Yamaha 5CH5-ME1 Manuals

Manuals and User Guides for Yamaha 5CH5-ME1. We have 1 Yamaha 5CH5-ME1 manual available for free PDF download: Service Manual

Yamaha 5CH5-ME1 Service Manual

Yamaha 5CH5-ME1 Service Manual (382 pages)

Brand: Yamaha | Category: Motorcycle | Size: 10.9 MB

Table of Contents

Table of Contents

6
- Chassis
  5
- Engine
  5
- General Information
  5
- Specifications
  5
- Troubleshooting
  5
  - Table of Contents
    6
- Gen Info
  8
- Model Label
  11
- Vehicle Identification Number
  11
- Gaskets, Oil Seals and O-Rings
  12
- Important Information
  12
- Preparation for Removal Procedures
  12
- Replacement Parts
  12
- Bearings and Oil Seals
  13
- Circlips
  13
- Lock Washers/Plates and Cotter Pins
  13
- Checking of Connections
  14
- Special Tools
  15
Spec Chapter 2. Specifications

20
- Chapter 2. Specifications
  22
- General Specifications
  22
- Engine
  25
- Maintenance Specifications
  25
- Chassis
  33
- Electrical
  38
- Conversion Table
  40
- General Torque Specifications
  40
- Engine
  41
- Chassis
  42
- Lubrication Layout
  43
- Cable Routing
  47
- Insp Adj
  52
Insp Adj Periodic Inspection and Adjustments Chapter 3.

53
- Chapter 3. Periodic Inspection and Adjustments
  55
- Introduction
  55
- Periodic Maintenance/Lubrication Intervals
  55
- Installation
  57
- Removal
  57
- Seat, Fuel Tank and Rear Cowling
  57
- Engine
  58
- Valve Clearance Adjustment
  58
- Drive Chain Adjustment
  61
- Idle Speed Adjustment
  61
- Throttle Cable Free Play Adjustment
  62
- Spark Plug Inspection
  63
- Ignition Timing Check
  65
- Compression Inspection
  66
- Engine Oil Level Check
  69
- Engine Oil Replacement
  71
- Clutch Adjustment
  75
- Engine Oil Pressure Check
  75
- Air Filter Cleaning
  78
- Fuel Filter Cleaning
  79
- Engine Oil Tank Filter Cleaning
  80
- Fuel Line Inspection
  82
- Suction Hose and Manifold Inspection
  82
- Exhaust System Inspection
  83
- Adjusting the Front Brake
  84
- Chassis
  84
- Adjusting the Rear Brake
  85
- Checking the Brake Fluid Level
  86
- Brake Hosing Inspection
  87
- Brake Pad Wear Inspection
  87
- Brake Circuit Bleeding
  88
- Drive Chain Slack Inspection and Adjustment
  89
- Drive Chain Lubrication
  90
- Adjusting the Front Fork
  91
- Front Fork Inspection
  91
- Rear Shock Absorber Adjustment
  92
- Steering Inspection
  94
- Tyre Inspection
  95
- Spoke Inspection and Tightening
  98
- Wheel Inspection
  98
- Cable Inspection
  99
- Lever and Pedal Lubrication
  99
- Rear Suspension Lubrication
  100
- Sidestand Lubrication
  100
- Checking and Charging the Battery
  101
- Electrical System
  101
- Checking the Fuses
  107
- Replacing the Headlight Bulbs
  108
- Replacing the Turn Indicator Light Bulb
  110
- Replacing the Tail/Brake Light Bulb
  111
- Chas
  113
Chas Chapter 4. Chassis

114
- Front Wheel and Brake Disc
  116
- Front Wheel and Brake Disc Removal
  116
- Front Wheel Disassembly
  118
- Front Wheel Inspection
  118
- Brake Disc Inspection
  120
- Front Wheel Assembly
  121
- Front Wheel Installation
  121
- Wheel Static Balance Adjustment
  121
- Brake Pad Removal
  123
- Front Brake
  123
- Brake Pad Replacement
  124
- Master Cylinder
  126
- Master Cylinder Assembly
  128
- Master Cylinder Inspection
  128
- Master Cylinder Installation
  129
- Brake Caliper
  131
- Brake Caliper Disassembly
  133
- Caliper Inspection
  133
- Caliper Assembly
  134
- Caliper Installation
  134
- Rear Wheel and Brake Disc
  136
- Rear Wheel and Brake Disc Removal
  136
- Rear Wheel Disassembly
  138
- Rear Wheel Inspection
  138
- Brake Disc Inspection
  139
- Rear Wheel Assembly
  140
- Rear Wheel Installation
  140
- Wheel Static Balance Adjustment
  142
- Brake Pad Removal
  144
- Brake Pad Replacement
  144
- Rear Brake
  144
- Master Cylinder
  147
- Master Cylinder Assembly
  148
- Master Cylinder Inspection
  148
- Master Cylinder Installation
  149
- Brake Pedal Removal
  150
- Brake Caliper
  151
- Brake Caliper Disassembly
  153
- Caliper Inspection
  153
- Caliper Installation
  154
- Front Fork
  157
- Front Fork Removal
  157
- Front Fork Disassembly
  158
- Front Fork Removal
  160
- Oil Replacement
  161
- Cleaning the Dust Seal
  164
- Seal and Bush Replacement
  165
- Anomalous Hydraulic Braking
  171
- Oil Leakage from Dust Seal
  171
- Front Fork Inspection
  172
- Front Fork Adjustment
  174
- Front Fork Installation
  174
- Steering
  176
- Steering Removal
  179
- Steering Inspection
  180
- Steering Installation
  180
- Rear Shock Absorber
  184
- Note on Disposal
  187
- Shock Absorber Removal
  188
- Shock Absorber Adjustment
  189
- Shock Absorber Inspection
  189
- Swingarm
  191
- Swingarm Removal
  192
- Swingarm Inspection
  193
- Lateral Free Play Adjustment
  194
- Swingarm Installation
  195
- Drive Chain Removal
  197
- Drive Chain, Drive Sprocket and Rear Wheel Sprocket
  197
- Drive Chain Inspection
  198
- Drive Chain Installation
  200
- Eng
  202
Eng Chapter 5. Engine

203
- Engine Removal
  205
- Muffler, Exhaust Pipe, Engine Protector, Drive Sprocket Crankcase Cover, Drive Sprocket and Shift Pedal
  205
- Engine Mounting Bolt
  208
- Cylinder Head, Cylinder, Camshaft and Piston
  209
- Engine Disassembly
  209
- Intermediate Starter Gear, Crankcase Cover (L) and Generator Stator
  212
- Crankcase Cover (R), Clutch, Primary Drive Gear and Balancer Shaft Gear
  213
- Oil Pump and Shift Lever
  216
- Ac Generator and Timing Chain
  217
- Crankcase(R)
  218
- Gearbox and Transmission
  220
- Balancer Shaft and Crankshaft
  221
- Oilstrainer
  221
- Rocker Arms
  222
- Valves
  223
- Cylinder Head
  225
- Inspection and Repair
  225
- Valves and Valve Guides
  226
- Valveseat
  227
- Valve Springs
  231
- Camshaft
  232
- Rocker Arms and Rocker Shaft
  232
- Camshaft Chain and Sprocket
  233
- Camshaft Chain Guide
  234
- Cylinder and Piston
  234
- Piston Rings
  236
- Clutch
  237
- Pistonpin
  237
- Oilpump
  239
- Transmission and Gearbox
  240
- Starter Transmission
  242
- Crankshaft
  243
- Balancer Shaft Drive and Driven Gears
  244
- Bearing and Oil Seal
  244
- Crankcase
  244
- Engine Assembly and Setting
  246
- Valves
  246
- Rocker Arms
  247
- Crankshaft and Balancer Shaft
  248
- Transmission
  250
- Gearbox
  251
- Transmission and Gearbox
  252
- Engine Oil Pump and Oil Strainer
  253
- Crankcase
  254
- Crankcase
  255
- Engine Oil Strainer
  255
- Shift Shaft and Oil Pump
  256
- Timing Chain
  258
- Piston and Rings
  259
- Cylinder
  260
- Cylinder Head
  261
- Camshaft and Timing Chain
  262
- Piston, Cylinder, Cylinder Head and Camshaft
  263
- Ac Generator
  269
- Oil Filter and Oil Hoses
  271
- Balancer Shaft Gear and Primary Transmission Gear
  272
- Clutch
  274
- Starter Gears
  277
- Starter Neutral Gear and Crankcase Cover (L)
  278
- Engine Reassembly
  280
- Carb
  283
- Elec
  302
Elec Chapter 7 Electrical

303
- Electrical Circuit Diagram
  305
- Colour Code
  306
- Electrical Components
  307
- Main Switch Inspection
  309
- Switch Check
  309
- Switch Connection
  309
- Bulb Inspection
  312
- Bulb Types
  312
- Light Inspection (Headlights, Tail Light and Brake Lights, Direction Indicator Lights, Instrument Lights, Etc)
  312
- Circuit Diagram
  315
- Ignition System
  315
- Diagnostics
  317
- Circuit Diagram
  325
- Electrical Starting System
  325
- Starting Circuit Operation
  327
- Diagnostics
  328
- Starter Motor
  334
- Charging System
  339
- Circuit Diagram
  339
- Diagnostics
  341
- Circuit Diagram
  345
- Light System
  345
- Diagnostics
  347
- Light System Inspection
  350
- Circuit Diagram
  355
- Diagnostics
  357
- Signal System Control
  359
- Trbl Shtg
  369
? Trbl Shtg Chapter 8° Troubleshooting

370
- Failure to Start/Difficulties in Starting
  372
- Fuel System
  372
- Electrical System
  373
- Poor Engine Compression
  373
- Poor Performance at Idle Speed
  374
- Unsatisfactory Performance at Medium-High Speed
  374
- Difficulties in Shifting
  375
- Disengaging Gears
  375
- Shifting Impossible
  375
- The Shift Pedal Fails to Move
  375
- Clutch Fails to Release
  376
- Clutch Slides
  376
- Clutch Slides or Fails to Release
  376
- Defective Brakes
  377
- Malfunctioning
  377
- Oil Leaks
  377
- Oil Leaks or Malfunctioning of Front Fork
  377
- Poor Braking
  377
- Unstable Steering
  378
- Defective Functioning of Lights and Indicators
  379
- Direction Indicators Fail to Turn off
  379
- Direction Indicators Fail to Turn on
  379
- Frequent Burning of Bulb
  379
- Delayed Turning on of Indicators
  380
- Excessive Indicator Intermittence Frequency
  380
- Overheating of Engine
  380
- The Horn Fails to Work
  380

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