer Drain plug : 20 Nm (2.0 m.Kg, 14.5 ft. lb) 5. Fill : • Oil in Crankcase Oil quantity : 1.0 L 6. Check : •...

  • Page 56: Air Filter Cleaning

    R-55 INSP AIR FILTER CLEANING 1. Remove: • Side Cover (R.H.) • Air Filter Case Cap ¿ • Spring Wire À • Air Filter Element Á • Element guide  CAUTION: WARNING Never operate the Engine without the Air Filter element installed. Unfiltered air will cause rapid wear of Engine parts and may damage the Engine.

  • Page 57: Clutch Cable Adjustment

    L-56 INSP CLUTCH CABLE ADJUSTMENT CLUTCH CABLE ADJUSTMENT 1. Check : • Clutch Cable free play ç Out of specification Ÿ Adjust, Free play (clutch lever) : 10 ~ 15 mm at lever end 2. Adjust: • Clutch Cable free play ææææææææææææææææææææææææææææææææææ...

  • Page 58: Chassis

    R-57 INSP FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT CHASSIS FRONT BRAKE ADJUSTMENT 1. Check : • Brake Lever free play a Out of specification Ÿ Adjust. Free play (Brake Lever): 10 ~ 15 mm at Brake Lever end 2. Adjust : •...

  • Page 59: Brake Shoe Inspection

    L-58 INSP REAR BRAKE ADJUSTMENT/ BRAKE SHOE INSPECTION ææææææææææææææææææææææææææææææææææ Adjustment steps : • Turn the Adjuster ¿ in or until the specified free play is obtained. Turning out ç Ÿ Free play is increased. Turning in è Ÿ Free play is decreased. CAUTION: WARNING Make sure that the Brake does not drag af-...

  • Page 60: Drive Chain Slack Adjustment

    R-59 INSP DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT NOTE: • Before checking and adjusting, rotate the Rear Wheel several revolutions and check the slack at several points to find the tight- est point. • Check and if necessary adjust the Drive Chain slack with the Rear Wheel in this “tight- est”...
  • Page 61 L-60 INSP DRIVE CHAIN SLACK ADJUSTMENT ææææææææææææææææææææææææææææææææææ Adjustment steps : • Loosen both the Locknuts Â. • Turn the Adjuster à in or out until the speci- fied Drive Chain slack is obtained. Turning in ç Ÿ Drive Chain slack is decreased.

  • Page 62: Steering Head Inspection

    R-61 INSP STEERING HEAD INSPECTION STEERING HEAD INSPECTION WARNING Securely support the Motorcycle so that there is no danger of it falling over. 1. Stand the Motorcycle on a level surface. NOTE : Stand the Motorcycle on its Center Stand. 2.
  • Page 63 L-62 INSP STEERING HEAD INSPECTION NOTE : Set the Torque Wrench to the Ring Nut Wrench so that they form a right angle. Ring nut-lower (final tightening) : 15.5 Nm (1.55 m.kg, 11.2 ft. lb) WARNING Avoid over torquing. • Check the Steering Stem by Turning it Lock to Lock.

  • Page 64: Front Fork Inspection

    R-63 INSP FRONT FORK INSPECTION FRONT FORK INSPECTION WARNING Securely support the motocycle so that there is no danger of it falling over. 1. Stand the Motorcycle on a level surface. 2. Check: • Inner tube Scratches/damage ” Replace. • Oil seal Excessive oil leakage ”...

  • Page 65: Rear Shock Absorber Adjustment

    L-64 INSP REAR SHOCK ABSORBER ADJUSTMENT ææææææææææææææææææææææææææææææææææ Adjustment steps: • Turn the Adjuster Ring in or out. Turning toward ç Ÿ Spring preload is increased. Turning toward è Ÿ Spring preload is decreased. Adjustment numbers: Standard Minimum Maximum CAUTION: WARNING •...

  • Page 66: Tyre Inspection

    R-65 INSP TYRE INSPECTION 2. Inspect : • Tyre surfaces Wear/damage Ÿ Replace Minimum Tyre tread Depth : (Front and rear) 1.6 mm ¿ Tread Depth À Side wall Á Wear indicator WARNING Basic weight : • It is dangerous to ride with a worn out tyre. With oil and full fuel tank 113 kg When the tyre tread begins to show signs...

  • Page 67: Spoke Inspection And Tightening

    L-66 INSP SPOKE INSPECTION AND TIGHTENEING SPOKES INSPECTION AND TIGHTENING 1. Inspect : • Spokes ¿ Bending/damage Ÿ Replace. Loose spoke Ÿ Retighten 2. Tighten : • Spokes NOTE : Be sure to tighten the Spokes before and after break-in. Nipple : 2 Nm (0.2 m.kg, 0.3 ft.lb) WHEEL INSPECTION...

  • Page 68: Electrical Battery Inspection

    R-67 INSP BATTERY INSPECTION ELECTRICAL BATTERY INSPECTION 1. Remove: • Side Cover (L.H.) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section. Page no 3-3 • Battery 2. Inspect : • Electrolyte level Electrotyte level should be between the Upper ¿ and Lower À level marks. Electrolyte level is too low Ÿ...

  • Page 69: Battery Installation

    L-68 INSP BATTERY INSTALLATION Replace the battery if: • Battery voltage does not rise to a specific value or bubbles fail to rise during charging. • Sulphation of one or more cells occurs, (as indicated by the plates turning white, or ma- terial accumulating in the bottom of the cell ).

  • Page 70: Fuse Inspection

    R-69 INSP FUSE INSPECTION FUSE INSPECTION CAUTION: WARNING Always turn off the Main Switch when checking or replacing the Fuse. Otherwise, a short circuit may occur. 1. Remove: • Side cover (left) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section Page no 3-3 •...

  • Page 71: Headlight Beam Adjustment

    L-70 INSP HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT HEADLIGHT BEAM ADJUSTMENT 1. Adjust : • Headlight beam (vertical) Push down Ÿ Headlight beam moves lower. Pull up Ÿ Headlight beam moves higher. HEADLIGHT BULB REPLACEMENT 1. Remove: • Cowling (as applicable) •...
  • Page 72 R-71 CHAPTER 4 ENGINE OVERHAUL ENGINE REMOVAL SIDE COVERS, SEAT AND FUEL TANK REMOVAL ....4-1 ENGINE OIL DRAIN ..............4-1 BATTERY ..................4-1 CARBURETOR ................4-1 CLUTCH CABLE ................4-1 DRIVE CHAIN ................4-2 EXHAUST MUFFLER ..............4-2 FOOTREST ASSEMBLY ............4-2 SHIFT PEDAL ................4-3 BATTERY BOX REMOVAL ............4-3 LEADS ..................4-3 ENGINE REMOVAL ..............4-3 MOUNTING ON ENGINE STAND ..........
  • Page 73 L-72 MAINTENANCE SPECIFICATIONS BEARINGS AND OIL SEALS .............4-31 CIRCLIPS AND WASHERS ............4-31 ENGINE ASSEMBLY AND ADJUSTMENT ........4-32 CRANKSHAFT ................4-35 TRANSMISSION ................4-37 SHIFTER..................4-38 CRANKCASE ................4-40 CDI MAGNETO................4-42 SHIFT SHAFT AND KICK STARTER .........4-44 CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP ....4-47 CYLINDER AND PISTON ............4-52 CYLINDER HEAD ...............4-53 CAM SPROCKET AND TIMING CHAIN ........4-54...

  • Page 74: Engine Removal

    R-73 ENGINE REMOVAL ENGINE REMOVAL It is not necessary to remove the Engine in order to remove the following parts. • Cylinder Head • Cylinder • Piston • Clutch • CDI Magneto SIDE COVERS, SEAT AND FUEL TANK REMOVAL 1. Remove : •...

  • Page 75: Clutch Cable

    L-74 ENGINE REMOVAL CLUTCH CABLE 1. Remove : • Clutch cable ææææææææææææææææææææææææææææææææææ Removal steps : • Loosen the locknut ¿ of the Clutch Lever. • Turn in the Adjuster À to enough to free the inner Clutch Cable • Unhook the Cable End from Push Lever Á on the Crankcase L.H.

  • Page 76: Shift Pedal

    R-75 ENGINE REMOVAL SHIFT PEDAL 1. Remove • Bolt (Shift Pedal) ¿ • Shift Pedal À BATTERY BOX 1. Remove • Bolt (Battery Box) ¿ 2 nos • Battery Box À LEADS 1. Disconnect: • Stator Coil Lead Coupler ¿ •...

  • Page 77: Engine Disassembly

    L-76 ENGINE DISASSEMBLY ENGINE DISASSEMBLY CYLINDER HEAD, CYLINDER AND PISTON NOTE: With Engine mounted on Motorcycle, the Cyl- inder Head, Camshaft and Cylinder can be maintained by removing the following parts. • Side Covers • Spark Plug Lead • Seat •...
  • Page 78 R-77 ENGINE DISASSEMBLY 5. Remove : • Tensioner Cap Bolt ¿ • Retract completely the Tensioner Rod by Screw in (clockwise) direction. • Bolts (timing chain tensioner ) À 2 Nos • Timing Chain Tensioner Assembly Á • Gasket 6. Remove : •...
  • Page 79 L-78 MAINTENANCE SPECIFICATIONS 9. Remove : • Dowel Pins ¿ • Gasket (Cylinder) À 10. Remove : • Piston Pin Circlip ¿ 2 nos • Piston Pin À , using Piston Pin Replacer • Piston Á NOTE : Before removing the Piston Pin Circlip, cover the Crankcase with a clean cloth to prevent the Circlip from falling into the Crankcase cavity.

  • Page 80: Clutch

    R-79 ENGINE DISASSEMBLY CLUTCH NOTE : The Clutch Assembly can be removed while the Engine is mounted on the Motorcycle by remov- ing the following parts and draining the Engine oil: • Kick Crank Assy. 1. Remove : • Nut kick Crank assy. •...

  • Page 81: Oil Pump

    L-80 ENGINE DISASSEMBLY 6. Remove : • Clutch Boss Nut ¿ • Lock Washer À • Clutch Boss Á • Thrust Washer  • Clutch Housing à • Spacer Ä • Washer Å 7. Loosen : • Nut ¿ (Primary Drive Gear) NOTE : •...

  • Page 82: Kick Starter

    R-81 ENGINE DISASSEMBLY KICK STARTER NOTE : The kick starter can be removed while the en- gine is mounted by removing the following part. • Kick Crank Assy • Crankcase Cover 2 (RH) • Clutch Drum Assy 1. Remove : •...
  • Page 83 L-82 ENGINE DISASSEMBLY CDI MAGNETO REMOVAL 1. Remove : • Nut (magneto) • Plain washer NOTE : • Loosen the Nut Magneto while holding the Magneto À with Magneto Holder ¿ Magneto Holder : YSST - 601 A 2. Attach •...

  • Page 84: Crankcase

    R-83 ENGINE DISASSEMBLY CRANKCASE 1. Remove : • Bolts (Crankcase RH-2 nos) ¿ 2. Remove : • Bolts (Crankcase LH-8 nos) NOTE : • Loosen the Bolts in a crisscross pattern. • Loosen each Bolts 1/4 turn at a time and re- move them after all are loose.

  • Page 85: Transmission And Shifter

    L-84 ENGINE DISASSEMBLY: TRANSMISSION AND SHIFTER TRANSMISSION AND SHIFTER 1. Remove : • Shift Fork Guide Bar ¿ (short) • Shift Fork Guide Bar À (long) • Shift Cam Á • Shift Fork -C Â • Shift Fork -R Ã •...
  • Page 86 R-85 ENGINE DISASSEMBLY DISASSEMBLY OF CYLINDER HEAD, ROCKER ARMS, CAMSHAFT AND VALVES 1. Loosen : • Valve Adjuster Locknuts ¿ • Valve Adjusters À 2. Remove : • Stopper Plate Á by opening allen bolt  3. Attach • Rocker arm shaft puller ¿ Rocker Arm Shaft Puller YSST - 608A 4.
  • Page 87 L-86 ENGINE DISASSEMBLY 7. Attach Valve Spring compression Tool ¿ Valve Spring Compressor : YSST - 603 8. Remove : • Valve Cotters À NOTE : Valve Spring compressor tool is to be attached between the Valve Spring retainer and the Valve face (Inlet and Exhaust) one at a time.

  • Page 88: Inspection And Repair

    R-87 INSPECTION AND REPAIR: CYLINDER HEAD INSPECTION AND REPAIR CYLINDER HEAD 1. Remove : • Carbon deposits from combustion chambers using a rounded scraper. NOTE : Do not use a sharp instrument to avoid dam- aging or scratching : • Spark Plug threads •...

  • Page 89: Valve Seats

    L-88 INSPECTION AND REPAIR:VALVE SEATS VALVE SEATS 1. Remove : • Carbon deposits from the Valve Face and Valve Seat. 2. Inspect : • Valve Seats Pitting/wear Ÿ reface the valve seat. 3. Measure : • Valve Seat width ç Out of specification Ÿ...
  • Page 90 R-89 INSPECTION AND REPAIRS ææææææææææææææææææææææææææææææææææ Lapping steps : • Apply coarse lapping compound ç to the Valve Face CAUTION: WARNING Do not let compound enter the gap between the Valve Stem and the Guide. • Apply molybdenum disulfide oil to the Valve Stem.

  • Page 91: Valve Springs And Valves

    L-90 INSPECTION AND REPAIR : VALVE SPRINGS AND VALVES VALVE SPRINGS AND VALVES 1. Measure : • Valve Spring free length ç Out of specification Ÿ Replace. Valve spring free length : 39.62 mm 2. Measure : •...

  • Page 92: Camshaft

    R-91 ENGINE INSPECTION AND REPAIR 6. Calculate : Stem Guide Clearance Stem-to-guide clearance = Valve guide inside diameter – Valve stem diameter Stem-to-guide clearance limit : Intake : 0.005 ~ 0.0325 mm Exhaust : 0.0125 ~ 0.026 mm ...

  • Page 93: Rocker Arms And Rocker Arm Shafts

    L-92 ENGINE INSPECTION AND REPAIR ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 1. Inspect : • Cam lobe contact surface ¿ • Adjuster surface À Wear/pitting/scratches/blue discoloration Ÿ Replace ææææææææææææææææææææææææææææææææææ Inspection steps : • Inspect the two contact areas on the Rocker Arms for signs of unusual wear.

  • Page 94: Timing Chain, Sprockets And Chain Guides

    R-93 ENGINE INSPECTION AND REPAIR TIMING CHAIN, SPROCKETS AND CHAIN GUIDES 1. Inspect : • Timing Chain Wear out/Stiffness/damage Ÿ Replace the Chain and the Sprockets as a set. 2. Inspect : • Cam Sprocket Wear/damage Ÿ Replace the Cam Sprocket and the timing chain as a set.

  • Page 95: Cylinder And Pistons

    L-94 ENGINE INSPECTION AND REPAIR CYLINDER AND PISTONS 1. Inspect : • Cylinder and Piston walls Vertical scratches Ÿ Rebore or replace the Cylinder and the Piston 2. Measure : • Piston-to-Cylinder clearance ææææææææææææææææææææææææææææææææææ Measurement steps : 1st step : •...

  • Page 96: Piston Rings

    R-95 ENGINE INSPECTION AND REPAIR PISTON RING INSPECTION 1. Measure : • Side clearance Out of specification Ÿ Replace the Piston and the Piston Rings as a set NOTE : Remove the carbon deposits from the Piston Ring Grooves and Rings before measuring the side clearance.

  • Page 97: Piston Pin

    L-96 ENGINE INSPECTION AND REPAIR PISTON PIN INSPECTION 1. Inspect : • Piston Pin Blue discoloration/grooves Ÿ Replace and inspect the lubrication system 2. Measure : • Piston Pin-to-Piston clearance ææææææææææææææææææææææææææææææææææ Measurement steps. • Measure the Piston Pin outside diameter ç using a micrometer.

  • Page 98: Crankshaft

    R-97 ENGINE INSPECTION AND REPAIR CRANKSHAFT 1. Measure : • Crankshaft runout, using a Surface plate and Dial gauge. Keep the Crankshaft on V blocks and rotate slowly while measuring. spescification Ÿ Replace Runout : 0.01 mm : <0.03 mm> 2.

  • Page 99: Primary Drive Gear

    L-98 ENGINE INSPECTION AND REPAIR PRIMARY DRIVE GEAR INSPECTION 1. Inspect : • Primary Drive Gear teeth ¿ • Primary Driven Gear teeth À Wear/damage Ÿ Replace both Gears as a set. NOTE : Refer the general specification for grading. Excessive noise during operation Ÿ...

  • Page 100: Push Rod

    R-99 ENGINE INSPECTION AND REPAIR 6. Inspect : • Dogs on the Primary Driven Gear ¿ Scoring/wear/damage Ÿ Deburr or replace • Clutch Boss Splines À Scoring/wear/damage Ÿ Replace NOTE : Scoring on the Clutch Housing Dogs and the Clutch Boss Splines will cause erratic operation of the clutch.

  • Page 101: Shift Fork Shift Cam

    L-100 ENGINE INSPECTION AND REPAIR SHIFT FORK SHIFT CAM INSPECTION 1. Inspect : • Shift Fork follower ¿ • Shift Fork Pawl À Scoring/bends/wear/damage Ÿ Replace 2. Inspect : • Shift Cam grooves ¿ Wear/damage/scratches Ÿ Replace • Shift Cam Segment À Wear/damage Ÿ...

  • Page 102: Kick Starter

    R-101 ENGINE INSPECTION AND REPAIR 5. Measure : • Axle runout (Main and Drive) Use a centering device and a dial gauge ¿ Out of specifications Ÿ Replace the bent Axle Runout : 0.01 mm : 0.03 mm 6. Inspect : •...

  • Page 103: Oil Pump

    L-102 ENGINE INSPECTION AND REPAIR OIL PUMP INSPECTION 1. Measure : • Tip clearance ç (between the inner rotor ¿ and the outer rotor À) using feeler gauge. • Side clearance è (between the outer rotor À and the Pump Housing Á) using feeler gauge Out of specification Ÿ...

  • Page 104: Oil Delivery Passage(Cc Cover Rh)

    R-103 ENGINE INSPECTION AND REPAIR DELIVERY PASSAGE INSPECTION CRANK CASE RH 1. Check : • Oil delivery passage Blockage Ÿ Blow the passage with com- pressed air. CRANKCASE 1. Thoroughly wash the crankcase L.H. & R.H. in mild solvent. 2. Thoroughly clean all the Gasket Mating surfaces and Crankcase Mating surfaces using solvent.

  • Page 105: Engine Assembly And Adjustment

    L-104 ENGINE ASSEMBLY AND ADJUSTMENTS ENGINE ASSEMBLY AND ADJUSTMENTS VALVES, ROCKER ARM AND CAMSHAFT ¿ Valve Cotters Æ Lock Nut À Valve Spring Retainer Ç Adjuster Á Valve Springs È Valve Rocker Arm  Valve Stem Seal É Rocker Arm Shaft Ã...
  • Page 106 R-105 ENGINE ASSEMBLY AND ADJUSTMENTS WARNING For Engine Assembly, replace the following parts with new ones : • O-Rings • Gaskets • Oil Seals • Copper Washers • Lock Washers • Circlips VALVES VALVE SPRINGS INSTALLATION 1. Deburr : • Valve Stem end ¿ Using an Oil Stone for smoothing.
  • Page 107 L-106 ENGINE ASSEMBLY AND ADJUSTMENTS 5. Secure the Valve Cotters onto the Valve Stem by tapping lightly with a mallet CAUTION: WARNING Do not hit so much as to damage the Valve CAMSHAFT AND ROCKER ARM INSTALLATION 1. Lubricate : •...

  • Page 108: Crankshaft

    R-107 ENGINE ASSEMBLY AND ADJUSTMENTS CRANKSHAFT à Crankshaft Bearing ¿ Crank Pin Ä Wood-ruff Key À Crank Shaft Á Connecting Rod Å Bearing Æ Spacer  Big end Bearing 4-35...
  • Page 109 L-108 ENGINE ASSEMBLY AND ADJUSTMENTS CRANKSHAFT 1. Insert : • CrankShaft in the Crankcase (L.H.) 2. Attach : • Crankshaft Installing Tool on Crankshaft Crankshaft Installing Tool YSST - 266 Spacer YSST - 267 3. Install : • Crankshaft by tightening the Nut ¿ NOTE : Hold the Connecting Rod at Top End with one hand while turning the Nut of the Installing Tool...

  • Page 110: Transmission

    R-109 ENGINE ASSEMBLY AND ADJUSTMENTS TRANSMISSION È Bearing ¿ Drive Sprocket É Bearing À Oil Seal Ê 4th Pinion Gear Á Bearing Ë 3rd Pinion Gear  4th Wheel Gear Ì 2nd Pinion Gear à Drive Axle Í Main axle Ã...

  • Page 111: Shifter

    L-110 ENGINE ASSEMBLY AND ADJUSTMENTS SHIFTER Ä Shift Fork Guide Bar (short) ¿ Shift Fork Guide Bar (long) Å Shift fork # C À Shift Fork # R Æ Torx Screw Á Shift Fork # L Ç Pin Shaft Cam Â...
  • Page 112 R-111 ENGINE ASSEMBLY AND ADJUSTMENTS TRANSMISSION, SHIFT CAM AND SHIFT FORK INSTALLATION 1. Measure : • Axle Main Assembled length ç Assembled length (Axle Main): 82.25 ~ 83.45 mm 2. Install : • Push rod # 2 ¿ in the Axle Main. 3.

  • Page 113: Crankcase

    L-112 ENGINE ASSEMBLY AND ADJUSTMENTS Tightening Sequence CRANKCASE ¿ Crankcase #1 (LH) À Dowel Pins Á Crankcase Breather Hose  Crankcase #2 (RH) à Holder Clutch Cable 4-40...
  • Page 114 ENGINE ASSEMBLY AND ADJUSTMENTS CRANKCASE LH 1. Apply : • Sealant on the Crankcase Mating surfaces Sealant Yamaha bond No. 1215: 90890-85505 2. Install : • Dowel Pins ¿ NOTE : Do not allow any sealant to come in contact with the Oil Galleries ç...

  • Page 115: Cdi Magneto

    L-114 ENGINE ASSEMBLY AND ADJUSTMENTS CDI MAGNETO Ã Stator Assy. ¿ Timing Chain Ä Gasket À Guide Stopper # 1 and # 2 Å Dowel Pin Á CDI Rotor Assy Æ Cover Crankcase #1 Â Wood-Ruff Key 4-42...
  • Page 116 R-115 ENGINE ASSEMBLY AND ADJUSTMENTS TIMING CHAIN AND GUIDE STOPPER#2 1. Install • Timing Chain ¿ 2. Install • Guide stopper#2 À with spacer • Tighten the bolt Á C.D.I. MAGNETO INSTALLATION 1. Install : • Woodruff Key ¿ 2. Install : •...

  • Page 117: Shift Shaft And Kick Starter

    L-116 ENGINE ASSEMBLY AND ADJUSTMENTS SHIFT SHAFT AND KICK STARTER ¿ Shift Shaft Å Circlip À Torsion Spring Æ Washer Á Stopper Lever Ç Kick Idle Gear  Return Spring È Kick Shaft Assy. à Segment É Cover Crankcase # 2 Ä...
  • Page 118 R-117 ENGINE ASSEMBLY AND ADJUSTMENTS SEGMENT AND SHIFT SHAFT 1. Install • Dowel Pins ¿ on the Cam Shifter À 2. Install : • Segment ¿ using Torx Bit Tool Torx Bit Tool YSST - 611 NOTE : Fit the Dowel Pins on the Cam Shifter to the lo- cating hole ç...
  • Page 119 L-118 ENGINE ASSEMBLY AND ADJUSTMENTS KICK STARTER INSTALLATION 1. Install : • Kick Axle Assembly ¿ • Kick Gear Clip À • Torsion Spring Á NOTE : Turn the Torsion Spring clockwise and hook into the proper hole ç in the Crankcase. 2.

  • Page 120: Clutch, Primary Drive Gear And Oil Pump

    R-119 ENGINE ASSEMBLY AND ADJUSTMENTS CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP ¿ Clutch Spring Æ Thrust Washer Í Key À Pressure Plate Ç Primary Driven Gear Î Oil Pump Drive Gear Á Push Plate È Ball Ï Oil Pump Driven Gear Â...
  • Page 121 L-120 ENGINE ASSEMBLY AND ADJUSTMENTS OIL PUMP INSTALLATION 1. Lubricate : • Oil delivery passage (Crankcase RH) • Oil Pump Assembly ¿ Recommended Lubricant: 4- Stroke Engine Oil 2. Install : • Drive gear (Oil Pump) ¿ • Gasket • Oil Pump Assy Á 3.
  • Page 122 R-121 ENGINE ASSEMBLY AND ADJUSTMENTS CLUTCH INSTALLATION 1. Install : • Oil Seal ¿ • Circlip • Push Lever Axle À NOTE : Install longer side ç of the Spring on Push Le- ver and smaller side è on the Crankcase Notch. 2.
  • Page 123 L-122 ENGINE ASSEMBLY AND ADJUSTMENTS ENGINE ASSEMBLY AND ADJUSTMENTS 6. Install : • Ball 7. Install : • Push Rod # 1 ¿ • Push Plate À • Plate Washer Á • Nut  (Push Rod # 1) 8. Install : •...
  • Page 124 R-123 ENGINE ASSEMBLY AND ADJUSTMENTS ENGINE ASSEMBLY AND ADJUSTMENTS • Hold the Adjuster to prevent it from moving and tighten the Locknut to specification CAUTION: WARNING Take care not to overtighten the Adjuster À and remove the freeplay between both Push Rods. •...

  • Page 125: Cylinder And Piston

    L-124 ENGINE ASSEMBLY AND ADJUSTMENTS CYLINDER AND PISTON ¿ Cylinder à Piston Pin Circlips À Gasket Cylinder Ä Piston Á Dowel Pins Å Pin Piston  Piston Rings 4-52...

  • Page 126: Cylinder Head

    R-125 ENGINE ASSEMBLY AND ADJUSTMENTS CYLINDER HEAD ¿ Bolt Flange Å Cylinder Head À Washer Æ Dowel Pin Á Bolt Ç Gasket Cylinder Head  Valve Cover (intake) È O-Ring à O-Ring É Cover Cylinder Head Side # 3 Ä Valve Cover (exhaust) Ê...

  • Page 127: Cam Sprocket And Timing Chain

    L-126 ENGINE ASSEMBLY AND ADJUSTMENTS CAM SPROCKET AND TIMING CHAIN  Cam Sprocket ¿ Gasket à Timing Chain À Timing Chain Tensioner Assembly Ä Guide Stopper # 1 Á Guide Stopper # 2 4-54...
  • Page 128 R-127 ENGINE ASSEMBLY AND ADJUSTMENTS PISTON RING, PISTON AND CYLINDER INSTALLATION 1. Install in following sequence • Expander Spacer (Oil Ring) ¿ • Side Rails (Oil Ring) À • 2nd Ring Á • Top Ring  NOTE : • Make sure to install the Piston Rings so that the “GTP TOP1”...
  • Page 129 L-128 ENGINE ASSEMBLY AND ADJUSTMENTS 4. Install : • Piston Rings ¿ NOTE : Offset the Piston Rings end gaps as shown. ç Top Ring End è Oil Ring end (lower) é Oil Ring End (upper) ê 2nd Ring End 5.
  • Page 130 R-129 ENGINE ASSEMBLY AND ADJUSTMENTS 2. Install : • Cylinder Head • Bolt with Washer (Cylinder Head) Bolts (Cylinder Head ): M8 (1-4) : 22 Nm (2.2 m.kg, 17 ft.lb) M6(5-6) : 10 Nm (1.0 m.kg., 7.2 ft. lb) NOTE : •...
  • Page 131 L-130 ENGINE ASSEMBLY AND ADJUSTMENTS 4. Install : • Plate Washer 5. Tighten • Bolt Sprocket ¿ Bolt (Timing Chain Sprocket) : 20 Nm (2. 0 m.kg, 14.5 ft. lb) NOTE : Install the Bolt while holding the Magneto Mounting nut with a Wrench. 6.
  • Page 132 R-131 ENGINE ASSEMBLY AND ADJUSTMENTS 8. Check : • Valve clearance specifications Out of specification Ÿ Adjust. Refer to the “VALVE CLEARANCE ADJUST- MENT” section in Chapter 3, Page no 3-8 9. Lubricate : • 4 Stroke Engine Oil Recommended Lubricant : Engine Oil - YAMALUBE 10.Install : •...

  • Page 133: Engine Mounting

    L-132 ENGINE ASSEMBLY AND ADJUSTMENTS 14. Install : • Spark Plug Spark Plug : 17.5 Nm (1.75 m.kg, 12.6 ft. lb) 15. Install : • Plug Drain Plug Drain : 20 Nm (2.0 m.kg, 2.0 ft.lb) ENGINE MOUNTING When remounting the Engine, reverse the re- moval procedure.
  • Page 134 R-133 ENGINE ASSEMBLY AND ADJUSTMENTS Engine Mount Bolt (Rear) : Bolt (Engine Mount stay front lower) 38 Nm (3.8 m.Kg.27.5 ft. lb) 38 Nm (3.8 m.kg., 27.5 ft.lb) Bolt (Engine mount Stay) : Engine Mount Bolt (Front lower) 38 Nm (3.8 m..kg, 27. 5 ft.lt) 38 Nm (3.8 m.kg., 27.5 ft.lb) Engine mount bolt (upper) Engine Mount bolt (from upper))
  • Page 135 L-134 ENGINE ASSEMBLY AND ADJUSTMENTS 11. Install: • Carburetor Refer to “CARBURETOR “ section in Chapter 5 page no 5-7 12. Tighten: • Air Filter Case Screws ¿ Bolts (Air Filter Case ): 7 Nm (0.7 m.kg, 5.1 ft.lb) 13. Install •...

  • Page 136: Carburetion

    R-135 CARB CARBURETION CHAPTER 5 CARBURETION CARBURETOR VIEW ..............5-1 REMOVAL ...................5-2 DISASSEMBLY ................5-3 INSPECTION ................5-4 ASSEMBLY .................5-6 INSTALLATION ................5-7 TUNING ..................5-8...
  • Page 137 L-136 CARB CARBURETOR CARBURETOR ¿ Throttle Cable Ê Throttle valve À Jet Needle Assembly Ë Nozzle Main Á Spring Throttle Valve Ì Screw Pilot Assembly  Plug Drain Í Jet Pilot à Float Chamber Body Î Starter Lever Ä O-Ring Ï...

  • Page 138: Removal

    R-137 CARB CARBURETOR REMOVAL 1. Remove : • Side Covers (LH & RH) Refer to the “SIDE COVER, SEAT AND FUEL TANK” section in Chapter 3, Page no 3-3 2. Drain : • Fuel (Float Chamber) NOTE : Place a rag under the over flow hose to absorb the spilt fuel.

  • Page 139: Disassembly

    L-138 CARB DISASSEMBLY DISASSEMBLY NOTE: The following parts can be cleaned and inspected without Carburetor Disassembly. • Throttle Valve Assembly • Starter lever • Starter Plunger Assembly • Before disassembly of Carburetor clean the outer surface of Carburtor and Check the Starter Lever Opeartion.
  • Page 140 R-139 CARB DISASSEMBLY/INSPECTION 7. Remove : • Pilot Screw Assembly ¿ (Spring, Washer and ‘O’ ring) • Pilot Jet À 8. Remove : • Cap plunger ¿ • Starter Lever Assembly À by opening Cap Plunger à • Starter Plunger Assembly Á 9.

  • Page 141: Inspection

    L-140 CARB INSPECTION Float 1. Inspect : • Damage Ÿ Replace Needle Valve and Valve Seat 1. Inspect • Needle Valve ¿ • valve seat À • O-Ring Á Damage/wear /blockage Ÿ Clean/Replace as a set Jets and Screws 1. Inspect : •...

  • Page 142: Assembly

    R-141 CARB ASSEMBLY ASSEMBLY Reverse the disassembly procedure. 1. Wash • All the parts in clean petroleum based solvent • Always use new ‘o’ rings 2. Install : • Pilot jet ¿ • Pilot screw assembly À 3. Install : •...

  • Page 143: Installation

    L-142 CARB INSTALLATION 8. Install • Throttle Stop Screw set ¿ 9. Install • Starter Plunger Assembly À with Starter Lever Á INSTALLATION Reverse the “REMOVAL” procedure 1. Install : • Spring, Throttle Valve with the Throttle Cable 2. Install : •...

  • Page 144: Tuning

    R-143 CARB CARBURETOR TUNING 8. Adjust : • Idling speed by Throttle Stop Screw ¿ Engine Idling Speed : 1300 - 1500 R.P.M. 9. Adjust : • Throttle Cable free play Refer “THROTTLE CABLE ADJUSTMENT” in Chapter 3, Page no 3-9 Carburetor Tuning ‘CO MEASUREMENT AND ADJUSTMENT”...
  • Page 145 L-144 CARB CARBURETOR TUNING CAUTION: WARNING Do not disturb settings of the Carburetor if the Engine performance is O.K. • If required, must record the existing set- ting (No. of turns) of the Pilot Screw. • To counter check the setting of the Pilot Screw, follow the ‘CO’...
  • Page 146 R-145 CARB CARBURETOR TUNING • Otherwise adjust Float level by bending the Float Tang  on the Float slightly up or down as required. • Install the Carburetor • Recheck the fuel level • Adjust Float height through Float Tang  By Bending Down Ÿ...
  • Page 147 L-146 CHAS FRONT WHEEL AND FRONT BRAKES CHAPTER 6 CHASSIS FRONT WHEEL AND FRONT BRAKE ........6-1 FRONT WHEEL .................6-1 FRONT BRAKE ................6-2 REMOVAL ...................6-3 FRONT WHEEL INSPECTION ..........6-4 BRAKE SHOE PLATE DISASSEMBLY ........6-5 SPEEDOMETER GEAR INSPECTION ........6-5 FRONT BRAKE INSPECTION ...........6-6 BRAKE SHOE PLATE ASSEMBLY ..........6-7 FRONT WHEEL INSTALLATION ..........6-9 REAR WHEEL AND REAR BRAKE ...........6-11...

  • Page 148: Front Wheel And Front Brake

    R-147 CHAS FRONT WHEEL AND FRONT BRAKES FRONT WHEEL ¿ Cotter Pin À Axle Nut Á Speedometer Cable Assy.  Wheel Axle à Spacer Ä Brake Shoe Plate Assy. Å Dust Seal/Collar Æ Front Wheel...

  • Page 149: Front Brake

    L-148 CHAS FRONT WHEEL AND FRONT BRAKES FRONT BRAKE Å Camshaft ¿ Brake Shoe Assy. Æ Bush À Oil Seal Ç Plate Washer Á Clutch Meter È Gear Meter  Gear Drive É O-Ring à Lever Camshaft Ê Oil Seal Ä...

  • Page 150: Removal

    R-149 CHAS FRONT WHEEL AND FRONT BRAKES REMOVAL WARNING • Securely support the Motorcycle on the centre stand so that there is no danger of it falling over. • Park the Motorcycle on a level surface 1. Loosen : • Lock nut ¿ and screw in the adjuster À fully to loosen the Brake Cable 2.

  • Page 151: Front Wheel Inspection

    L-150 CHAS FRONT WHEEL AND FRONT BRAKES Front Wheel Inspection : 1. Inspect • Front Wheel Axle (by rolling it on a flat surface) Bends Ÿ Replace Wheel Axle Bending Limit : 0.25 mm WARNING Do not attempt to straighten a bent Axle 2.

  • Page 152: Brake Shoe Plate Disassembly

    R-151 CHAS FRONT WHEEL AND FRONT BRAKES 5. Measure : • Front Wheel runout using a height gauge Over the specified limits Ÿ Correct/Replace Front Wheel runout limits : Radial ç : 0.5 mm Lateral è : 0.8 mm 6. Inspect : •...

  • Page 153: Front Brake Inspection

    L-152 CHAS FRONT WHEEL AND FRONT BRAKES FRONT BRAKE INSPECTION 1. Inspect : • Brake Lining surface Glazed areas Ÿ Replace Use Coarse Sand Paper for polishing of Brake Lining NOTE: After polishing , wipe the polished particles with a cloth. 2.

  • Page 154: Brake Shoe Plate Assembly

    R-153 CHAS FRONT WHEEL AND FRONT BRAKES BRAKE SHOE PLATE ASSEMBLY 1. Install : • Camshaft ¿ • Indicator Plate À ææææææææææææææææææææææææææææææææææ Installation steps : • Align the projection ç on the Indicator Plate À with the Camshaft notch è ææææææææææææææææææææææææææææææææææ...

  • Page 155: Front Wheel Installation

    L-154 CHAS FRONT WHEEL AND FRONT BRAKES FRONT WHEEL INSTALLATION Reverse the “REMOVAL” procedure Note the following points 1. Lubricate : • Axle Front Wheel • Bearings • Oil Seal (lips) • Drive/Driven Gear (Speedometer) Recommended lubricant : Lithium Soap base grease 2.
  • Page 156 R-155 CHAS FRONT WHEEL AND FRONT BRAKES 5 Install : • Meter Cable ¿ • Clip À • Brake Cable Á WARNING Make sure that the Brake Cable and Meter Cable is routed properly. 6. Check : • Front Brake for proper operation Improper operation Ÿ...

  • Page 157: Rear Wheel And Rear Brake

    L-156 CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL ¿ Adjuster Æ Driven Sprocket Axle Ç Rear Wheel Assembly À Pin È Brake Shoe Plate Assembly Á CompressionSpring  Cotter Pin É Damper Ê Bearing à Tension Bar Ë Spacer/Collar Ä...

  • Page 158: Rear Brake

    R-157 CHAS REAR WHEEL AND REAR BRAKE REAR BRAKE ¿ Brake Shoe Kit À Cam Lever Á Indicator Plate  Camshaft 6-11...

  • Page 159: Removal

    L-158 CHAS REAR WHEEL AND REAR BRAKE REMOVAL WARNING • Securely support the Motorcycle on centre stand so that there is no danger of it fall- ing over • Stand the Motorcycle on a level surface 1. Remove : • Chain Cover (upper ¿ and lower À) 2.

  • Page 160: Rear Wheel Inspection

    R-159 CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL INSPECTION 1. Inspect : • Axle Rear Wheel • Rear Wheel • Bearings Rear Wheel • Oil Seals Refer to “FRONT WHEEL INSPECTION” Page no 6-4 2. Measure : • Rear Wheel runout Refer to “FRONT WHEEL INSPECTION ”...

  • Page 161: Rear Wheel Installation

    L-160 CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL INSTALLATION Reverse the “REMOVAL” procedure 1. Install : • Rear Wheel Assembly • Brake Shoe Plate Assembly • Spacer with Chain Adjuster • Axle Rear Wheel NOTE : Make sure that the slots in the Rear Wheel Hub Damper fits over the tabs on the Clutch Hub as- sembly 2.

  • Page 162: Drive Chain And Sprockets

    R-161 CHAS DRIVE CHAIN AND SPROCKETS DRIVE CHAIN AND SPROCKETS ¿ Chain Case Å Drive Chain À Crankcase Cover 3 Æ Nut Driven Sprocket Axle Á Drive Sprocket Ç Driven Sprocket Assembly  Clip Chain Joint È Chain Tensioner à Link Plate É...

  • Page 163: Removal

    L-162 CHAS DRIVE CHAIN AND SPROCKETS REMOVAL 1. Stand the Motorcycle on a level surface. WARNING Securely support the Motorcycle on Centre stand so that there is no danger of it falling over. 2. Remove : • Chain Case (upper and lower) ¿ •...

  • Page 164: Drive Chain Inspection

    R-163 CHAS DRIVE CHAIN AND SPROCKETS DRIVE CHAIN INSPECTION 1. Inspect : • Drive Chain stiffness Stiffness Ÿ Clean and Lubricate or replace 2. Inspect : • Drive Chain ¿ • Driven Sprocket À More than 1/2 tooth wear ç Ÿ Replace the Drive Chain and both the Sprockets as a set.

  • Page 165: Clutch Hub Inspection

    L-164 CHAS DRIVE CHAIN AND SPROCKETS CLUTCH HUB INSPECTION 1. Inspect : Clutch Hub Wear/damage/cracks Ÿ Replace DRIVEN SPROCKET ASSEMBLY 1. Install • Driven Sprocket ¿ on Clutch Hub • Lock Washer À • Nut Á Nut (Driven Sprocket ): 26 Nm (2.6 m.kg, 19 ft.lb) NOTE : Tighten the Nuts in a crisscross pattern...
  • Page 166 R-165 CHAS DRIVE CHAIN AND SPROCKETS 3. Install : • Drive Sprocket • Drive Chain ¿ • Chain Joint À • Plate Á 4. Install : Clip ¿ CAUTION: WARNING Be sure to install the Chain Joint Clip to the di- rection as shown 5.

  • Page 167: Front Fork

    L-166 CHAS FRONT FORK FRONT FORK ¿ Front Fender Å Fork Spring Ë Spindle Taper À Cap Bolt Æ Seal Dust Ì Cylinder Comp Front Fork Á Holder Cable Ç Ring Snap Í Inner Tube  O Ring È Washer Î...

  • Page 168: Front Fork Removal

    R-167 CHAS FRONT FORK FRONT FORK REMOVAL WARNING Securely support the Motorcycle so there is no danger of it falling over 1. Stand the Motorcycle on a level surface 2. Elevate the Front Wheel by placing a suit- able stand under the Engine 3.
  • Page 169 L-168 CHAS FRONT FORK 3. Loosen : • Bolt Allen (Damper Rod) ¿ Loosen the Bolt (Damper Rod) ¿ while holding the Damper Rod with T-Handle À T-Handle YSST - 213 4. Remove : • Bolt (Damper Rod) ¿ • Washer À •...

  • Page 170: Front Fork Inspection

    R-169 CHAS FRONT FORK FRONT FORK INSPECTION 1. Inspect : • Inner Tube bending Inner Tube bending limit : 0.2 mm Scratches/bends/damage Ÿ Replace WARNING Do not attempt to straighten a bent Inner Tube as this may dangerously weaken the Tube 2.

  • Page 171: Front Fork Assembly

    L-170 CHAS FRONT FORK FRONT FORK ASSEMBLY Reverse the “DISASSEMBLY” procedure Note the following points NOTE : • When assembling the Front Fork be sure to replace the following parts • Oil Seal • Seal Dust • Snap Ring • Before assembling the Fork, make sure that all the components are clean.
  • Page 172 R-171 CHAS FRONT FORK 5. Tighten : • Bolt (Cylinder Complete) ¿ holding the Cylinder Complete with a T-Handle À Bolt (Cylinder Complete) : 23 Nm (2.3 m.kg, 17 ft.lb) T-Handle YSST - 213 6. Install : • Oil Seal ¿ Using TFF Oil Seal Installation Tool TFF Oil Seal Installation Tool...

  • Page 173: Front Fork Installation

    L-172 CHAS FRONT FORK 9. Fill : • Fork Oil ¿ Oil Quantity : Overhauling - 165 ± 3 ml Refilling - 153 ± 4 ml Recommended Oil : Teleshocab Oil 10. After filling up, slowly Pump the Fork up and down to distribute the Fork Oil 11.

  • Page 174: Steering Head And Handlebar

    R-173 CHAS STEERING HEAD AND HANDLEBAR STEERING HEAD AND HANDLEBAR È Ball Race Cover ¿ Holder Handle Bar Lower É Under Bracket À Holder Handlebar Upper Ê Ball Race (upper) Á Handlebar Ë Ball (upper) Â Grip Assembly (right) Ì Ball (lower) Ã...

  • Page 175: Removal

    L-174 CHAS STEERING HEAD AND HANDLEBAR REMOVAL WARNING Securely support the motorcycle so that there is no danger of it falling over Stand the motorcycle on a level surface 1. Remove : • Band ¿ • Brake Cable (front) À •...

  • Page 176: Handlebar Removal

    R-175 CHAS STEERING HEAD AND HANDLEBAR 7. Remove : Lock Washer ¿ Ring Nut (upper) À Damper Rubber Á 8. Remove : • Ring Nut (lower) ¿ Use a Ring Nut Wrench À Ring Nut Wrench : YSST - 621 WARNING Securely support the Steering Shaft so that there is no danger of it falling down...

  • Page 177: Steering Inspection

    L-176 CHAS STEERING HEAD AND HANDLEBAR STEERING INSPECTION 1. Wash the Bearing and Ball Races with a sol- vent 2. Inspect : • Bearing Races ¿ • Ball races À Pitting/Damage Ÿ Replace ææææææææææææææææææææææææææææææææææ Bearing Race replacement steps : • Remove the Ball Races on the Head Pipe us- ing Long Rod ¿...

  • Page 178: Handlebar Installation

    R-177 CHAS STEERING HEAD AND HANDLEBAR 4. Install : • Front Fork Refer to “FRONT FORK” Section, Page no 6-27 • Front Fender • Front Wheel Refer to “FRONT WHEEL” Section, Page no 6-8 HANDLEBAR INSTALLATION 1. Install : • Holder Handelbar Lower ¿ •...
  • Page 179 L-178 CHAS REAR SHOCK ABSORBER AND SWING ARM REAR SHOCK ABSORBER AND SWINGARM ¿ Rear Shock Absorber À Axle Nut Á Swing arm  Tension Bar à Seal Guard 6-32...

  • Page 180: Removal

    R-179 CHAS REAR SHOCK ABSORBER AND SWING ARM REMOVAL 1. Stand the Motorcycle on a level surface. WARNING Securely support the Motorcycle on a level sur- face 2. Remove : • Side Covers (left and right) • Seat • Cover Chaincase •...

  • Page 181: Inspection

    L-180 CHAS REAR SHOCK ABSORBER AND SWING ARM INSPECTION 1. Inspect : • Swingarm looseness Looseness exists Ÿ Tighten the Pivot Shaft nut or replace Bushes • Swingarm up and down movement Unsmooth movement/bending/rough spots Ÿ Replace Bushes 2. Inspect : •...
  • Page 182 R-181 CHAPTER 7 ELECTRICAL CIRCUIT DIAGRAM ..............7-1 LOCATION OF ELECTRICAL COMPONENTS ......7-2 CHECKING OF CONNECTIONS ..........7-3 IGNITION SYSTEM/CHARGING SYSTEM CIRCUIT DIAGRAM .............7-4 TROUBLESHOOTING ............7-4 CHARGING SYSTEM TROUBLESHOOTING ............7-9 LIGHTING SYSTEM CIRCUIT DIAGRAM .............7-10 TROUBLESHOOTING ............7-10 LIGHTING SYSTEM CHECK ..........7-12 SIGNAL SYSTEM CIRCUIT DIAGRAM .............7-14 TROUBLESHOOTING ............7-14...

  • Page 183: Circuit Diagram

    L-182 ELEC CIRCUIT DIAGRAM CIRCUIT DIAGRAM...

  • Page 184: Location Of Electrical Components

    R-183 ELEC ELECTRICAL COMPONENTS LOCATION OF ELECTRICAL COMPONENTS ¿ Main Switch Å Neutral Switch Assy À Flasher Relay Assy Æ Rectifier / Regulator Assy Á C.D.I. Unit Assy Ç Ignition Coil Assy  Battery È Spark Plug Cap à Fuse É...

  • Page 185: Checking Of Connections

    L-184 ELEC CHECKING OF CONNECTIONS CHECKING OF CONNECTIONS Dealing with wire pressed stains, rust, moisture etc. on the connector. 1. Disconnect • Connector ¿ 2. Dry each terminal with an air blower 3. Connect and disconnect the Connector two or three times. 4.

  • Page 186: Ignition System/Charging System

    R-185 ELEC IGNITION SYSTEM/ CHARGING SYSTEM IGNITION SYSTEM AND CHARGING SYSTEM CIRCUIT DIAGRAM TROUBLE SHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE. (NO SPARK OR INTERMITTENT SPARK) Note : PROCEDURE Remove the required parts before trouble shooting. CHECK 1. Spark Plug 1) Side covers (LH and RH) 2.
  • Page 187 L-186 ELEC IGNITION SYSTEM / CHARGING SYSTEM PROCEDURE STEPS Standard Spark Plug 1. SPARK PLUG DPR7EA (NGK) • Check the spark plug condition • Check the Spark Plug type • Check the Spark Plug gap Spark Plug Gap : 0.7 mm •...
  • Page 188 R-187 ELEC IGNITION SYSTEM / CHARGING SYSTEM æ Multimeter (+) lead Ÿ Orange Terminal ¿ 3A. IGNITION COIL RESISTANCE (Primary) Multimeter (-) lead Ÿ Earth À • Disconnect the Ignition Coil Connector From the Wire harness • Connect the Multimeter to the Ignition Coil. •...
  • Page 189 L-188 ELEC IGNITION SYSTEM/ CHARGING SYSTEM Mutimeter (+) lead Ÿ Blue/Yellow terminal ¿ 5. SENSOR COIL RESISTANCE Multimeter (-) lead Ÿ Green tertminal À • Disconnect the sensor Coil Coupler from the Wiring Harness • Connect the Multimeter (Ω X 100) to the sensor coil coupler •...
  • Page 190 R-189 ELEC IGNITION SYSTEM / CHARGING SYSTEM æ Multimeter (+) lead Ÿ Battery (+) terminal ¿ 7. RECTIFIER CUM REGULATOR UNIT Multimeter (-) lead Ÿ Battery (-) terminal À • Check the Charging Voltage Procedure Steps • Connect the Tachometer to Spark plug lead •...

  • Page 191: Charging System

    L-190 ELEC CHARGING SYSTEM TROUBLE SHOOTING IF THE BATTERY IS NOT CHARGED PROCEDURE Note : CHECK Remove the following parts before trouble shoot- 1. Fuse ing. 2. Battery 1) Side covers (LH ) 3. Charging voltage • Use Service Instruments as specified. 4.

  • Page 192: Lighting System

    R-191 ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM : AC TROUBLE SHOOTING IF THE HEAD LIGHT, HI BEAM INDICATOR LIGHT, TAILLIGHT AND METER LIGHT DO NOT WORK PROCEDURE Note : CHECK Remove the following parts before trouble 1. Lighting Coil resistance shooting.
  • Page 193 L-192 ELEC LIGHTING SYSTEM 1. LIGHTING COIL RESISTANCE Multimeter (+) lead Ÿ Yellow terminal ¿ Multimeter (-) lead Ÿ Black terminal À • Remove the C.D.I. Magento Coupler from the wiring Harness • Connect the Multimeter (Ω X 1) to the Light- ing Coil •...
  • Page 194 R-193 ELEC LIGHTING SYSTEM æ 4. LIGHTING VOLTAGE Multimeter (+) lead Ÿ Blue terminal ¿ Multimeter (-) lead Ÿ Black terminal À • Connect the Tachometer to Spark Plug lead. • Disconnect the Taillight coupler from wire harness • Connect the Multimeter (AC 20 V) to tail- light wire •...
  • Page 195 L-194 ELEC LIGHTING SYSTEM æ 6. INDIVIDUAL LIGHTING CIRCUITS A. If the Headlight and Highbeam Indicator Light do not work 1. BULB AND BULB SOCKET • Check the Bulb and Bulb socket for conti- nuity. NO CONTINUITY CONTINUITY 2. LIGHTING VOLTAGE Replace Bulb and/or Bulb Socket.

  • Page 196: Signal System

    R-195 ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM : DC TROUBLE SHOOTING IF THE FLASHER LIGHT, BRAKE LIGHT AND INDICATOR LIGHTS DO NOT WORK IF THE HORN DOES NOT WORK PROCEDURE Note : Remove the following parts before trouble shooting. CHECK 1.
  • Page 197 L-196 ELEC SIGNAL SYSTEM 1. FUSE Refer to “FUSE INSPECTION SECTION “ in Chapter 3, Page 3-30 NO CONTINUITY CONTINUITY 2. BATTERY Replace fuse • Check the Battery condition Refer to “BATTERY INSPECTION SEC- INCORRECT TION” in Chapter 3, Page 3-28 CORRECT •...
  • Page 198 R-197 ELEC SIGNAL SYSTEM 5. INDIVIDUAL SIGNAL SYSTEMS A. If the Horn does not work. 1. HORN SWITCH NO CONTINUITY • Disconnect the Handlebar Switch Coupler from Wireharness. • Check the continuity between the “Pink” and “Black” with switch in Pressed Position. Replace the Switch Handle (LH) CONTINUITY Multimeter (+) lead Ÿ...
  • Page 199 L-198 ELEC SIGNAL SYSTEM B. If the Brake Light does not work. 1. BULB AND BULB SOCKETS • Check the Bulb and Bulb sockets for con- NO CONTINUITY tinuity. CONTINUITY Replace Bulb and/or Bulb socket. 2. BRAKE SWITCH FRONT / REAR •...
  • Page 200 R-199 ELEC SIGNAL SYSTEM C. If the flasher light and/or turn indicator light fails to blink. 1. BULB AND BULB SOCKET • Check the Bulb and Bulb Socket continuity NO CONTINUITY CONTINUITY 2. TURN SWITCH Replace the Bulb and/or Bulb socket •...
  • Page 201 L-200 ELEC SIGNAL SYSTEM æ Multimeter (+) lead Ÿ Brown/White Terminal ¿ 4. FLASHER RELAY Multimeter (-) lead Ÿ Black Terminal À • Connect the Multimeter (DC20V) to the flasher relay coupler • Turn Main switch to ‘ON’ • Check for voltage (12V) on “Brown/White” lead at Flasher Relay and (-) terminal body earth OUT OF SPECIFICATION...
  • Page 202 R-201 ELEC SIGNAL SYSTEM D. If the neutral indicator lights fails to operate. 1. BULB AND BULB SOCKET • Check the bulb and bulb socket for conti- nuity. NO CONTINUITY CONTINUITY Replace the Bulb and/or Bulb Socket 2. NEUTRAL SWITCH •...
  • Page 203 L-202 CHAPTER 8 TROUBLE SHOOTING STARTING FAILURE/ HARD STARTING ........8-1 POOR IDLE SPEED PERFORMANCE ........8-2 POOR MEDIUM AND HIGH SPEED PERFORMANCE .... 8-2 POOR SPEED PERFORMANCE ..........8-3 CLUTCH SLIPPING / DRAGGING ..........8-3 FAULTY GEAR SHIFTING ............8-4 OVER HEATING .................8-4 FAULTY BRAKE .................8-4 FRONT FORK MALFUNCTION ..........

  • Page 204: Starting Failure/ Hard Starting

    R-203 TRBL SHTG STARTING FAILURE / HARD STARTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the related procedure in this manual for inspection, adjustment and replacement of parts.

  • Page 205: Poor Idle Speed Performance

    L-204 TRBL SHTG POOR IDLE SPEED PERFORMANCE IGNITION SYSTEM Ignition system • Faulty C.D.I Unit Spark Plug • Faulty Sensor Coil • Improper Plug gap • Broken Magneto Woodruff Key • Worn Electrodes • Wire between Terminals broken Switch • Improper heat range •...

  • Page 206: Poor Speed Performance

    R-205 TRBL SHTG POOR SPEED PERFORMANCE POOR SPEED PERFORMANCE Ignition System Compression System • Dirty Spark Plug • Worn Cylinder • Improper heat range • Worn of Seized Piston Rings • Faulty C.D.I. Unit • Cylinder Head Gasket Broken • Faulty Sensor Coil •...

  • Page 207: Faulty Gear Shifting

    L-206 TRBL SHTG FAULTY GEAR SHIFTING / OVERHEATING FAULTY GEAR SHIFTING HARD SHIFTING JUMPING -OUT OF GEAR Refer to “CLUTCH DRAGGING’’ Page no 8-3 SHIFT PEDAL DOES NOT MOVE Shift Shaft • Improperly returned Stopper Lever Shift Shaft • Bent Shift Shaft Shift Fork •...

  • Page 208: Front Fork Malfunction

    R-207 TRBL FRONT FORK MALFUNCTION / SHTG UNSTABLE HANDLING FRONT FORK MALFUNCTION OIL LEAKAGE MALFUNCTION • Bent damaged or rusty Inner Tube • Bent Inner Tube • Damaged or cracked Outer Tube • Deformed Outer Tube • Damaged oil seal lip. •...

  • Page 209: Faulty Signal And Lighting System

    L-208 TRBL SHTG FAULTY SIGNAL AND LIGHTING SYSTEM FAULTY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DIM FLASHER BLINKS SLOWER • Improper Bulb • Faulty Flasher Relay • Too many electric accessories • Insufficient Battery capacity (nearly dis- • Hard charging charged) •...

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