Yamaha Sirius T110LSE Service Manual
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Yamaha Sirius T110LSE Service Manual

Yamaha Sirius T110LSE Service Manual

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T110LE
T110LSE
SERVICE MANUAL
3S3-F8197-E0

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Summary of Contents for Yamaha Sirius T110LSE

  • Page 1 T110LE T110LSE SERVICE MANUAL 3S3-F8197-E0...
  • Page 3 EAS00000 T110LE/T110LSE SERVICE MANUAL ©2005 by Yamaha Motor Co., Ltd. First edition, October, 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 5 HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1:This is a chapter with its symbol on the upper right of each page. 2nd title 2:This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment”...

  • Page 7: General Information

    SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor 6 Chassis 7 Electrical system CARB CHAS 8 Troubleshooting...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 11: Gen Info

    INFO CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION ................... 1-1 VEHICLE IDENTIFICATION NUMBER ............. 1-1 ENGINE SERIAL NUMBER ................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 ..........
  • Page 12 INFO...

  • Page 13: General Information

    VEHICLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION VEHICLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The number 1 is stamped into the frame as shown. ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase. NOTE: Designs and specifications are subject to change without notice.

  • Page 14: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 15: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COT- TER PINS After removal, replace all lock washers/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. 300-000 EAS00024 BEARINGS AND OIL SEALS...

  • Page 16: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 9lead 9coupler 9connector 2. Check: 9lead 9coupler 9connector Moisture → Dry with compressed air. Rust/stains → Connect and disconnect several times.

  • Page 17: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 18 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Crankcase installer bolt 90890-01275 This tool is necessary for installing the crankshaft. Adoptor (M12) 90890-01278 This tool is necessary for installing the crankshaft. Tappet adjusting tool 90890-01311 This tool is necessary for adjusting valve clearance.
  • Page 19 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Thickness gauge 90890-03079 This tool is used to measure the valve clearance. Compression gauge 90890-03081 These tools are used to measure the engine compression. Pocket tester 90890-03112 This instrument is necessary for checking the electrical system.
  • Page 20 Valve guide reamer (4.5 mm) 90890-04118 This tool is needed rebore the new valve guide. Ignition checker 90890-06754 This instrument is necessary for check- ing the ignition system components. Yamaha bond No. 1215 90890-85505 This sealant (bond) is used for crankcase mating surface, etc.

  • Page 21: Spec

    SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 MAINTENANCE SPECIFICATIONS ..............2-4 ENGINE ......................2-4 TIGHTENING TORQUES ................. 2-10 CHASSIS ......................2-12 TIGHTENING TORQUES ................. 2-15 ELECTRICAL ....................2-17 GENERAL TIGHTENING TORQUE SPECIFICATIONS ........2-19 LUBRICATION POINTS AND LUBRICANT TYPES ..........2-20 ENGINE ......................
  • Page 22 SPEC...

  • Page 23: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model T110LE/T110LSE Model code 3S31 (T110LE) 3S41 (T110LSE) Dimensions Overall length 1,890 mm (74.4 in) Overall width T110LE:665 mm (26.2 in) T110LSE:675 mm (26.6 in) Overall height 1,030 mm (40.6 in) Seat height 760 mm (29.9 in) Wheelbase 1,200 mm (47.2 in) Minimum ground clearance...
  • Page 24 SPEC GENERAL SPECIFICATIONS Model T110LE/T110LSE Carburetor Type/quantity VM17SH/1 Manufacturer MIKUNI Spark plug Type C6HSA Manufacturer 0.6 − 0.7 mm (0.024 − 0.028 in) Spark plug gap Clutch type Wet, multiple-disc and centrifugal automatic Transmission Primary reduction system Spur gear Primary reduction ratio 67/18 (3.722) Secondary reduction system Chain drive...
  • Page 25 SPEC GENERAL SPECIFICATIONS Model T110LE/T110LSE Brake Front brake type T110LE:Drum brake T110LSE:Single disc brake operation Right hand operation Rear brake type Drum brake operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm Shock absorber Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper...

  • Page 26: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head Max. warpage “*” ---- 0.03 mm (0.0012 in) Cylinder 51.000 − 51.015 mm (2.0079 − 2.0085 in) 51.1 mm Bore (2.03 in) Out of round limit ---- 0.03 mm (0.0012 in) Camshaft Drive Method...
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Valve, valve seat, valve guide 0.05 − 0.09 mm (0.0020 − 0.0035 in) Valve clearance (cold) ---- 0.08 − 0.12 mm (0.0032 − 0.0045 in) ---- Valve dimensions Head Diameter Face Width Seat Width Margin Thickness 22.9 −...
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Valve spring Free length IN/EX 33.75 mm (1.33 in) 32.05 mm (1.26 in) Installed length (valve closed) IN/EX 24.2 mm (0.95 in) ---- IN/EX 138 − 148 N (31.02 − 33.27 lb, Compressed spring force ---- 14.07 −...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft 42.95 − 43.00 mm (1.691 − 1.693 in) Crank width “A” ---- Max. runout limit “C” ---- 0.03 mm (0.0012 in) 0.11 − 0.41 mm (0.0043 − 0.0161 in) Big end side clearance “D” ---- 0.004 −...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Kickstarter Kickstarter type Ratchet type ---- 5.8 − 14.7 N (1.3 − 3.3 lb)(0.59 − 1.50 kgf) ---- Kick clip friction force Carburetor Type VM17SH ---- I.D. mark 5VT1 00 ---- Main jet (M.J) #105 ---- Main air jet...
  • Page 31 SPEC MAINTENANCE SPECIFICATIONS Model T110LE/T110LSE Lubrication chart OIL RING PISTON CYLINDER HEAD CAMSHAFT CONNECTING ROD BIG END CRANKSHAFT CLUTCH TRANSMISSION OIL PUMP OIL STRAINER OIL PAN...

  • Page 32: Tightening Torques

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Tightening Thread torque Part to be tightened Part name Q’ty Remarks size Nm m·kg ft·lb Cylinder head Cylinder head (timing chain side) Bolt Spark plug — 12.5 1.25 9.0 Camshaft sprocket cover Screw Tappet cover (intake and exhaust side) —...
  • Page 33 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size Nm m·kg ft·lb Shift fork guide bar retainer Bolt Pickup coil Bolt Stator coil Bolt Neutral switch Bolt 2-11...

  • Page 34: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system Steering bearing type Ball and race bearing ---- Lock-to-lock angle (left/right) 45° ---- Front suspension Front fork travel 95 mm (3.74 in) ---- Fork spring free length 275.7 mm (10.85 in) 270 mm (10.63 in) Installed length...
  • Page 35 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Rear wheel Type Spoke wheel ---- 17 × 1.40 Rim size ---- Rim material Steel ---- Max. radial wheel runout ---- 1.0 mm (0.04 in) Max. lateral wheel runout ---- 0.5 mm (0.02 in) Drive chain Type/manufacturer 428/DAIDO...
  • Page 36 SPEC SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Rear brake Drum brake type Leading, trailing ---- 20 − 30 mm (0.79 − 1.18 in) Rear brake pedal free play (pedal ---- end) Drum inside diameter 130 mm (5.12 in) 131 mm (5.16 in) Lining thickness 4.0 mm (0.16 in)

  • Page 37: Tightening Torques

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Tightening torque Part to be tightened Thread size Remarks Nm m·kg ft·lb Handlebar bracket and lower bracket Handlebar and handlebar bracket Brake hose and brake master cylinder (T110LSE) Brake hose and brake caliper (T110LSE) Brake master cylinder and holder (T110LSE) Brake lever holder (T110LE)
  • Page 38 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks Nm m·kg ft·lb Front cowling bracket and crankcase cover (left and right) Main switch and frame Ignition coil and frame Fuel tank and frame Fuel cock and frame Seat and seat bracket NOTE: 1.

  • Page 39: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit System voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 10° at 1,500 r/min ---- Advanced type Digital ---- DC-C.D.I 248 − 372 Ω at 20 °(68 °F)/R–W Pickup coil resistance/color ---- C.D.I. unit model/manufacturer 5VT/MORIC ---- Ignition coil...
  • Page 40 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Electric starting system Type Constant mesh ---- Starter motor Model/manufacturer 3S4/MORIC ---- Operation voltage 12 V ---- Power output 0.35 kW ---- 0.018 − 0.022 Ω at 20 °C(68 °F) Armature coil resistance ---- Brush overall length 7 mm (0.28 in) 3.5 mm...

  • Page 41: General Tightening Torque Specifications

    SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00029 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 42: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips Bearings O-rings Cylinder head tightening nut and stud bolt thread Rocker arm inner surfaces Rocker arm shaft Camshaft Valve stem (IN, EX) Valve stem guide (IN, EX) Piston pin Piston outside and ring groove...
  • Page 43 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Transmission side plate inner surface Transmission pinion gears inner surface Starter motor guard bolt Yamaha bond No.1215 Generator lead grommet Yamaha bond No.1215 Crankcase cover bolt Yamaha bond No.1215 Crankcase mating surface Yamaha bond No.1215...

  • Page 44: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS Lubrication point Lubricant Front wheel oil seal lips Speedometer gear unit inner surface (T110LSE) Speedometer driven gear (T110LE) Front brake camshaft (T110LE) Speedometer drive gear (T110LE) Rear wheel oil seal lips Rear brake camshaft Brake torque rod bolt Front wheel axle Rear wheel axle...

  • Page 45: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING ∫ Push in the coupler between the handlebar and 1 Band 2 Choke cable speedometer assembly, after connected. ç Hock the wire harness onto the strap. 3 Headlight assembly ∂ Push in the coupler between the handlebar and 4 Wire harness 5 Brake hose (T110LSE) speedometer assembly, after connected.
  • Page 46 SPEC CABLE ROUTING 1 Wire harness å Pass through the wire harness onto the cable 2 Cable guide guide. 3 Choke cable ∫ Align the clamp with the white tape on the wire 4 Throttle cable harness. 5 Speedometer cable ç...
  • Page 47 SPEC CABLE ROUTING 1 Wire harness w Starter motor lead 2 Air vent hose e Choke cable 3 Air induction system vacuum hose r Throttle cable 4 Clamp t Main switch lead 5 A.C. magneto lead y Battery breather hose 6 Neutral switch lead u Fuel cock vacuum hose 7 Turn signal relay...
  • Page 48 SPEC CABLE ROUTING å Pass the wire harness, choke cable, and throttle cable through the guide. ∫ Pass the fuel hose and fuel cock vacuum hose through the guide. ç Pass the starter cable, neutral switch lead, and A.C. magneto lead through the guide. ∂...
  • Page 49 SPEC CABLE ROUTING 1 Rectifier/regulator w Main switch 2 Ignition coil e Starter motor cover 3 Air vent hose r Starter motor 4 Cover t Starter motor lead 5 Main switch lead y Footrest 6 Horn u Brake hose holder (T110LSE) 7 Spark plug lead i Cable guide (T110LSE) 8 Turn signal relay...
  • Page 50 SPEC CABLE ROUTING 1 Fuel sender w Battery positive lead 2 Battery breather hose e Wire harness 3 Starter motor lead 4 Rear brake light switch å Insert the battery breather hose into the hose 5 Rear brake light switch lead guide.
  • Page 51 SPEC CABLE ROUTING 1 Wire harness å Clamp the fuel sender lead wire harness. ∫ Align the white tape of the wire harness with the 2 Rectifier/regulator 3 Battery guide on the fuel tank. 4 C.D.I. unit ç To the battery. ∂...

  • Page 52: Chk Adj

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..................... 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ......3-1 COVERS ......................... 3-3 REMOVING THE FRONT COWLINGS ............3-3 INSTALLING THE FRONT COWLINGS ............3-3 REMOVING THE REAR COWLINGS ............... 3-4 INSTALLING THE REAR COWLINGS .............. 3-4 REMOVING THE HEADLIGHT ASSEMBLY .............
  • Page 53 LUBRICATING THE SIDESTAND..............3-35 LUBRICATING THE CENTERSTAND .............. 3-35 ELECTRICAL SYSTEM ..................3-36 CHECKING AND CHARGING THE BATTERY ..........3-36 CHECKING THE FUSE ..................3-40 REPLACING THE HEADLIGHT BULBS ............3-41 ADJUSTING THE HEADLIGHT BEAM ............. 3-42...

  • Page 54: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 55 • Check that the breather hose is working properly. • Correct if necessary. * It is recommended that these items be serviced by a Yamaha dealer. NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 56: Covers

    COVERS EASF0004 COVERS REMOVING THE FRONT COWLINGS 1. Remove: 9main switch cover 1 9center panel 2 NOTE: Remove the main switch cover by turning it in the direction of the arrow shown. 2. Remove: 9front cowlings (left and right) 1 3.

  • Page 57: Removing The Rear Cowlings

    COVERS REMOVING THE REAR COWLINGS 1. Remove: 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS”. 9side panel 1 2. Remove: 9rear panel 1 NOTE: Remove the rear panel by sliding it in the direc- tion of the arrow shown. 3.

  • Page 58: Removing The Headlight Assembly

    COVERS 3. Install: 9side panel 1 NOTE: Before tightening side panel screw, make sure that projections is securely fitted. 9front cowlings (left and right) Refer to “INSTALLING THE FRONTCOWL- INGS”. REMOVING THE HEADLIGHT ASSEMBLY 1. Remove: 9headlight assembly 1 2. Disconnect: 9turn signal light coupler 1 9headlight connectors 2 INSTALLING THE HEADLIGHT ASSEMBLY...

  • Page 59: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: 9Valve clearance adjustment should be made on a cold engine, at room temperature. 9When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 60 ADJUSTING THE VALVE CLEARANCE 4. Measure: 9valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.05–0.09 mm (0.0020–0.0035 in) Exhaust valve 0.08–0.12 mm (0.0032–0.0045 in) MMMMMMMMMMMMMMMMMMMMMMMM a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align the “I”...
  • Page 61 ADJUSTING THE VALVE CLEARANCE 9Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. Locknut 7 Nm (0.7 m·kg, 5.0 ft·lb) d. Measure the valve clearance again. e. If the valve clearance is still out of specifica- tion,repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained.

  • Page 62: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS”.

  • Page 63: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 6. Adjust: 9throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3–7 mm (0.12–0.28 in) 7.

  • Page 64: Checking The Spark Plug

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG 3. Adjust: 9throttle cable free play MMMMMMMMMMMMMMMMMMMMMMMM a. Pull back the adjusting nut cover. b. Loosen the locknut 1 c. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained.
  • Page 65 CHECKING THE SPARK PLUG 4. Check: 9spark plug type Incorrect → Change. Spark plug type (manufacturer) C6HSA (NGK) 5. Check: 9electrode 1 Damage/wear → Replace the spark plug. 9insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6.

  • Page 66: Measuring The Compression Pressure

    MEASURING THE COMPRESSION PRESSURE EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: 9valve clearance Out of specification → Adjust Refer to “ADJUSTING THE VALVE CLEAR- ANCE”. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 67 MEASURING THE COMPRESSION PRESSURE MMMMMMMMMMMMMMMMMMMMMMMM a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. To prevent sparking, ground the spark plug lead before cranking the engine. c.

  • Page 68: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EAS00070 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: Make sure the vehicle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3.

  • Page 69: Changing The Engine Oil

    CHANGING THE ENGINE OIL EAS00075 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: 9oil level plug 1 9engine oil drain plug 2 (with gasket) 4.

  • Page 70: Checking The Exhaust System

    CHECKING THE EXHAUST SYSTEM/ CLEANING THE AIR FILTER ELEMENT CHECKING THE EXHAUST SYSTEM 1. Check: 9exhaust pipe nuts 1 Loose/damage → Tighten/replace. 7 Nm (0.7 m•kg, 5.0 ft•lb) 9exhaust pipe gasket Exhaust gas leaks → Tighten/replace. 2. Check: 9exhaust pipe joint bolt 1 Loose/damage →...

  • Page 71: Adjusting The Clutch Release System

    CLEANING THE AIR FILTER ELEMENT/ ADJUSTING THE CLUTCH RELEASE SYSTEM 5. Install: 9air filter element 9air filter case cover Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.

  • Page 72: Checking The Carburetor Joint And Intake Manifold

    CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/ CHECKING THE FUEL AND VACUUM HOSES EAS00094 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS”. 2. Check: 9carburetor joint 1 9intake manifold 2 Cracks/damage →...

  • Page 73: Checking The Crankcase Breather Hose

    CHECKING THE CRANKCASE BREATHER HOSE EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS”. 9side panel Refer to “REMOVING THE REAR COWL- INGS”. 2. Check: 9crankcase breather hose 1 Cracks/damage → Replace. Loose connection →...

  • Page 74: Chassis

    ADJUSTING THE FRONT BRAKE(T110LE)/ ADJUSTING THE REAR BRAKE EAS00109 CHASSIS EAS00113 ADJUSTING THE FRONT BRAKE (T110LE) 1. Check: 9brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 10–20 mm (0.39–0.79 in) 2.

  • Page 75: Checking The Front Brake Pads (T110Lse)

    ADJUSTING THE REAR BRAKE/ CHECKING THE FRONT BRAKE PADS (T110LSE) 2. Adjust: 9brake pedal free play MMMMMMMMMMMMMMMMMMMMMMMM a. Turn the adjuster 1 in direction a or b until the specified brake pedal free play is obtained. Brake pedal free play is Direction a a increased.

  • Page 76: Checking The Rear Brake Shoes (T110Lse)

    CHECKING THE REAR BRAKE SHOES (T110LSE)/ CHECKING THE FRONT AND REAR BRAKE SHOES (T110LE)/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00126 CHECKING THE REAR BRAKE SHOES (T110LSE) 1. Operate the brake. 2. Check: 9wear indicator 1 Reaches the wear limit line 2 → Replace the brake shoes as a set.

  • Page 77: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT BRAKE HOSE (T110LSE) 3. Adjust: 9rear brake light operation timing MMMMMMMMMMMMMMMMMMMMMMMM a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time.

  • Page 78: Bleeding The Hydraulic Brake System (T110Lse)

    BLEEDING THE HYDRAULIC BRAKE SYSTEM (T110LSE) EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM (T110LSE) Bleed the hydraulic brake system when- ever: 9 9 the system is disassembled. 9 9 a brake hose is loosened, disconnected or replaced. 9 9 the brake fluid level is very low. 9 9 brake operation is faulty.

  • Page 79: Adjusting The Drive Chain Slack

    BLEEDING THE HYDRAULIC BRAKE SYSTEM(T110LSE)/ ADJUSTING THE DRIVE CHAIN SLACK NOTE: Loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle grip. h. Tighten the bleed screw and then release the brake lever. i.
  • Page 80 ADJUSTING THE DRIVE CHAIN SLACK 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.

  • Page 81: Lubricating The Drive Chain

    LUBRICATING THE DRIVE CHAIN/ CHECKING THE BRAKE FLUID LEVEL (T110LSE) EAS00143 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas.

  • Page 82: Checking And Adjusting The Steering Head

    CHECKING THE BRAKE FLUID LEVEL(T110LSE)/ CHECKING AND ADJUSTING THE STEERING HEAD 9 9 When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Brake fluid may damage painted surfaces and plastic parts.
  • Page 83 CHECKING AND ADJUSTING THE STEERING HEAD 4. Adjust: 9steering head MMMMMMMMMMMMMMMMMMMMMMMM a. Pull back the rubber cover 1. b. Loosen the upper ring nut 2 c. Loosen the lower ring nut 3 and then tight- en it to specification with a steering nut wrench 4.

  • Page 84: Checking The Front Fork

    CHECKING THE FRONT FORK EAS00149 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Check: 9inner tube Damage/scratches → Replace. 9oil seal Oil leakage →...

  • Page 85: Checking The Tires

    CHECKING THE TIRES EASF0015 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 9tire pressure Out of specification → Regulate. 9 9 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 86 Ltd. for this model. The front and rear tires should always be by the same manufactur- er 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 vehi- cle. 3-33...

  • Page 87: Checking And Tightening The Spokes

    CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES 9 9 New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. 9 9 After a tire has been repaired or replaced, be sure to tighten the tire air valve stem locknut 1 1 to specification.

  • Page 88: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVER AND PEDALS/ LUBRICATING THE SIDESTAND/LUBRICATING THE CENTERSTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. Damaged outer cable may cause the cable to corrode and interfere with its movement.

  • Page 89: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00176 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 9 9 Wear protective eye gear when handling or working near batteries.
  • Page 90 CHECKING AND CHARGING THE BATTERY 2. Disconnect: 9battery leads (from the battery terminals) First, disconnect the negative battery lead 1, and then the positive battery lead 2. 3. Remove: 9battery 4. Check: 9electrolyte level The electrolyte level should be between the minimum level mark a and the maximum level mark b.
  • Page 91 CHECKING AND CHARGING THE BATTERY 9 9 Loosen the battery sealing caps. 9 9 Make sure the battery breather hose and battery vent are free of obstructions. 9 9 To ensure maximum performance, always charge a new battery before using it. 9 9 Do not use a high-rate battery charger.
  • Page 92 CHECKING AND CHARGING THE BATTERY 9warpage or buckling of the battery plates or insulators is evident. 7. Check: 9battery breather hose and battery vent Obstruction → Clean. Damage → Replace. 8. Install: 9battery 9. Connect: 9battery breather hose 1 9 9 When checking the battery, make sure the battery breather hose is properly installed and routed correctly.

  • Page 93: Checking The Fuse

    CHECKING THE FUSE EASF0017 CHECKING THE FUSE To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Open the seat, and then open the battery cover. 2. Remove: 9fuse holder 1 3.

  • Page 94: Replacing The Headlight Bulbs

    REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to the headlight bulb. 1. Remove: 9headlight assembly Refer to “REMOVING THE HEADLIGHT ASSEMBLY”. 2. Remove: 9headlight bulb holder 1 3. Remove: 9headlight bulb 1 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 95: Adjusting The Headlight Beam

    ADJUSTING THE HEADLIGHT BEAM EAS00186 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: 9headlight beam (vertically) MMMMMMMMMMMMMMMMMMMMMMMM a. Loosen the bolt 1. b. Slide the bottom of the headlight unit for- ward a or backward b. Slide forward Headlight beam is raised. Slide backward Headlight beam is lowered.

  • Page 96: Eng

    CHAPTER 4 ENGINE REMOVING THE ENGINE ..................4-1 ENGINE OIL ...................... 4-1 CARBURETOR ....................4-1 MUFFLER AND EXHAUST PIPE ..............4-1 FOOTREST AND ENGINE GUARD ..............4-2 BRAKE PEDAL ....................4-2 SHIFT PEDAL....................4-3 FRONT COWLING BRACKET ................4-3 WIRE, CABLE AND HOSE ................4-3 ENGINE ASSEMBLY ..................
  • Page 97 CYLINDER AND PISTON ..................4-31 REMOVING THE CYLINDER AND PISTON ............ 4-32 CHECKING THE CYLINDER AND PISTON ............. 4-33 CHECKING THE PISTON RINGS ..............4-34 CHECKING THE PISTON PIN ................4-35 INSTALLING THE PISTON AND CYLINDER ........... 4-36 GENERATOR AND STARTER CLUTCH ............... 4-38 REMOVING THE GENERATOR ...............
  • Page 98 SHIFT SHAFT ......................4-62 REMOVING THE SHIFT SHAFT ..............4-63 CHECKING THE SHIFT SHAFT ............... 4-65 CHECKING THE STOPPER LEVER ..............4-65 CHECKING THE SHIFT GUIDE ............... 4-65 CHECKING THE OIL SEAL ................4-65 INSTALLING THE SHIFT SHAFT ..............4-66 CRANKCASE AND CRANKSHAFT ..............

  • Page 100: Removing The Engine

    REMOVING THE ENGINE EASF0018 ENGINE REMOVING THE ENGINE NOTE: It is not necessary to remove the engine in order to remove the following components. • Cylinder head • Cylinder • Piston • Clutch • Kickstarter • Shift shaft • Oil pump •...

  • Page 101: Footrest And Engine Guard

    REMOVING THE ENGINE 2. Remove: • exhaust pipe nuts 1 • exhaust pipe 2 FOOTREST AND ENGINE GUARD 1. Remove: • footrest bolts 1 • footrest 2. Remove: • starter motor guard bolts 1 • starter motor guard 2 3. Remove: •...

  • Page 102: Shift Pedal

    REMOVING THE ENGINE SHIFT PEDAL 1. Remove: 9shift pedal bolt 1 9shift pedal 2 FRONT COWLING BRACKET 1. Remove: 9front cowling bracket bolts 1 9front cowling bracket 2 WIRE, CABLE AND HOSE 1. Remove: 9negative battery lead 1 9positive battery lead 2 9battery breather hose 2.
  • Page 103 REMOVING THE ENGINE 4. Remove: 9crankcase breather hose 1 5. Disconnect: 9stator coil coupler 1 9pickup coil coupler 2 9neutral switch coupler 3 6. Disconnect: 9starter motor lead coupler 1 ENGINE ASSEMBLY 1. Remove: 9rear upper mounting nut 9washer 9front mounting nut 9washer 9rear lower mounting nut 9washer...

  • Page 104: Wire, Cable And Hose

    INSTALLING THE ENGINE EASF0019 INSTALLING THE ENGINE ENGINE ASSEMBLY Securely support the vehicle so there is no danger of it falling over when installing engine. 1. Install: 9engine assembly 9rear lower mounting bolt 9front mounting bolt 9rear upper mounting bolt 9washer 9rear lower mounting nut 34 Nm (3.4 m·kg, 25 ft•lb)

  • Page 105: Brake Pedal

    9starter motor guard 9starter motor guard bolts 23 Nm (2.3 m·kg, 17 ft•lb) NOTE: Apply sealant to the thread of starter motor guard bolt 1. Yamaha bond No. 1215 90890-85505 2. Install: 9footrest 9footrest bolts 23 Nm (2.3 m·kg, 17 ft•lb) MUFFLER 1.

  • Page 106: Carburetor

    INSTALLING THE ENGINE CARBURETOR 1. Install: 9carburetor assembly Refer to “CARBURETOR” in chapter 5. 2. Adjust: 9throttle cable free play 9rear brake light operation timing Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” and “ADJUSTING THE REAR BRAKE LIGHT SWITCH” in chapter 3.

  • Page 107: Cylinder Head

    CYLINDER HEAD EASF0023 CYLINDER HEAD 1 Intake manifold 8 Camshaft sprocket cover 2 Tappet cover (intake side) 9 Dowel pin 3 Cylinder head 0 Gasket 4 Spark plug q Timing chain tensioner 5 Tappet cover (exhaust side) 6 Timing chain guide (exhaust side) 7 Camshaft sprocket...

  • Page 108: Removing The Cylinder Head

    CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9carburetor assembly Refer to “CARBURETOR” in chapter 5. 9exhaust pipe Refer to “REMOVING THE ENGINE”. 2. Remove: 9air induction system pipe bolts 9air induction system pipe 1 9air induction system pipe gasket...
  • Page 109 CYLINDER HEAD 6. Align: • “I” mark a on the generator rotor (with the stationary pointer b on the crank- case) MMMMMMMMMMMMMMMMMMMMMMMM a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align the “I” mark c on the camshaft sprocket with the stationary point- er d on the cylinder head.

  • Page 110: Checking The Cylinder Head

    CYLINDER HEAD 10. Remove: 9cylinder head bolts 9cylinder head nuts 9cylinder head " NOTE: 9Loosen the nuts in the proper sequence as shown. 9Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. 11.

  • Page 111: Checking Timing Chain Guide

    CYLINDER HEAD 3. Measure: 9cylinder head warpage Out of specification → Resurface the cylin- der head. Maximum cylinder head warpage 0.03 mm (0.0012 in) MMMMMMMMMMMMMMMMMMMMMMMM a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c.

  • Page 112: Checking The Timing Chain Tensioner

    CYLINDER HEAD EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: 9timing chain tensioner Cracks/damage → Replace. MMMMMMMMMMMMMMMMMMMMMMMM a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. b.
  • Page 113 CYLINDER HEAD 3. Tighten: 9cylinder head nuts 22 Nm (2.2 m·kg, 16 ft•lb) 9cylinder head bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) " NOTE: 9Lubricate the cylinder head nuts and bolts with engine oil. 9Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages.
  • Page 114 CYLINDER HEAD 5. Install: 9timing chain tensioner MMMMMMMMMMMMMMMMMMMMMMMM a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise.
  • Page 115 CYLINDER HEAD 8. Check: 9“I” mark a Align the “I” mark on the generator rotor with the stationary pointer b on the crank- case. 9“I” mark c Align the “I” mark on the camshaft sprocket with the stationary pointer d on the cylinder head.

  • Page 116: Camshaft

    CAMSHAFT EASf0020 CAMSHAFT 1 Locknut 2 Adjusting screw 3 Rocker arm 4 Rocker arm shaft 5 Camshaft 6 Camshaft retainer 4-17...

  • Page 117: Removing The Rocker Arms And Camshaft

    CAMSHAFT EASF0022 REMOVING THE ROCKER ARMS AND CAMSHAFT NOTE: Prior to remove the rocker arms and camshaft, remove the cylinder head. 1. Loosen: 9locknuts 1 9adjusting screws 2 2. Remove: 9camshaft retainer 1 3. Remove: 9camshaft 1 NOTE: Screw an 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft.

  • Page 118: Checking The Camshaft

    CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: 9camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 9camshaft lobe dimensions a and b → specification Replace camshaft. Camshaft lobe dimension limit Intake a a 25.745 mm (1.0136 in) b b 21.015 mm (0.8274 in) Exhaust a a 25.749 mm (1.0137 in) b b 20.924 mm (0.8238 in)
  • Page 119 CAMSHAFT 2. Check: 9rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: 9rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 10.000 – 10.015 mm (0.3937 – 0.3943 in) <Limit>: 10.030 mm (0.3949 in) 4.

  • Page 120: Checking The Camshaft Sprocket

    CAMSHAFT EAS00207 CHECKING THE CAMSHAFT SPROCKET 1. Check: 9camshaft sprocket Worn more than 1/4 tooth a → Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain 2 Camshaft sprocket EAS00212 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1.

  • Page 121: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EASF0024 VALVES AND VALVE SPRINGS 1 Valve cotter 2 Upper spring seat 3 Valve spring 4 Valve stem seal 5 Lower spring seat 6 Intake valve 7 Exhaust valve 4-22...

  • Page 122: Removing The Valves

    VALVES AND VALVE SPRINGS EASF0025 REMOVING THE VALVES NOTE: Prior to remove the valves, remove the cylinder head, camshaft and rocker arms. The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.

  • Page 123: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 2. Remove: 9valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor Valve spring compressor 90890-04019 3. Remove: 9upper spring seat 1 9valve spring 2 9valve stem seal 3 9lower spring seat 4 9valve 5 NOTE:...
  • Page 124 VALVES AND VALVE SPRINGS 2. Replace: 9valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100°C in an oven. MMMMMMMMMMMMMMMMMMMMMMMM a. Remove the valve guide with the valve guide remover 1.

  • Page 125: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: 9valve stem runout Out of specification → Replace the valve. NOTE: 9When installing a new valve, always replace the valve guide. 9If the valve is removed or replaced, always replace the valve stem seal. Valve stem runout limit 0.01 mm (0.0004 in) EAS00240...
  • Page 126 VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. LLLLLLLLLLLLLLLLLLLLLLLL 4. Lap: 9valve face 9valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

  • Page 127: Checking The Valve Springs

    VALVES AND VALVE SPRINGS j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. LLLLLLLLLLLLLLLLLLLLLLLL EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.
  • Page 128 VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 9valve stem end (with an oil stone) 2. Lubricate: 9valve stem 1 9valve stem seal 2 (with the recommended lubricant) Recommended lubricant Engine oil 3.
  • Page 129 VALVES AND VALVE SPRINGS 4. Install: 9valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor Valve spring compressor 90890-04019 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.

  • Page 130: Cylinder And Piston

    CYLINDER AND PISTON EASF0027 CYLINDER AND PISTON 1 Cylinder 8 Piston pin 2 Cylinder gasket 9 Piston pin clip 3 Dowel pin 4 Top ring 5 2nd ring 6 Oil ring 7 Piston 4-31...

  • Page 131: Removing The Cylinder And Piston

    CYLINDER AND PISTON EASF0028 REMOVING THE CYLINDER AND PISTON NOTE: Prior to removing the cylinder and piston, remove the cylinder head. 1. Remove: 9cylinder 1 2. Remove: 9dowel pins 1 9gasket 2 3. Remove: 9piston pin clip 1 9piston pin 2 9piston 3 Do not use a hammer to drive the piston pin out.

  • Page 132: Checking The Cylinder And Piston

    CYLINDER AND PISTON EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: 9piston wall 9cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: 9piston-to-cylinder clearance MMMMMMMMMMMMMMMMMMMMMMMM a. Measure cylinder bore “C” with the cylinder bore gauge.

  • Page 133: Checking The Piston Rings

    CYLINDER AND PISTON Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.020 – 0.025 mm (0.0008 – 0.0010 in) <Limit>: 0.15 mm (0.0059 in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

  • Page 134: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: 9piston ring end gap Out of specification → Replace the piston ring. NOTE: The end gap of the oil ring expander cannot be measured. If the end gaps of the oil ring rails are excessive, replace all three piston rings. Piston ring end gap Top ring 0.10 –...

  • Page 135: Installing The Piston And Cylinder

    CYLINDER AND PISTON 4. Calculate: 9piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter b b – Piston pin outside diameter a a Piston-pin-to-piston-pin-bore clearance 0.002 – 0.017 mm (0.0001 –...
  • Page 136 CYLINDER AND PISTON 3. Install: 9gasket 1 9dowel pins 2 4. Lubricate: 9piston 9piston rings 9cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: 9piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring å...

  • Page 137: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EASF0034 GENERATOR AND STARTER CLUTCH 1 Starter clutch gear 8 Starter clutch idle gear shaft t Crankcase cover (left) 2 Starter clutch roller 9 Starter clutch idle gear 3 Starter clutch spring cap 0 Stator coil lead holder 4 Starter clutch spring q Pickup coil 5 Starter clutch...

  • Page 138: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS00346 REMOVING THE GENERATOR 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9front cowling (left) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9shift pedal 9drive sprocket cover Refer to “REMOVING THE DRIVE CHAIN...

  • Page 139: Removing The Starter Clutch

    GENERATOR AND STARTER CLUTCH 6. Remove: 9generator rotor 1 (with the flywheel puller 2) 9woodruff key Flywheel puller 90890-01362 EAS00344 REMOVING THE STARTER CLUTCH 1. Remove: 9starter clutch idle gear shaft 1 9starter clutch idle gear 2 9starter clutch gear 3 9washer 2.

  • Page 140: Checking The Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS00351 CHECKING THE STARTER CLUTCH 1. Check: 9starter clutch rollers 1 Damage/wear → Replace. 2. Check: 9starter clutch idle gear 1 9starter clutch gear 2 Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: 9starter clutch gear contacting surfaces a Damage/pitting/wear →...

  • Page 141: Installing The Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: 9starter clutch 1 14 Nm (1.4 m•kg, 10.1 NOTE: 9While holding the generator rotor 2 with the sheave holder, tighten the starter clutch bolt. 9Do not allow the sheave holder to touch the projection on the generator rotor.
  • Page 142 GENERATOR AND STARTER CLUTCH 3. Apply: 9sealant (on to the generator lead grommet) Yamaha bond No. 1215 90890-85505 4. Install: 9gasket 9crankcase cover 10 Nm (1.0 m•kg, 7.2 ft•lb) 4-43...

  • Page 143: Kickstarter

    KICKSTARTER EASF0035 KICKSTARTER 1 Kickstarter lever 8 Kickstarter ratchet gear clip 2 Crankcase cover (right) 9 Kickstarter ratchet gear 3 Gasket 0 Kickstarter gear 4 Dowel pin q Kickstarter shaft 5 Kickstarter spring guide 1 6 Kickstarter spring 7 Kickstarter spring guide 2 10 Nm (1.0 m•kg, 7.2 ft•lb ) 4-44...

  • Page 144: Removing The Kickstarter

    KICKSTARTER REMOVING THE KICKSTARTER 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9muffler 9footrest 9brake pedal Refer to “REMOVING THE ENGINE”.

  • Page 145: Checking The Kickstarter

    KICKSTARTER 6. Remove: 9kickstarter spring guide 1 1 9kickstarter spring 2 9kickstarter spring guide 2 3 9circlip 4 9kickstarter ratchet gear clip 5 9kickstarter ratchet gear 6 9circlip 7 9shim 8 9wave washer 9 9kickstarter gear 0 9kickstarter shaft q EAS00339 CHECKING THE KICKSTARTER 1.

  • Page 146: Installing The Kickstarter

    9crankcase cover bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Apply sealant to the threads of the crankcase cover bolts 2. Yamaha bond No. 1215 90890-85505 3. Install: 9kickstarter lever 1 9kickstarter lever bolt 10 Nm (1.0 m•kg, 7.2 ft•lb)

  • Page 147: Clutch

    CLUTCH EASF0029 CLUTCH 1 Clutch boss nut 9 Clutch plate #2 u Clutch release adjusting 2 Clutch boss 0 Clutch push rod #1 screw 3 Clutch housing q Clutch shoe housing nut 4 Clutch push rod #2 w Clutch shoe housing 5 Clutch pressure plate bolt e Cage 6 Clutch pressure plate...

  • Page 148: Removing The Clutch

    CLUTCH EAS00277 REMOVING THE CLUTCH 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9muffler 9footrest 9brake pedal Refer to “REMOVING THE ENGINE”.
  • Page 149 CLUTCH 6. Straighten the lock washer tab. 7. Loosen: 9clutch boss nut 1 NOTE: While holding the clutch boss 2 with the uni- versal clutch holder 3, loosen the clutch boss nut. Universal clutch holder 90890-04086 8. Remove: 9clutch boss nut 1 9lock washer 2 9clutch boss 3 9washer 4...

  • Page 150: Checking The Friction Plates

    CLUTCH 10. Remove: 9collar 1 9clutch shoe housing 2 9washer 3 9rollers 4 9cage springs 5 9cage 6 9clutch shoe housing boss 7 9clutch shoe 8 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates.

  • Page 151: Checking The Clutch Springs

    CLUTCH EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: 9clutch spring Damage → Replace the clutch springs as a set. 2. Measure: 9clutch spring free length a Out of specification → Replace the clutch springs as a set.

  • Page 152: Checking The Clutch Pressure Plate

    CLUTCH EAS00286 CHECKING THE CLUTCH PRESSURE PLATE 1. Check: 9clutch pressure plate Cracks/damage → Replace. EAS00288 CHECKING THE CLUTCH PUSH ROD 1. Check: 9clutch push rod #2 Cracks/damage/wear → Replace the clutch push rod #2. 2. Measure: 9clutch push rod #2 bending limit Out of specification →...

  • Page 153: Checking The Clutch Shoe Housing

    CLUTCH CHECKING THE CLUTCH SHOE HOUSING 1. Check: 9clutch shoe housing Damage/wear → Replace. 2. Measure: 9clutch shoe housing inside diameter a Out of specification → Replace. Clutch shoe housing inside diame- 105 mm (4.13 in) <Limit>: 106 mm (4.17 in) CHECKING THE CLUTCH SHOE 1.

  • Page 154: Checking The Clutch Release Shift Arm

    CLUTCH CHECKING THE CLUTCH RELEASE SHIFT ARM 1. Check: 9clutch release shift arm 1 Damage/wear → Replace. 9clutch release adjusting screw 2 Damage/wear → Replace. EAS00293 INSTALLING THE CLUTCH 1. Install: 9washer 9cage 1 9cage springs 2 9rollers 3 9clutch shoe housing boss 4 2.
  • Page 155 CLUTCH 4. Tighten: 9clutch boss nut 1 70 Nm (7.0 m•kg, 50 ft•lb) NOTE: While holding the clutch boss 2 with the univer- sal clutch holder 3, tighten the clutch boss nut. Universal clutch holder 90890-04086 5. Bend the lock washer tab along a flat side of the nut.

  • Page 156: Oil Pump

    OIL PUMP EASF0032 OIL PUMP 1 Oil pump driven gear 8 Engine oil drain bolt 2 Oil pump assembly 3 Gasket 4 Oil filter 5 Oil pump drive gear 6 Oil strainer 7 Gasket 4-57...

  • Page 157: Removing The Oil Pump

    OIL PUMP REMOVING THE OIL PUMP 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9clutch shoe Refer to “CLUTCH”. 3. Remove: 9oil filter 1 4. Remove: 9oil pump drive gear 1 9oil pump driven gear 2 5.

  • Page 158: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: 9oil pump drive gear 1 9oil pump driven gear 2 9oil pump housing 3 9oil pump housing cover 4 Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: 9inner-rotor-to-outer-rotor-tip clearance a 9outer-rotor-to-oil-pump-housing clearance 9oil-pump-housing-to-inner-rotor-and-outer-...

  • Page 159: Checking The Oil Strainer

    OIL PUMP EAS00328 CHECKING THE OIL STRAINER 1. Check: 9oil strainer Damage → Replace. Contaminants → Clean with solvent. CHECKING THE OIL FILTER 1. Check: 9oil filter Damage → Replace. Contaminants → Clean with solvent. EAS00375 ASSEMBLING THE OIL PUMP 1.

  • Page 160: Installing The Oil Pump

    OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1. Install: 9gasket 9oil pump assembly 1 7 Nm (0.7 m•kg, 5.0 ft•lb) NOTE: Install the gasket with section a in the position as shown in the illustration. After tightening the bolts, make sure the oil pump turns smoothly.

  • Page 161: Shift Shaft

    SHIFT SHAFT EASF0037 SHIFT SHAFT 1 Shift lever assembly 8 Shift guide spring t Stopper lever spring 2 Shift drum segment 9 Shift fork guide bar y Stopper lever assembly 3 Washer 0 Shift pedal 4 Thrust bearing q Shift shaft 5 Guide w Shift lever 6 Pawl holder...

  • Page 162: Removing The Shift Shaft

    SHIFT SHAFT REMOVING THE SHIFT SHAFT 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9clutch Refer to “CLUTCH”. 9oil pump driven gear Refer to “OIL PUMP”. 3. Remove: 9shift fork guide bar 1 9washer 2 9shift guide spring 4.
  • Page 163 SHIFT SHAFT 6. Remove: 9shift shaft assembly 1 9shift shaft spring stopper 2 9shift lever assembly 3 7. Remove: 9circlip 1 9washer 2 9shift shaft spring 3 9shift lever 4 9shift shaft 5 8. Remove: 9stopper lever assembly 1 9stopper lever spring 2 9.

  • Page 164: Checking The Shift Shaft

    SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: 9shift shaft 1 9shift lever 2 Bends/damage/wear → Replace. 9springs Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: 9stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace. 9stopper lever spring Damage/wear →...

  • Page 165: Installing The Shift Shaft

    SHIFT SHAFT EAS00331 INSTALLING THE SHIFT SHAFT 1. Install: 9shift drum segment 1 12 Nm (1.2 m•kg, 8.6 ft•lb) NOTE: Apply locking agent (LOCTITE ® ) to the threads of shift drum segment screw. 2. Install: 9stopper lever 1 9stopper lever spring 2 NOTE: 9Hook the ends 3 of the stopper lever spring onto the stopper lever and the crankcase boss.

  • Page 166: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT EASF0037 CRANKCASE AND CRANKSHAFT 1 Right crankcase 8 Crankshaft assembly 2 Shift fork guide bar retainer 9 Timing chain 3 Dowel pin 0 Timing chain guide (intake side) 4 Left crankcase 5 Starter motor lead holder 6 Gear position pointer 7 Neutral switch 4-67...

  • Page 167: Disassembling The Crankcase

    CRANKCASE AND CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 9engine Refer to “REMOVING THE ENGINE”. 2. Remove: 9starter motor lead 9starter motor Refer to “STARTER MOTOR” in chapter 7. 3. Remove: 9cylinder head Refer to “CYLINDER HEAD”. 9cylinder 9piston Refer to “CYLINDER AND PISTON”. 9clutch Refer to “CLUTCH”.

  • Page 168: Checking The Crankshaft And Connecting Rod

    CRANKCASE AND CRANKSHAFT 6. Remove: 9crankcase bolts 9starter motor lead holders 1 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 loosened, remove them. 7.
  • Page 169 CRANKCASE AND CRANKSHAFT 2. Measure: 9big end side clearance Out of specification → Replace the crank- shaft. Big end side clearance 0.11 – 0.41 mm (0.0043 – 0.0161 in) 3. Measure: 9crankshaft width Out of specification → Replace the crank- shaft.

  • Page 170: Checking The Crankcase

    CRANKCASE AND CRANKSHAFT EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: 9crankcase Cracks/damage → Replace. 9oil delivery passages Obstructions → Blow out with compressed air.

  • Page 171: Installing The Crankshaft

    90890-01278 EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: 9 9 sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery 1. 2. Install: 9dowel pins 2 3.
  • Page 172 4. Install: 9starter motor lead holders 9crankcase bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Apply sealant to the threads of crankcase bolt Yamaha bond No. 1215 90890-85505 5. Apply: 9engine oil (onto the crankshaft bearings and oil deliv- ery holes) 6.

  • Page 173: Transmission

    TRANSMISSION EASF0041 TRANSMISSION 1 Collar 9 Main axle/1st pinion gear 2 1st wheel gear 0 4th pinion gear 3 4th wheel gear q 3rd pinion gear 4 3rd wheel gear w 2nd pinion gear 5 Side plate e Shift fork guide bar 6 Side plate spring r Shift fork “R”...

  • Page 174: Removing The Transmission

    TRANSMISSION EASF0042 REMOVING THE TRANSMISSION NOTE: Prior to removing the transmission, separate the crankcase. 1. Remove: 9shift fork guide bar 1 9shift fork guide bar spring 9shift fork “R” 2 9shift fork “L” 3 9shift drum 4 NOTE: Note the position of each part. Pay particular attention to location and direction of shift forks.
  • Page 175 TRANSMISSION 2. Remove: 9circlips 1 9washers 2 9collars 3 91st wheel gear 4 94th wheel gear 5 93rd wheel gear 6 9side plate 7 9side plate spring 8 9drive axle/2nd wheel gear 9 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to both of the shift forks.

  • Page 176: Checking The Shift Drum Assembly

    TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: 9shift drum grooves 1 Damage/scratches/wear → Replace the shift drum assembly. 9shift drum bearing Damage/pitting → Replace the shift drum assembly. EAS00424 CHECKING THE TRANSMISSION 1. Measure: 9main axle runout (with a centring device and dial gauge 1) Out of specification →...

  • Page 177: Assembling The Transmission

    TRANSMISSION 4. Check: 9transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. NOTE: 19.3~19.5 mm When reassembling the drive axle, press the 2nd wheel gear 1 onto the drive axle 2 as shown.
  • Page 178 TRANSMISSION 2. Check: 9transmission 9shift drum 9shift forks Rough movement → Repair. NOTE: 9Oil each gear, shaft, and bearing thoroughly. 9Before assembling the crankcase, be sure that the transmission is in neutral and that the gears turn freely. 4-79...
  • Page 179 4-80...

  • Page 180: Carb

    CARB CHAPTER 5 CARBURETOR CARBURETOR ...................... 5-1 REMOVING THE CARBURETOR ..............5-2 DISASSEMBLING THE CARBURETOR ............5-3 CHECKING THE CARBURETOR ..............5-5 ASSEMBLING THE CARBURETOR ..............5-7 INSTALLING THE CARBURETOR ..............5-7 MEASURING AND ADJUSTING THE FUEL LEVEL......... 5-8 CHECKING THE FUEL COCK OPERATION............. 5-9 AIR INDUCTION SYSTEM..................
  • Page 181 CARB...

  • Page 182: Carburetor

    CARB CARBURETOR EASF0043 CARBURETOR CARBURETOR 1 Starter plunger assem- 6 Jet needle set e Needle jet o Float pivot pin 7 Throttle valve r Main jet p Float chamber 2 Coasting enricher 8 Throttle stop screw set t Pilot jet a Fuel drain screw 9 Pilot air screw set y Needle valve...

  • Page 183: Removing The Carburetor

    CARB CARBURETOR REMOVING THE CARBURETOR Gasoline is highly flammable. Avoid spilling fuel on the hot engine. 1. Remove: 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 2. Loosen: 9fuel drain screw 1 3. Drain: 9fuel (from float chamber) 4.

  • Page 184: Disassembling The Carburetor

    CARB CARBURETOR 7. Loosen: 9carburetor joint clamp screw 1 8. Remove: 9bolts 2 9carburetor assembly 3 9carburetor joint 4 9. Remove: 9starter plunger assembly 1 (from starter cable) 10. Remove: 9throttle valve assembly 1 9throttle valve spring 2 11. Remove: 9throttle valve 1 9jet needle set 2 NOTE:...
  • Page 185 CARB CARBURETOR 1. Remove: 9coasting enricher cover 9coasting enricher spring 1 9coasting enricher 2 2. Remove: 9pilot air screw set 1 3. Remove: 9throttle stop screw set 1 4. Remove: 9float chamber 1 9float chamber rubber gasket 5. Remove: 9main jet 1 9needle jet 2 9pilot jet 3...

  • Page 186: Checking The Carburetor

    CARB CARBURETOR 6. Remove: 9float pivot pin 1 9float 2 9needle valve 3 EAS00485 CHECKING THE CARBURETOR 1. Check: 9carburetor body 9float chamber 9jet housing → Replace. Cracks/damage 2. Check: 9fuel passages Obstructions → Clean. MMMMMMMMMMMMMMMMMMMMMMMM a. Wash the carburetor in a petroleum-based solvent.
  • Page 187 CARB CARBURETOR 6. Check: 9needle valve Damage/wear → Replace. 7. Check: 9coasting enricher 1 9coasting enricher spring 2 Cracks/damage → Replace. 8. Check: 9jet needle 1 9needle jet 2 9main jet 3 9pilot jet 4 9pilot air screw 5 9throttle stop screw 6 Bends/damage/wear →...

  • Page 188: Assembling The Carburetor

    CARB CARBURETOR 11. Check: 9hose joints Cracks/damage → Replace. 12. Check: 9air vent hose 9fuel hoses Cracks/damage/wear → Replace. Obstructions → Clean. Blow out the hoses with compressed air. EAS00487 ASSEMBLING THE CARBURETOR 9 9 Before assembling the carburetor, wash all of the parts in a petroleum-based sol-vent.

  • Page 189: Measuring And Adjusting The Fuel Level

    CARB CARBURETOR 5. Adjust: 9throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3–7 mm (0.12–0.28 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1.

  • Page 190: Checking The Fuel Cock Operation

    CARB CARBURETOR 2. Adjust: 9fuel level MMMMMMMMMMMMMMMMMMMMMMMM a. Remove the carburetor. b. Check the needle valve. c. If worn, replace the needle valve. d. If fine, adjust the float level by the needle valve is slightly bending the float tang 1. e.

  • Page 191: Air Induction System

    CARB AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
  • Page 192 CARB AIR INDUCTION SYSTEM 1 Air cut-off valve assembly 2 Air induction system hose (air cut-off valve assembly to cylinder head) 3 Air induction system vacuum hose 4 Air induction system hose (air cut-off valve assembly to air filter) 5 Air filter 5-11...

  • Page 193: Removing The Air Induction System

    CARB AIR INDUCTION SYSTEM REMOVING THE AIR INDUCTION SYS- 1. Remove: 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9rear cowling (left) Refer to “REMOVING THE REAR COWL- INGS” in chapter 3. 9air filter 1 2.

  • Page 194: Chas

    CHAS CHAPTER 6 CHASSIS FRONT WHEEL AND BRAKE DISC (T110LSE) ........... 6-1 REMOVING THE FRONT WHEEL ..............6-2 CHECKING THE FRONT WHEEL ..............6-3 CHECKING THE BRAKE DISC ................. 6-5 CHECKING THE SPEEDOMETER GEAR UNIT..........6-6 INSTALLING THE FRONT WHEEL ..............6-7 FRONT WHEEL AND DRUM BRAKE (T110LE) ...........
  • Page 195 CHAS HANDLEBAR ......................6-44 REMOVING THE HANDLEBAR ................ 6-45 CHECKING THE HANDLEBAR ................. 6-47 INSTALLING THE HANDLEBAR ..............6-47 STEERING HEAD ....................6-50 REMOVING THE LOWER BRACKET ............... 6-51 CHECKING THE STEERING HEAD ..............6-51 INSTALLING THE STEERING HEAD ..............6-53 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM .......

  • Page 196: Front Wheel And Brake Disc (T110Lse)

    CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) EASF0044 CHASSIS FRONT WHEEL AND BRAKE DISC (T110LSE) 1 Front wheel axle 2 Brake disc 3 Spacer 4 Oil seal 5 Bearing 6 Spacer 7 Speedometer gear unit 23 Nm (2.3 m·kg, 17 ft·lb ) 39 Nm 3.9 m·kg, 28 ft·lb )

  • Page 197: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) EAS00519 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9speedometer cable 1 9axle nut 2 9washer 3 3.

  • Page 198: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) EAS00526 CHECKING THE FRONT WHEEL 1. Check: 9wheel axle Roll the wheel axle on a flat surface. → Replace. Bends Do not attempt to straighten a bent wheel axle. 2. Check: 9tire Damage/wear → Replace. Refer to “CHECKING THE TIRES”...
  • Page 199 CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) 5. Check: 9spacers Damage/wear → Replace. 9 9 After mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim.

  • Page 200: Checking The Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) d. Install the new wheel bearings and oil seals in the reverse order of disassembly. Do not contact the wheel bearing inner race 4 4 or balls 5 5 . Contact should be made only with the outer race 6 6 .

  • Page 201: Checking The Speedometer Gear Unit

    CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) 3. Measure: 9brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Brake disc thickness limit (mini- mum) 3.0 mm (0.12 in) 4. Adjust: 9brake disc deflection MMMMMMMMMMMMMMMMMMMMMMMM a.

  • Page 202: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: 9wheel axle 9wheel bearings 9oil seal lips 9speedometer gear unit Recommended lubricant Lithium-soap-based grease 2. Install: 9brake disc 9front wheel Refer to “CHECKING THE BRAKE DISC”. NOTE: Make sure the projection a on the speedometer gear unit fits between the projections on the...

  • Page 203: Front Wheel And Drum Brake (T110Le)

    CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) EASF0045 FRONT WHEEL AND DRUM BRAKE (T110LE) 1 Front wheel axle 0 Brake camshaft 2 Collar q Brake shoe plate 3 Oil seal w Speedometer driven gear 4 Bearing e Brake shoe wear indicator 5 Spacer r Brake camshaft lever 6 Oil seal...

  • Page 204: Removing The Front Wheel

    CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) EAS00519 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9brake cable adjusting nut 9brake cable 9boot 9compression spring...

  • Page 205: Checking The Front Wheel

    CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) 2. Remove: 9brake shoes 1 9speedometer clutch 2 9speedometer drive gear 3 9washer 4 3. Remove: 9brake camshaft lever 1 9brake shoe wear indicator 2 9brake camshaft 3 NOTE: When removing the brake camshaft lever, mark the position on the brake camshaft lever where it is aligned with the punch mark in the brake camshaft.

  • Page 206: Checking The Speedometer Gear Unit

    CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1. Check: 9speedometer clutch Bends/damage/wear → Replace. 2. Check: 9speedometer drive gear 1 9speedometer driven gear 2 Damage/wear → Replace. EAS00536 CHECKING THE BRAKE The following procedure applies to all of the brake shoes.

  • Page 207: Assembling The Brake Shoe Plate

    CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) 3. Measure: 9brake drum inside diameter a Out of specification → Replace the wheel. Brake drum inside diameter limit (maximum) Front: 111 mm (4.37 in) Rear: 131 mm (5.16 in) 4. Check: 9brake drum inner surface Oil deposits →...

  • Page 208: Assembling The Front Wheel

    CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) 2. Install: 9speedometer driven gear 1 9bushing (with the special tool 2) Meter gear bush tool 90890-01052 EAS00538 ASSEMBLING THE FRONT WHEEL 1. Install: 9brake shoe plate assembly Align the tab on the speedometer clutch with the slot in the wheel hub.

  • Page 209: Rear Wheel And Brake

    CHAS REAR WHEEL AND BRAKE EASF0049 REAR WHEEL AND BRAKE 1 Brake rod adjusting nut 0 Cotter pin 2 Brake camshaft lever q Brake torque rod 3 Pin w Rear wheel drive hub damper 4 Drive chain puller (right) e Rear wheel drive hub 5 Brake shoe wear indicator r Drive chain case (lower) 6 Brake shoe plate...

  • Page 210: Removing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE EAS00563 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 211 CHAS REAR WHEEL AND BRAKE 5. Remove: 9rear wheel axle nut 1 9washer 9rear wheel axle 2 9washer 9collar 6. Remove: 9rear wheel assembly 1 NOTE: Push the rear wheel forward and remove the drive chain from the driven sprocket. 7.

  • Page 212: Disassembling The Brake Shoe Plate

    CHAS REAR WHEEL AND BRAKE 10. Remove: 9O-ring 9rear wheel drive hub dampers 1 DISASSEMBLING THE BRAKE SHOE PLATE 1. Remove: 9brake shoes 1 9brake shoe spring 1 2 (52 mm, 2.01 in) 9brake shoe spring 2 3 (48 mm, 1.89 in) A : Rear wheel side 2.

  • Page 213: Checking The Rear Wheel Drive Hub

    CHAS REAR WHEEL AND BRAKE 2. Check: 9tire Damage/wear → Replace. Refer to “CHECKING THE TIRES” in chap- ter 3. 3. Measure: 9radial wheel runout 9lateral wheel runout Refer to “FRONT WHEEL AND BRAKE DISC (T110LSE)”. EAS00567 CHECKING THE REAR WHEEL DRIVE 1.

  • Page 214: Assembling The Brake Shoe Plate

    CHAS REAR WHEEL AND BRAKE EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 9brake camshaft 1 9brake shoe wear indicator 2 9brake camshaft lever 7 Nm (0.7 m·kg, 5.0 ft·lb) MMMMMMMMMMMMMMMMMMMMMMMM a. Install the brake camshaft so its punch mark a is positioned as shown.
  • Page 215 CHAS REAR WHEEL AND BRAKE 4. Adjust: 9drive chain slack Drive chain slack 25–35 mm (0.98–1.38 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 5. Tighten: 9wheel axle nut 60 Nm (6.0 m·kg, 43 ft·lb) Do not loosen the wheel axle nut after tight- ening it to the specified torque.

  • Page 216: Front Brake (T110Lse)

    CHAS FRONT BRAKE (T110LSE) FRONT BRAKE (T110LSE) EASF0052 FRONT BRAKE CALIPER 1 Brake pad retaining pin 8 Brake caliper piston seal 2 Air bleed screw 9 Brake pad 3 Brake caliper 0 Brake pad spring 4 Brake caliper bracket 5 Lower brake caliper retaining bolt 6 Brake caliper piston 7 Brake caliper dust seal...

  • Page 217: Replacing The Front Brake Pads

    CHAS FRONT BRAKE (T110LSE) EAS00579 Disc brake components rarely require disas- sembly. Therefore, always follow these preventive measures: 9 9 Never disassemble brake components unless absolutely necessary. 9 9 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.
  • Page 218 CHAS FRONT BRAKE (T110LSE) 2. Remove: 9clips 9brake pad retaining pin 9brake pads 1 9brake pad spring 3. Measure: 9brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.4 mm (0.06 in) 4.

  • Page 219: Disassembling The Front Brake Caliper

    CHAS FRONT BRAKE (T110LSE) 5. Lubricate: 9brake pad retaining pin Recommended lubricant Lithium-soap-based grease 9Do not allow grease to contact the brake pads. 9Remove any excess grease. 6. Install: 9brake caliper bolts 35 Nm (3.5 m·kg, 25 ft·lb) 7. Check: 9brake fluid level Below the minimum level mark a →...
  • Page 220 CHAS FRONT BRAKE (T110LSE) 1. Remove: 9union bolt 1 9copper washers 2 9brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: 9brake caliper 1 9pin 9brake pad retaining pin 9brake pads 9brake pad spring 3.

  • Page 221: Checking The Front Brake Caliper

    CHAS FRONT BRAKE (T110LSE) EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every two years Brake hose Every four years Every two years and Brake fluid whenever the brake is disassembled 1.

  • Page 222: Assembling And Installing The Front Brake Caliper

    CHAS FRONT BRAKE (T110LSE) EAS00634 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 9 9 Before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid. 9 9 Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 223 CHAS FRONT BRAKE (T110LSE) 4. Fill: 9brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 3 or 4 9 9 Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 224: Front Brake Master Cylinder

    CHAS FRONT BRAKE (T110LSE) EASF0050 FRONT BRAKE MASTER CYLINDER 1 Brake master cylinder kit 8 Front brake light switch 2 Brake master cylinder reser- voir cap 3 Brake master cylinder reser- voir diaphragm 4 Brake master cylinder 5 Brake master cylinder holder 6 Brake hose 7 Brake lever 26 Nm (2.6 m•kg, 19 ft•lb )

  • Page 225: Disassembling The Front Brake Master Cylinder

    CHAS FRONT BRAKE (T110LSE) EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9headlight assembly Refer to “REMOVING THE HEADLIGHT ASSEMBLY”...

  • Page 226: Checking The Front Brake Master Cylinder

    CHAS FRONT BRAKE (T110LSE) 5. Remove: 9brake master cylinder kit 1 6. Remove: 9brake master cylinder reservoir cap 1 9brake master cylinder reservoir diaphragm holder 2 9brake master cylinder reservoir diaphragm 3 7. Remove: 9brake hose 1 9brake hose retainers 2 9brake hose holder 3 EAS00590 CHECKING THE FRONT BRAKE MAS-...

  • Page 227: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT BRAKE (T110LSE) 3. Check: 9brake master cylinder reservoir 1 Cracks/damage → Replace. 9brake master cylinder reservoir diaphragm 2 Damage/wear → Replace. 4. Check: 9brake hose 1 Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 9 9 Before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid.
  • Page 228 CHAS FRONT BRAKE (T110LSE) 3. Install: 9copper washers 1 9brake hose 2 9union bolt 26 Nm (2.6 m·kg, 19 ft·lb) Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING”. NOTE: Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads).
  • Page 229 CHAS FRONT BRAKE (T110LSE) 5. Bleed: 9brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (T110LSE)” in chapter 3. 6. Check: 9brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL (T110LSE)”...

  • Page 230: Front Fork

    CHAS FRONT FORK EASF0054 FRONT FORK 1 Front fork cap bolt 0 Front fender 2 Dust seal 3 Oil seal clip 4 Oil seal 5 Fork spring 6 Damper rod 7 Inner tube 8 Outer tube 9 Damper rod bolt 6-35...

  • Page 231: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.

  • Page 232: Disassembling The Front Fork Legs

    CHAS FRONT FORK 7. Remove: 9front fork cap bolt 1 (with a 10-mm hexagonal wrench) 8. Loosen: 9lower bracket pinch bolt 2 Before loosening the lower bracket pinch bolt, support the front fork leg. 9. Remove: 9front fork leg EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the...
  • Page 233 CHAS FRONT FORK 4. Remove: 9damper rod assembly bolt 9copper washer NOTE: While holding the damper rod assembly with a 10 mm hexagon nut/socket wrench 1 and the Thandle 2, loosen the damper rod assembly bolt 3. T-handle 90890-01326 5. Remove: 9inner tube 9rebound spring 9damper rod...

  • Page 234: Checking The Front Fork Legs

    CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 9inner tube 1 9outer tube 2 Bends/damage/scratches → Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2.

  • Page 235: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 9 9 Make sure the oil levels in both front fork legs are equal. 9 9 Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 236 CHAS FRONT FORK NOTE: Tighten the damper rod assembly bolt 1 while holding the damper rod with the T-handle 2 and a 10 mm hexagon nut/socket wrench 3. T-handle 90890-01326 4. Install: 9oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachment 3) Fork seal driver weight 90890-01184...

  • Page 237: Installing The Front Fork Legs

    CHAS FRONT FORK 6. Fill: 9front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.059 L (59cm Recommended oil Fork oil 10W or equivalent Front fork leg oil level a a (from the top of the inner tube, with the inner tube fully compressed and without the fork spring)
  • Page 238 CHAS FRONT FORK 3. Install: 9front fender (lower) 10 Nm (1.0 m·kg, 7.2 ft·lb) 9front fork cover (upper) 7 Nm (0.7 m·kg, 5.0 ft·lb) 4. Install: (T110LSE) 9front wheel Refer to “FRONT WHEEL AND BRAKE DISC (T110LSE)”. 9brake hose retainers 9brake caliper assembly Refer to “FRONT BRAKE (T110LSE)”.

  • Page 239: Handlebar

    CHAS HANDLEBAR EASF0055 HANDLEBAR 1 Rear view mirror (left and right) 2 Throttle grip 3 Right handlebar switch 4 Handlebar 5 Left handlebar switch 6 Handlebar grip 7 Starter cable 8 Throttle cable 9 Handlebar bracket 32 Nm (3.2 m•kg, 23 ft•lb ) 53 Nm (5.3 m•kg, 38 ft•lb ) 16 Nm (1.6 m•kg, 12 ft•lb ) 6-44...

  • Page 240: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS”...
  • Page 241 CHAS HANDLEBAR 7. Remove: 9right handlebar switch 1 8. Remove: 9throttle cable 1 9throttle grip 2 9. Remove: 9washer 9starter lever 1 9starter cable 2 9spring washer 10. Remove: 9left handlebar switch 1 11. Remove: 9handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

  • Page 242: Checking The Handlebar

    CHAS HANDLEBAR 12. Remove: 9wire harness strap 1 13. Remove: 9handlebar 1 9washers 9bushings 9handlebar bracket 2 EAS00668 CHECKING THE HANDLEBAR 1. Check: 9handlebar 1 Bends/cracks/damage → Replace. Do not attempt to straighten a bent handle- bar as this may dangerously weaken it. EAS00670 INSTALLING THE HANDLEBAR 1.
  • Page 243 CHAS HANDLEBAR 3. Install: 9bushings 9washers 9handlebar 16 Nm (1.6 m·kg, 12 ft·lb) 9wire harness strap Refer to “CABLE ROUTING” in chapter 2. 4. Install: 9handlebar grip MMMMMMMMMMMMMMMMMMMMMMMM a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b.
  • Page 244 CHAS HANDLEBAR 8. Install: 9brake master cylinder (T110LSE) 11 Nm (1.1 m·kg, 7.9 ft·lb) Refer to “FRONT BRAKE (T110LSE)”. 9brake lever holder (T110LE) 7 Nm (0.7 m·kg, 5.0 ft·lb) 9. Install: 9plastic locking ties Refer to “CABLE ROUTING” in chapter 2. 10.

  • Page 245: Steering Head

    CHAS STEERING HEAD EASF0057 STEERING HEAD 1 Rubber cover 2 Upper ring nut 3 Lower ring nut 4 Ball race cover 5 Bearing inner race 6 Upper bearing 7 Bearing outer race 8 Lower bearing 9 Lower bracket 6-50...

  • Page 246: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9front panel Refer to “REMOVING THE FRONT COWL- INGS”...
  • Page 247 CHAS STEERING HEAD 2. Check: 9bearings 1 9bearing races 2 Damage/pitting → Replace. 3. Replace: 9bearings 9bearing races MMMMMMMMMMMMMMMMMMMMMMMM a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.

  • Page 248: Installing The Steering Head

    CHAS STEERING HEAD EAS00683 INSTALLING THE STEERING HEAD 1. Lubricate: 9upper bearing 9lower bearing 9bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 9lower ring nut 9upper ring nut Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3. 3. Install: 9front fork legs Refer to “FRONT FORK”.

  • Page 249: Rear Shock Absorber Assembly And Swingarm

    REAR SHOCK ABSORBER ASSEMBLY AND CHAS SWINGARM REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 1 Rear shock absorber 2 Brake torque rod 3 Swingarm 4 Bushing 5 Swingarm pivot shaft 6 Drive chain case (upper) 6-54...

  • Page 250: Removing The Rear Shock Absorber Assemblies And Swingarm

    REAR SHOCK ABSORBER ASSEMBLY AND CHAS SWINGARM EAS00691/EAS00702 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 251 REAR SHOCK ABSORBER ASSEMBLY AND CHAS SWINGARM 5. Remove: 9rear shock absorber bolt (left and right) 1 9washer 9rear shock absorber nut (left and right) 2 9washers 9rear shock absorber assembly (left and right) 3 6. Measure: 9swingarm side play 9swingarm vertical movement MMMMMMMMMMMMMMMMMMMMMMMM a.

  • Page 252: Checking The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLY AND CHAS SWINGARM 7. Remove: 9swingarm pivot shaft nut 1 9muffler stay 9washer 2 9swingarm pivot shaft 3 9swingarm 4 EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both rear shock absorber assemblies. 1.

  • Page 253: Checking The Swingarm

    REAR SHOCK ABSORBER ASSEMBLY AND CHAS SWINGARM EAS00707 CHECKING THE SWINGARM 1. Check: 9swingarm Bends/cracks/damage → Replace. 2. Check: 9swingarm pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. Do not attempt to straighten a bent pivot shaft.
  • Page 254 REAR SHOCK ABSORBER ASSEMBLY AND CHAS SWINGARM 2. Install: 9swingarm 9swingarm pivot shaft 9washer 9swingarm pivot shaft nut 51 Nm (5.1 m·kg, 37 ft·lb) 3. Install: 9rear shock absorber assemblies 9rear shock absorber nuts 9rear shock absorber bolts 32 Nm (3.2 m·kg, 23 ft·lb) 4.

  • Page 255: Drive Chain And Sprockets

    CHAS DRIVE CHAIN AND SPROCKETS DRIVE CHAIN AND SPROCKETS 1 Rear wheel drive hub 0 Circlip 2 Driven sprocket q Drive sprocket cover 3 Lock washer 4 Collar 5 Oil seal 6 Bearing 7 Master link 8 Drive chain 9 Drive sprocket 6-60...

  • Page 256: Removing The Drive Chain And Sprockets

    CHAS DRIVE CHAIN AND SPROCKETS EAS00706 REMOVING THE DRIVE CHAIN AND SPROCKETS 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 257: Checking The Drive Chain

    CHAS DRIVE CHAIN AND SPROCKETS 7. Straighten the lock washer tabs. 8. Remove: 9driven sprocket nuts 9driven sprocket bolts 9lock washers 1 9driven sprocket 2 EAS00710 CHECKING THE DRIVE CHAIN 1. Measure: 1 2 3 4 5 6 7 8 9 0 q w e r t 9Measure the length of 15 links on the inner side a and outer side b of the pin and cal- culate the length between pin centers.

  • Page 258: Installing The Drive Chain And Sprockets

    CHAS DRIVE CHAIN AND SPROCKETS 4. Check: 9drive chain rollers 1 Damage/wear → Replace the drive chain. 9drive chain side plates 2 Cracks/damage/wear → Replace the drive chain. 5. Lubricate: 9drive chain Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 6.
  • Page 259 CHAS DRIVE CHAIN AND SPROCKETS 3. Install: 9drive sprocket 1 9circlip 2 NOTE: Install the drive sprocket with the flat side a towards the engine. 4. Lubricate: 9drive chain 9master link Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 5.

  • Page 260: Elec

    ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ................7-1 CHECKING SWITCH CONTINUITY ..............7-3 CHECKING THE SWITCHES ................7-5 CHECKING THE BULBS AND BULB SOCKETS ..........7-7 TYPES OF BULBS ................... 7-7 CHECKING THE CONDITION OF THE BULBS ..........7-8 CHECKING THE CONDITION OF THE BULB SOCKETS .......
  • Page 261 ELEC...

  • Page 262: Electrical System

    ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Main switch 7 Ignition coil 2 Positive battery lead 8 Wire harness 3 Negative battery lead 4 Battery 5 Fuse 6 Rear brake light switch...
  • Page 263 ELEC ELECTRICAL COMPONENTS 1 Horn 2 Turn signal relay 3 Fuel gauge 4 Starter relay 5 C.D.I. unit 6 Neutral switch 7 Rectifier/regulator...

  • Page 264: Checking Switch Continuity

    ELEC CHECKING SWITCH CONTINUITY EAS00730 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. Never insert the tester probes into the cou- pler terminal slots 1 1 .
  • Page 265 ELEC CHECKING SWITCH CONTINUITY...

  • Page 266: Checking The Switches

    ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 267 ELEC CHECKING THE SWITCHES 1 Horn switch 2 Dimmer switch 3 Turn signal switch 4 Neutral switch 5 Rear brake light switch 6 Fuse 7 Start switch 8 Light switch 9 Front brake light switch (T110LSE) 0 Front brake light switch (T110LE) q Main switch...

  • Page 268: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.

  • Page 269: Checking The Condition Of The Bulbs

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 9bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 9 9 Be sure to hold the socket firmly when removing the bulb.

  • Page 270: Checking The Condition Of The Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: 9bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the...

  • Page 271: Ignition System

    ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 7-10...

  • Page 272: Troubleshooting

    ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no 9Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. fuse Minimum open-circuit voltage 2.
  • Page 273 ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance 9Disconnect the spark plug cap from the 9Remove the spark plug cap from the spark spark plug. plug lead. 9Connect the pocket tester (“Ω × 1k” range) to 9Connect the ignition checker 1 as shown.
  • Page 274 ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Pickup coil resistance 9Disconnect the ignition coil connector from 9Disconnect the pickup coil coupler from the the ignition coil terminal. wire harness. 9Connect the pocket tester (Ω × 1) to the igni- 9Connect the pocket tester (Ω...
  • Page 275 ELEC IGNITION SYSTEM EAS00754 9. Wiring 9Check the entire ignition system wiring. Refer to “CIRCUIT DIAGRAM”. 9Is the ignition system wiring properly con- nected and without defects? Properly connect or Replace the C.D.I. repair the ignition unit. system wiring. 7-14...

  • Page 276: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7-15...

  • Page 277: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery 9Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. fuse Minimum open-circuit voltage 2. battery 12.8 V or more at 20 °C 3.
  • Page 278 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00764 4. Starter relay 6. Start switch 9Remove the starter relay from the starter 9Check the start switch for continuity. relay coupler on the wire harness. Refer to “CHECKING THE SWITCHES”. 9Connect the pocket tester (Ω × 1) and bat- 9Is the start switch OK? tery (DC 12 V) to the starter relay coupler as shown.

  • Page 279: Starter Motor

    ELEC STARTER MOTOR EASF0061 STARTER MOTOR 1 Starter motor yoke 2 Armature 3 Brush set 4 Starter motor lead 5 Starter motor front cover 7-18...

  • Page 280: Removing The Starter Motor

    ELEC STARTER MOTOR REMOVING THE STARTER MOTOR 1. Remove: 9footrest assembly 9starter motor guard Refer to “REMOVING THE ENGINE” in chapter 4. 2. Remove: 9starter motor 1 3. Remove: 9starter motor lead 1 DISASSEMBLING THE STARTER MOTOR 1. Remove: 9starter motor front cover bolts (with washers) 9starter motor front cover 1 9gasket 2...
  • Page 281 ELEC STARTER MOTOR 2. Measure: 9commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 16.6 mm (0.65 in) 3. Measure: 9mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

  • Page 282: Assembling The Starter Motor

    ELEC STARTER MOTOR 5. Measure: 9brush length a Out of specification → Replace the brush- es as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: 9brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 3.92–5.88 N (400–600 gf) 7.

  • Page 283: Charging System

    ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 7-22...

  • Page 284: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery 9Check the condition of the battery. The battery cannot be charged. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. fuse Minimum open-circuit voltage 2. battery 12.8 V or more at 20 °C 3.
  • Page 285 ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Charging coil resistance 9Connect the engine tachometer to the spark 9Disconnect the stator coil coupler from the plug lead. wire harness. 9Connect the pocket tester (Ω × 1) to the 9Connect the pocket tester (DC 20 V) to the battery as shown.

  • Page 286: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 7-25...

  • Page 287: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 EAS00776 TROUBLESHOOTING 2. Lighting coil resistance Any of the following fail to light: head- 9Disconnect the stator coil coupler from the light, high beam indicator light, taillight, or wire harness. meter light. 9Connect the pocket tester (Ω × 1) to the lighting coil terminals as shown.

  • Page 288: Checking The Lighting System

    ELEC LIGHTING SYSTEM EAS00788 3. Voltage CHECKING THE LIGHTING SYSTEM 9Connect the pocket tester (AC 20 V) to the 1. The headlight and the high beam indicator headlight and high beam indicator light con- light fail to come on. nectors as shown. EAS00784 åWhen the dimmer switch is set to “%”.
  • Page 289 ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light bulb and socket 1. Tail/brake light bulb and socket 9Check the meter light bulb and socket for 9Check the tail/brake light bulb and socket for continuity.

  • Page 290: Signaling System

    ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 7-29...
  • Page 291 ELEC SIGNALING SYSTEM 1 Main switch 2 Fuse 3 Battery r Rear brake light switch t Front brake light switch y Turn signal relay u Horn o Horn switch a Turn signal switch s Tail/brake light d Rear turn signal light f Front turn signal light h Neutral switch j Fuel sender...

  • Page 292: Troubleshooting

    ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery 9 9 Any of the following fail to light: turn sig- 9Check the condition of the battery. nal light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE 9 9 The horn fails to sound. BATTERY”...

  • Page 293: Checking The Signaling System

    ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 9Disconnect the pink connector at the horn 1. The horn fails to sound. terminal. 1. Horn switch 9Connect a jumper lead 1 to the horn termi- nal and ground the jumper lead. 9Check the horn switch for continuity.
  • Page 294 ELEC SIGNALING SYSTEM EAS00797 3. Voltage 2. The tail/brake light fails to come on. 9Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket tail/brake light coupler (wire harness side) as shown. 9Check the tail/brake light bulb and socket for Positive tester probe →...
  • Page 295 ELEC SIGNALING SYSTEM EAS00799 3. Voltage 3. The turn signal light, turn signal indicator 9Connect the pocket tester (DC 20 V) to the light or both fail to blink. turn signal relay coupler as shown. 1. Turn signal indicator light bulb and socket Positive tester probe →...
  • Page 296 ELEC SIGNALING SYSTEM 5. Voltage 4. Voltage 9Connect the pocket tester (DC 20 V) to the 9Connect the pocket tester (DC 20 V) to the turn signal light coupler (wire harness side) turn signal relay coupler as shown. as shown. Positive tester probe →...
  • Page 297 ELEC SIGNALING SYSTEM EAS00801 9Set the main switch to “ON”. 4. The gear position indicator lights fail to 9Set the turn signal switch to “4” or “6”. come on. 9Measure the voltage (DC 12 V) of the chocolate 1 or dark green lead terminal 2 1.
  • Page 298 ELEC SIGNALING SYSTEM EAS00804 3. Voltage 5. The fuel level gauge fails to operate. 9Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler (wire harness side) as shown. 9Remove the fuel sender from the fuel tank. 9Connect the pocket tester to the fuel sender Neutral indicator light Positive tester probe →...
  • Page 299 ELEC SIGNALING SYSTEM 3. Fuel level gauge 2. Voltage 9Connect the pocket tester (DC 20 V) to the 9Set the main switch to “ON”. 9Move the float up 1 or down 2. meter assembly coupler (wire harness side) 9Check that the fuel level gauge needle as shown.

  • Page 300: Trbl Shtg

    TRBL SHTG CHAPTER 8 TROUBLESHOOTING TROUBLESHOOTING ................... 8-1 ELECTRICAL SYSTEM ..................8-1 COMPRESSION SYSTEM ................8-2 INTAKE AND EXHAUST SYSTEM ..............8-3...
  • Page 301 TRBL SHTG...

  • Page 302: Troubleshooting

    TRBL TROUBLESHOOTING SHTG EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM *CHECK ALL WIRES CONNECTIONS IGNITION COIL (see page 7-13) 8 Primary or secondary windings are broken or faulty MAIN SWITCH (see page 7-5) 8 Spark plug wire is faulty 8 Main switch is shorted 8 Spark plug cap is faulty SPARK PLUG C.D.I.

  • Page 303: Compression System

    TRBL TROUBLESHOOTING SHTG COMPRESSION SYSTEM...

  • Page 304: Intake And Exhaust System

    TRBL TROUBLESHOOTING SHTG INTAKE AND EXHAUST SYSTEM FUEL COCK 8 Clogged FUEL TANK CAP DRY TYPE 8 Clogged AIR FILTER ELEMENT FUEL HOSE 8 Dirty or clogged 8 Clogged, damaged or kinked SILENCER EXHAUST PIPE 8 Clogged 8 Cracked or broken 8 Carbon deposits...
  • Page 305 TRBL SHTG...
  • Page 307 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 308 T110LE/T110LSE WIRING DIAGRAM 1 Main switch 2 Fuse 3 Battery 4 Starter relay 5 Starter motor 6 Right handlebar switch 7 Start switch 8 Light switch 9 Rectifier/ regulator Br R 0 A. C. magneto q C. D. I. unit w Ignition coil e Spark plug r Rear brake light switch...

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