Yamaha Fazer Service Manual
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Yamaha Fazer Service Manual

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  • Page 1 SERVICE MANUAL...
  • Page 2 FAZER SERVICE MANUAL YAMAHA MOTOR INDIA PVT. LIMITED All rights reserved. Any reprinting or unauthorised use without the written permission of YAMAHA MOTOR INDIA PVT. LIMITED is expressly prohibited.

  • Page 3: Specifications

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

  • Page 4: How To Use This Manual

    HOW TO USE THIS MANUAL MANUAL ORGANISATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the Title of the Chapter with its symbol on the upper right corner of each page. 2nd title 2 : This title indicates the Section of the chapter and only appears on the first page of each section.

  • Page 5: Periodic Inspection And

    ILLUSTRATED SYMBOLS Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number and content. 1. General 2. Specifications SPEC Information INFO 3. Periodic inspection INSP 4. Engine and adjustment CHAS CARB 6. Chassis 5. Carburetion TRBL 8.
  • Page 6 INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND INSP ADJUSTMENTS ENGINE CARBURETION CARB CHASSIS CHAS ELECTRICAL ELEC TROUBLE SHOOTING TRBL SHTG...

  • Page 7: Table Of Contents

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

  • Page 8: Motorcycle Identification

    INFO MOTORCYCLE IDENTIFICATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The Frame Serial Number ¿ is stamped into the right side of the Steering Head Pipe. ENGINE SERIAL NUMBER The Engine Serial Number À is stamped on the top portion of RH Crankcase. ( Engine Serial Number does not contain Year and Month of production) XXXXXX...

  • Page 9: Important Information

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

  • Page 10: All Replacement Parts

    INFO IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use Yamalube Oil and Grease recommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality. GASKETS, OIL SEALS, AND O-RINGS 1.

  • Page 11: Special Service Tools

    INFO YAMAHA SPECIAL SERVICE TOOLS YAMAHA SPECIAL SERVICE TOOLS The appropriate Yamaha Special Service Tools are necessary for proper maintenance of the Motorcycle. Using the correct Yamaha Special Service Tool will help to prevent damage caused by the use of improper tools or improvised techniques.
  • Page 12 INFO YAMAHA SPECIAL SERVICE TOOLS 9. Crank Shaft Removal Tool. Scraper YSST - 265 YSST - 612 This tool is used to remove the Crank Shaft This tool is used for scraping the sealent from the Crank Case. from Crankcase surface. Feeler Gauge 10.

  • Page 13: Special Service Tools

    INFO SPECIAL SERVICE TOOLS 19 Racer Installing Tool 24. Bearing Puller YSST-626 YSST - 623 To install upper and lower Racer Bearing This tool is used to remove the Bearing 6201 of the Axle Main. 20 TFF Top Plug Spanner 25.

  • Page 14: Service Instruments

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

  • Page 15: Special Service Materials

    INFO SERVICE INSTRUMENTS 9. Tyre pressure gauge 11. Torque Wrench (10-50 Ft-Lb) (20-100 Ft-Lb) This instrument is used for checking the This tool is used to tighten the Nuts/Bolts Tyre Pressure at a specified torque. 10. Vaccum Gauge 12. Feeler gauge This instrument is used for checking intake This instrument is used to check clearance/ vaccum.
  • Page 16 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ............ 2-1 MAINTENANCE SPECIFICATIONS ENGINE ..................2-4 CHASSIS ..................2-10 ELECTRICAL ................2-13 GENERAL TORQUE SPECIFICATIONS ........2-15 LUBRICATION POINTS AND LUBRICANT TYPE ENGINE ..................2-16 CHASSIS ..................2-17 ENGINE LUBRICATION ROUTE ............. 2-18 ENGINE BEARINGS ................

  • Page 17: Specifications

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS DESCRIPTION SPECIFICATION Model : FAZER Model Code : 5YY1 Engine model code: 5YY1 DIMENSIONS: Overall length 2065 Overall width Overall height 1060 Seat height Wheelbase 1300 Minimum ground clearance Minimum turning radius 2065 Dry weight :...
  • Page 18 SPEC GENERAL SPECIFICATIONS DESCRIPTION SPECIFICATION Clutch type : Wet, Multiple disc Transmission : Primary reduction system Helical gear Primary reduction ratio 68/19 (3.579 : 1) Secondary reduction system Chain drive Secondary reduction ratio 45/14 (3.214 : 1) Transmission type Constant mesh 4-speed Operation Left foot operation Gear ratio...
  • Page 19 SPEC GENERAL SPECIFICATIONS DESCRIPTION SPECIFICATION Brake : Front brake Type Drum Brake (Dia 150 mm) Operation Right hand operation Rear brake Type Drum brake (Dia 130 mm) Operation Right foot operation Suspension : Front suspension Telescopic fork Rear suspension Swingarm Shock absorbser : Front shock absorber Coil spring/Oil damper...

  • Page 20: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE DESCRIPTION SPECIFICATION Cylinder : Bore size 54.000 ~ 54.018 mm (in five grades) Piston : Piston to Cylinder Clearance 0.020 ~ 0.027 mm <Limit> <0.15mm> Piston size “D” 53.977 ~ 53.996 mm Cylinder Piston Grading (in five grades) Matching of Grades Piston...
  • Page 21 SPEC MAINTENANCE SPECIFICATIONS DESCRIPTION SPECIFICATION Cylinder head : <Warp limit> <0.03 mm (0.0012 in)> Lines indicate straightedge measurement. Camshaft : Drive method Chain Drive Cam dimensions Intake “ A ” 25.881 ~ 25.981 mm <Limit> <25.851 mm> “ B “ 21.195 ~ 21.295 mm <Limit>...
  • Page 22 SPEC MAINTENANCE SPECIFICATIONS DESCRIPTION SPECIFICATION Stem outside diameter 5.975 ~ 5.990 mm 5.960 ~ 5.975 mm <Limit> <5.950 mm> <5.935 mm> Guide inside diameter 6.000 ~ 6.012 mm 6.000 ~ 6.012 mm <Limit> <6.042 mm> <6.042 mm> Stem to guide clearance 0.010 ~0.037 mm 0.025 ~ 0.052 mm <Limit>...
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS DESCRIPTION SPECIFICATION Clutch : Friction plate thickness 2.90 ~ 3.10 mm Quantity 5 pcs. <Friction plate wear limit> <2.80 mm> Clutch Plate thickness 1.6 ± 0.15 mm Quantity 4 pcs. <Wrap limit> 0.05 mm Clutch Spring free length 32 mm Quantity 4 pcs.
  • Page 24 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE (ENGINE) Part to be tightened Parts Thread Q’ty Tightening torque Remark name size Nm m.kg ft.lb Cylinder Head Bolt Bolt Spark Plug 12.5 1.25 Cylinder Head Side Cover Bolt Valve Cover 17.5 1.75 CDI Magneto Rotor Bolt Stopper Guide Bolt...
  • Page 25 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE (ENGINE) Part to be tightened Parts Thread Q’ty Tightening torque Remark name size Nm m.kg ft.lb Stopper lever Bolt Sensor Assembly Bolt Neutral Switch Assembly Tightening sequence Cylinder Head Ä Ã À Á ¿ Â È...

  • Page 26: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS DESCRIPTION SPECIFICATION Steering system : Steering Bearing type Retainer Ball Cage No./size of steel balls (upper) 19 pcs. / 1/4 in (lower) 16 pcs. / 1/4 in Front suspension : Front Fork travel 120 mm Fork Spring free length 316.9 mm <Limit>...
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS DESCRIPTION SPECIFICATION Front Drum Brake : Type Leading, Trailing Brake Drum inside diameter 150mm <Wear limit> <151> Lining Thickness 4.0 mm <Wear limit> <2 mm> Shoe Spring free length Spring 1 57.0 mm Spring 2 63.0 mm Rear drum brake : Type Leading, Trailing...
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE (CHASSIS) PARTS TO BE TIGHTENED THREAD TIGHTENING TORQUE SIZE m.kg ft.lb Front Engine Stay and Mount M 8 X 1.25 27.5 Front Engine Stay and Frame M 10 X 1.25 Rear Engine Mount and Frame M 8 X 1.25 27.5 Upper Engine Stay and Mount...

  • Page 29: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL DESCRIPTION SPECIFICATION Voltage : Ignition system : Ignition timing (B.T. D. C) 7º ± 2º BTDC at 1400 rpm. Advancer Type Electrical type CDI : Digitally Controlled Magneto model/manufacturer 5YY/DENSO 240 Ω ± 20% Sensor Coil (Color) CDI Unit Model/manufacturer 5KA/ Denso IgnitionCoil :...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Circuit Breaker : Type Fuse Amperage for individual circuit X quantity : Main 10A X 1pc. Reserve 10A X 1pc. 2-14...

  • Page 31: General Torque Specifications

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

  • Page 32: Lubrication Points And Lubricant Type

    SPEC LUBRICATION POINTS AND LUBRICANT TYPE LUBRICATION POINTS AND LUBRICANT TYPE ENGINE Lubrication points (part name) Lubricant type Oil Seal lips (all) Bearing Retainer (all) Bolt (Cylinder Head) O-ring (Cylinder Head Side Cover and Valve Cover) Crank Pin Connecting Rod (big end) Piston Pin Valve Stem and Valve Guide Oil Seal (Valve Stem End)

  • Page 33: Chassis

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

  • Page 34: Engine Lubrication Route

    SPEC ENGINE LUBRICATION ROUTE Engine Lubrication route CAUTION: WARNING DO NOT DAMAGE CRANK CASE SURFACES, OTHERWISE OIL LEAKAGE WILL START 2-18...
  • Page 35 SPEC ENGINE LUBRICATION ROUTE Engine Lubrication route CAUTION: WARNING FOR IMPROVED PERFORMANCE, ALWAYS USE YAMALUBE OIL 2-19...

  • Page 36: Engine Bearings

    SPEC ENGINE BEARINGS ENGINE BEARINGS 2-20...

  • Page 37: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING É Flasher light lead (left) Æ through the Cable Guide of ¿ Handlebar switch (left) Ê Flasher Light the right side. À Clutch cable Ë Flasher light lead (right) C Clamp Wireharness È and Á Starter Wire A Pass the Clutch Cable À, front fork.
  • Page 38 SPEC CABLE ROUTING ¿ Headlight assembly Î Brake Cable E Pass the battery breather À Handlebar switch lead Ï H.T. Coil hose Ì through the hole Á Speedometer cable Ð Air Induction system of the lower left side of  Cable guide A Pass wireharness the Battery Box...
  • Page 39 SPEC CABLE ROUTING ¿ Throttle cable È A.I.S. Unit A Pass the high tension cord À through the À High tension cord É Starter wire cable guide and starter wire. Á Ignition Coil Ê Carburettor Breather B Pass the throttle cable ¿ and starter wire Â...
  • Page 40 SPEC CABLE ROUTING ¿ C.D.I. Unit à Stop/tail light lead À Rectifier regulator Ä Wireharness Á Flasher relay Å Carburettor Air Vent  Flasher light lead Æ Tail Light Assembly A Clamp the Wire Harness lead. B Pass the Wire Harness between Frame and Rear Fender ¿...
  • Page 41 INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENTS PERIODIC MAINTENANCE / LUBRICATION INTERVALS ..3-1 SIDE COVER, SEAT AND FUEL TANK REMOVAL ................... 3-3 INSTALLATION ................3-5 ENGINE VALVE CLEARANCE CHECKING ADJUSTMENT ....3-6 IDLING CO MEASUREMENT, AND ADJUSTMENT ....3-8 THROTTLE CABLE ADJUSTMENT SPARK PLUG INSPECTION AND ADJUSTMENT....3-10 IGNITION TIMING CHECK ............3-11 COMPRESSION PRESSURE MEASUREMENT ......3-13...

  • Page 42: Periodic Maintenance/Lubrication Intervals

    INSP INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable Motorcycle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to Motorcycles already in service as well as to new Motorcycles that are being prepared for sale.
  • Page 43 Check operation, free play, Cable damage. - THROTTLE Readjust or replace as required - CLUTCH - FRONT BRAKE It is recommended that above be serviced by authorised YAMAHA MOTOR INDIA PRIVATE LIMITED dealer *Service more frequently when the vehicle is driven in dusty areas.

  • Page 44: Side Cover, Seat And Fuel Tank

    INSP SIDE COVERS, SEAT AND FUEL TANK SIDE COVERS, SEAT AND FUEL TANK REMOVAL SIDE COVER (LH) 1. Remove • Side Cover (LH) ¿ ææææææææææææææææææææææææææææææææææ Removal steps : • Open the Lock ¿ using Main Switch Key. • Pull the Lug À / Lug Á towards you to remove it from the Fuel Tank.
  • Page 45 INSP SIDE COVERS, SEAT AND FUEL TANK REMOVAL SEAT 1. Remove • Side Cover LH and RH • Bolts 2 Nos - Bolts ¿ and À from LH/RH À ¿ side • Seat ææææææææææææææææææææææææææææææææææ Removal steps : • Open bolts ¿ and À inside the side covers. •...

  • Page 46: Installation

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

  • Page 47: Engine

    INSP VALVE CLEARANCE CHECKING AND ADJUSTMENT ENGINE VALVE CLEARANCE CHECKING AND ADJUSTMENT NOTE : Valve clearance checking and adjustment should be made with the Engine in cold condi- tion, at room temperature. When the Valve clearance is to be measured or adjusted, the Piston must be at Top Dead Cen- ter (T.D.C.) on the compression stroke and marking on Cam Sprocket should be aligned...
  • Page 48 INSP VALVE CLEARANCE CHECKING AND ADJUSTMENT ææææææææææææææææææææææææææææææææææ è Checking steps : Measurement steps : • Rotate the Crankshaft anticlockwise to align the slit ç third mark on the rotor with the sta- ç tionary pointer è on the Crankcase Cover LH when the Piston is at Top Dead Center (T.D.C.) and in compression stroke.

  • Page 49: Idling Co Measurement, And Adjustment

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

  • Page 50: Throttle Cable Adjustment

    INSP IDLING ‘CO’ MEASUREMENT AND ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT 5. Adjust : • ‘CO’ concentration ææææææææææææææææææææææææææææææææææ Adjustment steps : • Turn the pilot screw ¿ in or out until the speci- fied ‘CO’ concentration is obtained. Turning in ” ‘CO’ concentratin decreases Turning out ”...
  • Page 51 INSP THROTTLE CABLE ADJUSTMENT/ SPARK PLUG INSPECTION • Loosen the Locknut ¿ on the Throttle Cable. • Turn the Adjuster À in or out until the specified free play is obtained. è Turning IN ç Ÿ Free play is increased. ¿...

  • Page 52: Ignition Timing Check

    INSP SPARK PLUG INSPECTION/ IGNITION TIMING CHECKING PROCEDURE 6. Install : • Spark Plug Spark Plug : 12.5 Nm (1.25 mkg, 9 ftlb) NOTE : • Before installing a Spark Plug, clean the Gas- ket surface and Plug surface. • If a Torque Wrench is not available, a good estimate of the correct tightening torque is to finger tighten ¿...
  • Page 53 INSP IGNITION TIMING CHECKING PROCEDURE 3. Check : • Ignition timing ********************************************* Checking steps : • Start the Engine and let it warm up for sev- eral minutes or run the Motorcycle for approx. 4 kms. • Maintain the Engine idling speed Engine idling speed : 1,300 ~ 1,500 r/min ç...

  • Page 54: Compression Pressure Measurement

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

  • Page 55: Engine Oil Level Inspection

    INSP ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT 8. Install : • Fuel tank • Seat • Side covers Refer to “SIDE COVERS, SEAT AND FUEL TANK” section Page no 3-3 ENGINE OIL LEVEL INSPECTION 1. Stand the Motorcycle on a level surface us- ing the Center Stand.
  • Page 56 INSP ENGINE OIL REPLACEMENT/ EXHAUST SYSTEM INSPECTION 4. Install : • Drain plug ¿ with Washer ¿ Drain plug : 20 Nm (2.0 m.Kg, 14.5 ft. lb) 5. Fill : • Oil in Crankcase Oil quantity : Refill 1.0 L 6.

  • Page 57: Air Filter Cleaning

    INSP AIR FILTER CLEANING 1. Remove: • Side Cover (R.H.) ¿ • Air Filter Case Cap ¿ - Unscrew 4 Nos. Screws • Spring Wire À • Air Filter Element Á • Element guide  CAUTION: WARNING Never operate the Engine without the Air Filter element installed.

  • Page 58: Clutch Cable Adjustment

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

  • Page 59: Front Brake Adjustment

    INSP FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT CHASSIS FRONT BRAKE ADJUSTMENT 1. Check : • Brake Lever free play a Out of specification Ÿ Adjust. Free play (Brake Lever): 25 ~ 30 mm at Brake Lever end 2. Adjust : •...

  • Page 60: Brake Shoe Inspection

    INSP REAR BRAKE ADJUSTMENT/ BRAKE SHOE INSPECTION ææææææææææææææææææææææææææææææææææ Adjustment steps : • Turn the Adjuster ¿ in or until the specified free play is obtained. Turning out ç Ÿ Free play is increased. Turning in è Ÿ Free play is decreased. ¿...

  • Page 61: Drive Chain Slack Adjustment

    INSP DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT NOTE: • Before checking and adjusting, rotate the Rear Wheel several revolutions and check the slack at several points to find the tight- est point. • Check and if necessary adjust the Drive Chain slack with the Rear Wheel in this “tight- est”...
  • Page 62 INSP DRIVE CHAIN SLACK ADJUSTMENT ææææææææææææææææææææææææææææææææææ Adjustment steps : • Loosen both the Locknuts Â. Â • Turn the Adjuster Á in or out until the speci- ç fied Drive Chain slack is obtained. Turning in ç Ÿ Drive Chain slack is decreased.

  • Page 63: Steering Head Inspection

    INSP STEERING HEAD INSPECTION STEERING HEAD INSPECTION WARNING Securely support the Motorcycle so that there is no danger of it falling over. 1. Stand the Motorcycle on a level surface. NOTE : Stand the Motorcycle on its Center Stand. 2. Elevate the Front wheel by placing a suit- able stand under the Engine.
  • Page 64 INSP STEERING HEAD INSPECTION NOTE : Set the Torque Wrench to the Ring Nut Wrench so that they form a right angle. Ring nut-lower (final tightening) : 23 Nm (2.3 m.kg, 17 ft. lb) WARNING Avoid over torquing. • Check the Steering Stem by Turning it Lock to Lock.

  • Page 65: Front Fork Inspection

    INSP FRONT FORK INSPECTION FRONT FORK INSPECTION WARNING TFF OIL SEALS ¿ Securely support the motocycle so that there is no danger of it falling over. 1. Stand the Motorcycle on a level surface. 2. Check: • Inner tube Scratches/damage ➔ Replace. •...

  • Page 66: Rear Shock Absorber Adjustment

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

  • Page 67: Tyre Inspection

    INSP TYRE INSPECTION 2. Inspect : • Tyre surfaces Wear/damage Ÿ Replace Minimum Tyre tread Depth : (Front and Rear) 1.6 mm ¿ Tread Depth À Side wall Á Wear indicator WARNING • It is dangerous to ride with a worn out Cold tyre pressure Front 25 psi...

  • Page 68: Spoke Inspection And Tightening

    INSP SPOKE INSPECTION AND TIGHTENEING SPOKES INSPECTION TIGHTENING ¿ 1. Inspect : • Spokes ¿ Bending/damage Ÿ Replace. Loose spoke Ÿ Retighten 2. Tighten : • Spokes Nipple Tighting Tool YSST - 629 NOTE : Be sure to tighten the Spokes before and after break-in.

  • Page 69: Electrical Battery Inspection

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

  • Page 70: Battery Installation

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

  • Page 71: Fuse Inspection

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

  • Page 72: Headlight Beam Adjustment

    INSP HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT HEADLIGHT BEAM ADJUSTMENT À 1. Loosen: • Bolt ¿ 2. Loosen: • Screw À - 2 Nos. 3. Adjust : • Headlight beam (vertical) ¿ Push down Ÿ Headlight beam moves lower. Pull up Ÿ Headlight beam moves higher. NOTE : Punch Mark is given on the Adjuster Bracket for reference to tighten the Bolt ¿.
  • Page 73 CHAPTER 4 ENGINE OVERHAUL ENGINE REMOVAL SIDE COVERS, SEAT AND FUEL TANK REMOVAL ....4-1 ENGINE OIL DRAIN ..............4-1 BATTERY ..................4-1 CARBURETOR ................4-1 CLUTCH CABLE ................4-1 DRIVE CHAIN ................4-2 EXHAUST MUFFLER ..............4-2 FOOTREST ASSEMBLY ............4-2 SHIFT PEDAL ................4-3 BATTERY BOX REMOVAL ............4-3 LEADS ..................4-3 ENGINE REMOVAL ..............4-3...
  • Page 74 CIRCLIPS AND WASHERS ............4-31 ENGINE ASSEMBLY AND ADJUSTMENT ........ 4-32 CRANKSHAFT ................4-35 TRANSMISSION ................ 4-37 SHIFTER ..................4-38 CRANKCASE ................4-40 CDI MAGNETO................4-42 SHIFT SHAFT AND KICK STARTER ......... 4-44 CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP ....4-47 CYLINDER AND PISTON............

  • Page 75: Engine Removal

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

  • Page 76: Clutch Cable

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

  • Page 77: Shift Pedal

    ENGINE REMOVAL SHIFT PEDAL À 1. Remove • Bolt (Shift Pedal) ¿ • Shift Pedal À ¿ BATTERY BOX ¿ 1. Remove ¿ • Bolt (Battery Box) ¿ 3 nos • Battery Box À À LEADS 1. Disconnect: • Stator Coil Lead Coupler ¿ •...

  • Page 78: Engine Disassembly

    ENGINE DISASSEMBLY ENGINE DISASSEMBLY CYLINDER HEAD, CYLINDER AND PISTON NOTE: With Engine mounted on Motorcycle, the Cyl- inder Head, Camshaft and Cylinder can be maintained by removing the following parts. • Side Covers • Spark Plug Lead • Seat • Engine Mount Stay •...
  • Page 79 ENGINE DISASSEMBLY 5. Remove : ¿ • Tensioner Cap Bolt ¿ • Retract completely the Tensioner Rod by Screw in (clockwise) direction. • Bolts (timing chain tensioner ) À 2 Nos Á • Timing Chain Tensioner Assembly Á • Gasket À...
  • Page 80 MAINTENANCE SPECIFICATIONS 9. Remove : • Dowel Pins ¿ - 2 Nos À • Gasket (Cylinder) À ¿ 10. Remove : Á • Piston Pin Circlip ¿ 2 nos • Piston Pin À , using Piston Pin Replacer À • Piston Á NOTE : ¿...

  • Page 81: Clutch

    ENGINE DISASSEMBLY CLUTCH À NOTE : Á The Clutch Assembly can be removed while the Engine is mounted on the Motorcycle by remov- ing the following parts and draining the Engine oil: • Kick Starter. Á ¿ 1. Remove : •...

  • Page 82: Oil Pump

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

  • Page 83: Kick Starter

    ENGINE DISASSEMBLY KICK STARTER NOTE : The kick starter can be removed while the en- gine is mounted by removing the following part. • Kick Crank Assy • Crankcase Cover 2 (RH) • Clutch Drum Assy Á 1. Remove : •...
  • Page 84 ENGINE DISASSEMBLY CDI MAGNETO REMOVAL ¿ 1. Remove : • Nut (magneto) • Plain washer NOTE : À • Loosen the Nut Magneto while holding the Magneto À with Magneto Holder ¿ Magneto Holder : YSST - 627 ¿ 2. Attach •...

  • Page 85: Crankcase

    ENGINE DISASSEMBLY CRANKCASE 1. Remove : • Bolts (Crankcase RH-2 nos) ¿ ¿ ¿ 2. Remove : • Bolts (Crankcase LH-8 nos) Â Á NOTE : • Loosen the Bolts in a crisscross pattern. Ä • Loosen each Bolts 1/4 turn at a time and re- Ã...

  • Page 86: Transmission And Shifter

    ENGINE DISASSEMBLY: TRANSMISSION AND SHIFTER TRANSMISSION AND SHIFTER 1. Remove : • Shift Fork Guide Bar ¿ (short) ¿ • Shift Fork Guide Bar À (long) • Shift Cam Á Á • Shift Fork -C • Shift Fork -R À •...
  • Page 87 ENGINE DISASSEMBLY DISASSEMBLY OF CYLINDER HEAD, À ROCKER ARMS, CAMSHAFT AND VALVES 1. Loosen :  Á ¿ • Valve Adjuster Locknuts ¿ • Valve Adjusters À 2. Remove : • Stopper Plate Á by opening allen bolt  3. Attach ¿...
  • Page 88 ENGINE DISASSEMBLY 7. Attach ¿ Valve Spring compression Tool ¿ À Valve Spring Compressor : YSST - 603 8. Remove : • Valve Cotters À NOTE : Valve Spring compressor tool is to be attached between the Valve Spring retainer and the Valve face (Inlet and Exhaust) one at a time.

  • Page 89: Inspection And Repair

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

  • Page 90: Valve Seats

    INSPECTION AND REPAIR:VALVE SEATS VALVE SEATS 1. Remove : • Carbon deposits from the Valve Face and Valve Seat. 2. Inspect : • Valve Seats Pitting/wear Ÿ reface the valve seat. 3. Measure : • Valve Seat width ç Out of specification Ÿ Reface the Valve Seat.
  • Page 91 INSPECTION AND REPAIRS ææææææææææææææææææææææææææææææææææ Lapping steps : • Apply coarse lapping compound ç to the Valve Face CAUTION: WARNING Do not let compound enter the gap between the Valve Stem and the Guide. • Apply molybdenum disulfide oil to the Valve Stem.

  • Page 92: Valve Springs And Valves

    INSPECTION AND REPAIR : VALVE SPRINGS AND VALVES VALVE SPRINGS AND VALVES 1. Measure : • Valve Spring free length ç Out of specification Ÿ Replace. Valve spring free length : 39.62 mm ç <Limit 38.17 mm> 2. Measure : •...

  • Page 93: Camshaft

    ENGINE INSPECTION AND REPAIR 6. Calculate : Stem Guide Clearance Stem-to-guide clearance = Valve guide inside diameter – Valve stem diameter Stem-to-guide clearance limit : Intake : 0.010 ~ 0.00370 mm <limit : 0.08 mm> Exhaust : 0.025 ~ 0.052 mm <limit : 0.10 mm>...

  • Page 94: Rocker Arms And Rocker Arm Shafts

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

  • Page 95: Timing Chain, Sprockets And Chain Guides

    ENGINE INSPECTION AND REPAIR TIMING CHAIN, SPROCKETS AND CHAIN GUIDES 1. Inspect : • Timing Chain Wear out/Stiffness/damage Ÿ Replace the Chain and the Sprockets as a set. 2. Inspect : • Cam Sprocket Wear/damage Ÿ Replace the Cam Sprocket and the timing chain as a set. 3.

  • Page 96: Cylinder And Pistons

    ENGINE INSPECTION AND REPAIR CYLINDER AND PISTONS 1. Inspect : • Cylinder and Piston walls Vertical scratches Ÿ Rebore or replace the Cylinder and the Piston 2. Measure : • Piston-to-Cylinder clearance ææææææææææææææææææææææææææææææææææ Measurement steps : 1st step : • Measure the Cylinder Bore “C” with a Cylin- der Bore Gauge.

  • Page 97: Piston Rings

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

  • Page 98: Piston Pin

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

  • Page 99: Crankshaft

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

  • Page 100: Primary Drive Gear

    ENGINE INSPECTION AND REPAIR BALANCER WEIGHT INSPECTION Inspect: • Balancer drive gear teeth ¿ • Balancer driven gear teeth À Wear/damage Ÿ Replace as a set Inspect: • Balancer Shaft • Wear/bend/damageŸ Replace PRIMARY DRIVE GEAR INSPECTION 1. Inspect : •...

  • Page 101: Push Rod

    ENGINE INSPECTION AND REPAIR 4. Inspect : • Clutch Springs Damage Ÿ Replace the Clutch springs as a set. 5. Measure • Free length (Clutch Spring) ç Out of specification Ÿ Replace the Clutch ç springs as a set. Free length (Clutch Spring) : 32.0 mm <Limit>...

  • Page 102: Shift Fork Shift Cam

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

  • Page 103: Kick Starter

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

  • Page 104: Oil Pump

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

  • Page 105: Oil Delivery Passage(Cc Cover Rh)

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

  • Page 106: Engine Assembly And Adjustment

    ENGINE ASSEMBLY AND ADJUSTMENTS ENGINE ASSEMBLY AND ADJUSTMENTS VALVES, ROCKER ARM AND CAMSHAFT ¿ Valve Cotters Æ Lock Nut À Valve Spring Retainer Ç Adjuster Á Valve Springs È Valve Rocker Arm  Valve Stem Seal É Rocker Arm Shaft Ã...
  • Page 107 ENGINE ASSEMBLY AND ADJUSTMENTS WARNING ¿ ¿ For Engine Assembly, replace the following parts with new ones : • O-Rings • Gaskets • Oil Seals • Copper Washers • Lock Washers • Circlips VALVES VALVE SPRINGS INSTALLATION 1. Deburr : •...
  • Page 108 ENGINE ASSEMBLY AND ADJUSTMENTS 5. Secure the Valve Cotters onto the Valve Stem by tapping lightly with a mallet CAUTION: WARNING Do not hit so much as to damage the Valve CAMSHAFT AND ROCKER ARM INSTALLATION ¿ 1. Lubricate : •...

  • Page 109: Crankshaft

    ENGINE ASSEMBLY AND ADJUSTMENTS CRANKSHAFT Ã Crankshaft Bearing ¿ Crank Pin Ä Wood-ruff Key À Crank Shaft Á Connecting Rod Å Gear Balancer Æ Balancer Assy. Â Big end Bearing Ç Bearing 4-35...
  • Page 110 ENGINE ASSEMBLY AND ADJUSTMENTS CRANKSHAFT 1. Insert : • CrankShaft in the Crankcase (L.H.) 2. Attach : • Crankshaft Installing Tool on Crankshaft Crankshaft Installing Tool YSST - 266 Spacer YSST - 267 3. Install : • Crankshaft by tightening the Nut ¿ NOTE : Hold the Connecting Rod at Top End with one hand while turning the Nut of the Installing Tool...

  • Page 111: Transmission

    ENGINE ASSEMBLY AND ADJUSTMENTS TRANSMISSION Ç 1st Wheel Gear ¿ Drive Sprocket È Bearing À Oil Seal É Bearing Á Bearing Ê 4th Pinion Gear  4th Wheel Gear Ë 3rd Pinion Gear à Drive Axle Ì 2nd Pinion Gear Ä...

  • Page 112: Shifter

    ENGINE ASSEMBLY AND ADJUSTMENTS SHIFTER Ä Shift Fork Guide Bar (short) ¿ Shift Fork Guide Bar (long) Å Shift fork # C À Shift Fork # R Æ Torx Screw Á Shift Fork # L Ç Pin Shaft Cam  Shift Cam Ã...
  • Page 113 ENGINE ASSEMBLY AND ADJUSTMENTS TRANSMISSION, SHIFT CAM AND SHIFT FORK INSTALLATION 1. Measure : • Axle Main Assembled length ç Assembled length (Axle Main): 82.25 ~ 83.45 mm 2. Install : • Push rod # 2 ¿ in the Axle Main. 3.

  • Page 114: Crankcase

    ENGINE ASSEMBLY AND ADJUSTMENTS Tightening Sequence ¿ Ç Â Á È Ä Ã Æ Å À CRANKCASE ¿ Crankcase #1 (LH) À Dowel Pins Á Crankcase Breather Hose  Crankcase #2 (RH) à Holder Clutch Cable 4-40...
  • Page 115 ENGINE ASSEMBLY AND ADJUSTMENTS CRANKCASE LH 1. Apply : • Sealant on the Crankcase Mating surfaces Sealant Yamaha bond No. 1215: 2. Install : • Dowel Pins ¿ NOTE : ç Do not allow any sealant to come in contact with the Oil Galleries ç...

  • Page 116: Cdi Magneto

    ENGINE ASSEMBLY AND ADJUSTMENTS CDI MAGNETO Ã Stator Assy. ¿ Timing Chain Ä Gasket À Guide Stopper # 1 and # 2 Å Dowel Pin Á CDI Rotor Assy Æ Cover Crankcase #1 Â Wood-Ruff Key 4-42...
  • Page 117 ENGINE ASSEMBLY AND ADJUSTMENTS TIMING CHAIN AND GUIDE STOPPER#2 À 1. Install ¿ Á • Timing Chain ¿ 2. Install • Guide stopper#2 À with spacer • Tighten the bolt Á C.D.I. MAGNETO INSTALLATION ¿ 1. Install : • Woodruff Key 2.

  • Page 118: Shift Shaft And Kick Starter

    ENGINE ASSEMBLY AND ADJUSTMENTS SHIFT SHAFT AND KICK STARTER ¿ Shift Shaft Å Circlip À Torsion Spring Æ Washer Á Stopper Lever Ç Kick Idle Gear  Return Spring È Kick Shaft Assy. à Segment É Cover Crankcase # 2 Ä...
  • Page 119 ENGINE ASSEMBLY AND ADJUSTMENTS SEGMENT AND SHIFT SHAFT ¿ 1. Install À • Dowel Pins ¿ on the Cam Shifter À 2. Install : • Segment ¿ using Torx Bit Tool Torx Bit Tool YSST - 611 NOTE : ¿ Fit the Dowel Pins on the Cam Shifter to the lo- cating hole on the Cam Shifter and install the Segment ¿...
  • Page 120 ENGINE ASSEMBLY AND ADJUSTMENTS KICK STARTER INSTALLATION 1. Install : ¿ À Á Â Ã Ä Å • Kick axle ¿ • Ratchet gear with return spring À • Shim Á • Ratchet gear  • Shim à • Torsion spring Ä •...

  • Page 121: Clutch, Primary Drive Gear And Oil Pump

    ENGINE ASSEMBLY AND ADJUSTMENTS CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP ¿ Clutch Spring Æ Thrust Washer Í Key À Pressure Plate Ç Primary Driven Gear Î Oil Pump Drive Gear Á Push Plate È Ball Ï Oil Pump Driven Gear Â...
  • Page 122 ENGINE ASSEMBLY AND ADJUSTMENTS OIL PUMP INSTALLATION 1. Lubricate : • Oil delivery passage (Crankcase RH) ¿ • Oil Pump Assembly ¿ Recommended Lubricant: 4- Stroke Engine Oil 2. Install : • Drive gear (Oil Pump) ¿ ¿ • Gasket Á...
  • Page 123 ENGINE ASSEMBLY AND ADJUSTMENTS CLUTCH INSTALLATION 1. Install : • Oil Seal ¿ • Circlip ¿ • Push Lever Axle À NOTE : Install longer side ç of the Spring on Push Le- À ver and smaller side è on the Crankcase Notch. 2.
  • Page 124 ENGINE ASSEMBLY AND ADJUSTMENTS ENGINE ASSEMBLY AND ADJUSTMENTS 6. Install : • Ball ¿ ¿ 7. Install : • Push Rod # 1 ¿ • Push Plate À ¿ À  Á • Plate Washer Á • Nut  (Push Rod # 1) 8.
  • Page 125 ENGINE ASSEMBLY AND ADJUSTMENTS ENGINE ASSEMBLY AND ADJUSTMENTS • Hold the Adjuster to prevent it from moving and tighten the Locknut to specification À CAUTION: WARNING ¿ Take care not to overtighten the Adjuster À and remove the freeplay between both Push Rods. •...

  • Page 126: Cylinder And Piston

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

  • Page 127: Cylinder Head

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

  • Page 128: Cam Sprocket And Timing Chain

    ENGINE ASSEMBLY AND ADJUSTMENTS CAM SPROCKET AND TIMING CHAIN  Cam Sprocket ¿ Gasket à Timing Chain À Timing Chain Tensioner Assembly Ä Guide Stopper # 1 Á Guide Stopper # 2 4-54...
  • Page 129 ENGINE ASSEMBLY AND ADJUSTMENTS PISTON RING, PISTON AND CYLINDER INSTALLATION 1. Install in following sequence • Expander Spacer (Oil Ring) ¿ • Side Rails (Oil Ring) À • 2nd Ring Á • Top Ring  NOTE : • Make sure to install the Piston Rings so that the RN mark is located on the upper side of the 2nd Ring.
  • Page 130 ENGINE ASSEMBLY AND ADJUSTMENTS 4. Install : • Piston Rings ¿ NOTE : Offset the Piston Rings end gaps as shown. ç Top Ring End è Oil Ring end (lower) é Oil Ring End (upper) ê 2nd Ring End 5. Lubricate : •...
  • Page 131 ENGINE ASSEMBLY AND ADJUSTMENTS 2. Install : Â ¿ • Cylinder Head • Bolt with Washer (Cylinder Head) Bolts (Cylinder Head ): Á M8 (1-4) : À 22 Nm (2.2 m.kg, 17 ft.lb) M6(5-6) : Ä Ã 10 Nm (1.0 m.kg., 7.2 ft. lb) NOTE : •...
  • Page 132 ENGINE ASSEMBLY AND ADJUSTMENTS 4. Install : ¿ • Plate Washer 5. Tighten • Bolt Sprocket ¿ Bolt (Timing Chain Sprocket) : 20 Nm (2. 0 m.kg, 14.5 ft. lb) NOTE : Install the Bolt while holding the Magneto Mounting nut with a Wrench. ê...
  • Page 133 ENGINE ASSEMBLY AND ADJUSTMENTS 8. Check : • Valve clearance specifications Out of specification Ÿ Adjust. Refer to the “VALVE CLEARANCE ADJUST- MENT” section in Chapter 3, Page no 3-8 9. Lubricate : • 4 Stroke Engine Oil Recommended Lubricant : Engine Oil - YAMALUBE 10.Install : À...

  • Page 134: Engine Mounting

    ENGINE ASSEMBLY AND ADJUSTMENTS 14. Install : • Spark Plug Spark Plug : 12.5 Nm (1.25 m.kg, 12.6 ft. lb) 15. Install : • Plug Drain ¿ ¿ Plug Drain : 20 Nm (2.0 m.kg, 2.0 ft.lb) ENGINE MOUNTING When remounting the Engine, reverse the re- moval procedure.
  • Page 135 ENGINE ASSEMBLY AND ADJUSTMENTS Engine Mount Bolt (Rear) : Bolt (Engine Mount stay front lower) 38 Nm (3.8 m.Kg.27.5 ft. lb) 55 Nm (5.5 m.kg., 40 ft.lb) Bolt (Engine mount Stay) : Engine Mount Bolt (Front lower) 38 Nm (3.8 m..kg, 27. 5 ft.lt) 38 Nm (3.8 m.kg., 27.5 ft.lb) Engine mount bolt (upper) Engine Mount bolt (from upper))
  • Page 136 ENGINE ASSEMBLY AND ADJUSTMENTS 11. Install: • Carburetor Refer to “CARBURETOR “ section in Chapter 5 page no 5-7 12. Tighten: • Air Filter Case Screws Bolts (Air Filter Case ): 7 Nm (0.7 m.kg, 5.1 ft.lb) 13. Install • Battery Box •...
  • Page 137 CARB CARBURETION CHAPTER 5 CARBURETION CARBURETOR VIEW ..............5-1 REMOVAL ................... 5-2 DISASSEMBLY ................5-3 INSPECTION ................5-4 ASSEMBLY ................. 5-6 INSTALLATION ................5-7 TUNING ..................5-8 FUEL LEVEL ADJUSTMENT ............5-9 THROTTLE POSITION SENSOR (TPS) ........5-10 AIR INDUCTION SYSTEM ............5-12...
  • Page 138 CARB CARBURETOR CARBURETOR PLUNGER FLOAT PIN FIXING SCREW SCREW (TOP COVER) AIR VENT HOSE FCB O-RING TOP COVER THROTTLE POSITION SENSOR FLOAT CHAMBER BODY PISTON VALVE SPRING (TPS) KIT ASSY HOLDER (JET NEEDLE) PILOT SCREW DRAIN SCREW JET NEEDLE RETAINER SPRING SPRING FCB - FIXING SCREW RING...

  • Page 139: Removal

    CARB CARBURETOR R E M O VA L 1 . Remove : • Side Covers (LH /RH) Refer to the “SIDE COVER, SEAT AND FUEL TANK” section in Chapter 3, Page No.- 3-3 2. Close • Fuel 3. Drain : •...

  • Page 140: Disassembly

    CARB DISASSEMBLY DISASSEMBLY NOTE: The following parts can be cleaned and inspected without Carburetor Disassembly. • Throttle Cable • Starter Plunger Assembly • Fuel Hose, Air vent Hose, over flow Hose • Before disassembly of Carburetor clean the outer surface of Carburettor and Check the Starter cable operator.
  • Page 141 CARB DISASSEMBLY/INSPECTION 6. Remove : • Needle Valve- ¿ Â Á 7. Open : • Main jet- À # 127.5 ¿ • Main Nozzle- Á À • Pilot Jet- Â 8. Remove : • Pilot screw Assy.¿ (With spring, washer ¿...

  • Page 142: Inspection

    CARB INSPECTION Float 1. Inspect : • Damage/Leakage Ÿ Replace Jets Screws Diaphragam 1. Inspect : • Jet Needle ¿ • Main Nozzle À • Main Jet Á • Pilot jet Â Ä • Throttle Stop Screw à  À •...

  • Page 143: Assembly

    CARB ASSEMBLY ASSEMBLY Reverse the disassembly procedure. 1. Wash • All the parts in clean petroleum based solvent • Always use new ‘o’ Rings 2. Install : • Pilot screw assembly ¿ 3. Install : • Main Nozzle ¿ Á •...

  • Page 144: Installation

    CARB INSTALLATION 8. Install ¿ • Piston Valve Assy. with Diaphragm ¿ NOTE : Hold the piston Valve Assy. with diaphragm open condition and Aligns the diaphragn match mark with carburetor mark,, Then put the pan head with spring on Top of diaphragn press the spring to same holding position of piston Valve and tighten the screw pan head.

  • Page 145: Tuning

    CARB CARBURETOR TUNING 8. Adjust : • Idling speed by Throttle Stop Screw ¿ Engine Idling Speed : 1300 - 1500 R.P.M. 9. Adjust : • Throttle Cable free play Refer “THROTTLE CABLE ¿ ADJUSTMENT” in Chapter 3, Page no 3-9 Carburetor Tuning ‘CO MEASUREMENT AND ADJUSTMENT”...

  • Page 146: Fuel Level Adjustment

    CARB CARBURETOR TUNING CAUTION: WARNING Do not disturb settings of the Carburetor if the Engine performance is O.K. • If required, must record the existing set- ting (No. of turns) of the Pilot Screw. • To counter check the setting of the Pilot Screw, follow the ‘CO’...

  • Page 147: Throttle Position Sensor (Tps)

    CARB CARBURETOR TUNING • Otherwise adjust Float level by bending the Float Tang  on the Float slightly up or down  as required. • Install the Carburetor • Recheck the fuel level • Adjust Float height through Float Tang  By Bending Down Ÿ...
  • Page 148 CARB CARBURETOR TUNING • Check/adjust the idle rpm - 1300~1500 • Remove side covers, seat & fuel tank • Check TPS input & output voltage at idling & full throttle position without starting the engine at CDI unit. • Check TPS Input voltage Make connection as below Multimeter YTPS...

  • Page 149: Air Induction System

    CARB CARBURETOR TUNING AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases 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 150 CHAS FRONT WHEEL AND FRONT BRAKES CHAPTER 6 CHASSIS FRONT WHEEL AND FRONT BRAKE ........6-1 FRONT WHEEL ................. 6-1 FRONT BRAKE ................6-2 REMOVAL ................... 6-3 FRONT WHEEL INSPECTION ..........6-4 BRAKE SHOE PLATE DISASSEMBLY ........6-5 SPEEDOMETER GEAR INSPECTION........6-5 FRONT BRAKE INSPECTION ...........

  • Page 151: Front Wheel And Front Brake

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

  • Page 152: Front Brake

    CHAS FRONT WHEEL AND FRONT BRAKES FRONT BRAKE Å Bush ¿ Brake Shoe Assy. Æ Plate Washer À Oil Seal Ç Gear Meter Á Gear drive È O-Ring  Lever Camshaft à Indicator Plate Ä Camshaft ¿ È Å À Æ...

  • Page 153: Removal

    CHAS FRONT WHEEL AND FRONT BRAKES REMOVAL WARNING À ¿ • Securely support the Motorcycle on the centre stand so that there is no danger of it falling over. • Park the Motorcycle on a level surface 1. Loosen : •...

  • Page 154: Front Wheel Inspection

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

  • Page 155: Brake Shoe Plate Disassembly

    CHAS FRONT WHEEL AND FRONT BRAKES 5. Measure : • Front Wheel runout using a height gauge Over the specified limits Ÿ Correct/Replace Front Wheel runout limits : Radial ç : 1.5 mm (max) Lateral è : 1.5 mm (max) 6.

  • Page 156: Front Brake Inspection

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

  • Page 157: Brake Shoe Plate Assembly

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

  • Page 158: Front Wheel Installation

    CHAS FRONT WHEEL AND FRONT BRAKES FRONT WHEEL INSTALLATION Reverse the “REMOVAL” procedure Note the following points 1. Lubricate : • Axle Front Wheel • Bearings • Oil Seal (lips) • Drive/Driven Gear (Speedometer) Recommended lubricant : Lithium Soap base grease 2.
  • Page 159 CHAS FRONT WHEEL AND FRONT BRAKES 5 Install : ¿ • Meter Cable ¿ À • Clip À • Brake Cable Á thru nozzle Á • Bush   • Nut WARNING Make sure that the Brake Cable and Meter Cable is routed properly.

  • Page 160: Rear Wheel And Rear Brake

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

  • Page 161: Rear Brake

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

  • Page 162: Removal

    CHAS REAR WHEEL AND REAR BRAKE REMOVAL ¿ WARNING • Securely support the Motorcycle on centre Á stand so that there is no danger of it fall- ing over • Stand the Motorcycle on a level surface À 1. Remove : •...

  • Page 163: Rear Wheel Inspection

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

  • Page 164: Rear Wheel Installation

    CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL INSTALLATION Reverse the “REMOVAL” procedure 1. Install : • Chain Adjuster in Rear Swinging fork • Rear Wheel Assembly in Sprocket Hub with spacer • Brake Shoe Plate Assembly • Spacer between Chain Sprocket and Frame •...

  • Page 165: Drive Chain And Sprockets

    CHAS DRIVE CHAIN AND SPROCKETS DRIVE CHAIN AND SPROCKETS ¿ Chain Case Å Drive Chain À Crankcase Cover 3 Æ Spacer Á Drive Sprocket Ç Driven Sprocket Assembly  Clip Chain Joint È Chain Tensioner Adjuster à Link Plate É Circlip Ä...

  • Page 166: Removal

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

  • Page 167: Drive Chain Inspection

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

  • Page 168: Clutch Hub Inspection

    CHAS DRIVE CHAIN AND SPROCKETS CLUTCH HUB INSPECTION 1. Inspect : Clutch Hub Wear/damage/cracks Ÿ Replace DRIVEN SPROCKET ASSEMBLY Á 1. Install ¿ • Driven Sprocket ¿ on Clutch Hub • Lock Washer À • Nut Á • Bolt  À...
  • Page 169 CHAS DRIVE CHAIN AND SPROCKETS 3. Install : À • Drive Chain ¿ • Chain Joint À ¿ Á • Plate Á • Chain Joint Clip   4. Install : Clip ¿ CAUTION: WARNING Be sure to install the Chain Joint Clip to the di- rection as shown 5.

  • Page 170: Front Fork

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

  • Page 171: Front Fork Removal

    CHAS FRONT FORK FRONT FORK REMOVAL WARNING ¿ Securely support the Motorcycle so there is no danger of it falling over 1. Stand the Motorcycle on a level surface 2. Elevate the Front Wheel by placing a suit- able stand under the Engine 3.
  • Page 172 CHAS FRONT FORK 4. Loosen : • Bolt Allen (Damper Rod) ¿ Loosen the Bolt (Damper Rod) ¿ while holding the Damper Rod with T-Handle À T-Handle ¿ YSST - 213 À 5. Remove : • Bolt (Damper Rod) ¿ •...

  • Page 173: Front Fork Inspection

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

  • Page 174: Front Fork Assembly

    CHAS FRONT FORK FRONT FORK ASSEMBLY Reverse the “DISASSEMBLY” procedure Note the following points NOTE : • When assembling the Front Fork be sure to replace the following parts • Oil Seal • Seal Dust • Snap Ring • Before assembling the Fork, make sure that all the components are clean.
  • Page 175 CHAS FRONT FORK 5. Tighten : • Bolt (Cylinder Complete) ¿ holding the Cylinder Complete with a T-Handle À Bolt (Cylinder Complete) : 23 Nm (2.3 m.kg, 17 ft.lb) ¿ T-Handle À YSST - 213 6. Install : • Oil Seal ¿ Using TFF Oil Seal À...

  • Page 176: Front Fork Installation

    CHAS FRONT FORK 9. Fill : • Fork Oil ¿ Oil Quantity : Overhauling - 151 ± 3 ml Refilling - 139 ± 3 ml Recommended Oil : Teleshocab Oil 10. After filling up, slowly Pump the Fork up and down to distribute the Fork Oil 11.

  • Page 177: Steering Head And Handlebar

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

  • Page 178: Removal

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

  • Page 179: Handlebar Removal

    CHAS STEERING HEAD AND HANDLEBAR 7. Remove : Lock Washer ¿ ¿ Ring Nut (upper) À Damper Rubber Á À Á 8. Remove : • Ring Nut (lower) ¿ Use a Ring Nut Wrench À À Ring Nut Wrench : YSST - 621 WARNING ¿...

  • Page 180: Steering Inspection

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

  • Page 181: Handlebar Installation

    CHAS STEERING HEAD AND HANDLEBAR 4. Install : • Front Fork Refer to “FRONT FORK” Section, Page no 6-27 • Front Fender • Front Wheel Refer to “FRONT WHEEL” Section, Page no 6-8 HANDLEBAR INSTALLATION 1. Install : • Holder Handelbar Lower ¿ •...
  • Page 182 CHAS REAR SHOCK ABSORBER AND SWING ARM REAR SHOCK ABSORBER AND SWINGARM ¿ Rear Shock Absorber À Axle Nut Á Swing arm  Tension Bar à Seal Guard 6-32...

  • Page 183: Removal

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

  • Page 184: Inspection

    CHAS REAR SHOCK ABSORBER AND SWING ARM INSPECTION 1. Inspect : • Swingarm looseness Looseness exists Ÿ Tighten the Pivot Shaft nut or replace Bushes • Swingarm up and down movement Unsmooth movement/bending/rough spots Ÿ Replace Bushes 2. Inspect : •...
  • Page 185 ELEC CHAPTER 7 ELECTRICAL CIRCUIT DIAGRAM ..............7-1 LOCATION OF ELECTRICAL COMPONENTS ......7-2 CHECKING OF CONNECTIONS ..........7-3 IGNITION SYSTEM/CHARGING SYSTEM CIRCUIT DIAGRAM ............. 7-4 TROUBLESHOOTING ............7-4 CHARGING SYSTEM TROUBLESHOOTING ............7-9 LIGHTING SYSTEM CIRCUIT DIAGRAM ............. 7-10 TROUBLESHOOTING ............

  • Page 186: Circuit Diagram

    ELEC CIRCUIT DIAGRAM...

  • Page 187: Location Of Electrical Components

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

  • Page 188: Checking Of Connections

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

  • Page 189: Ignition System/Charging System

    ELEC IGNITION SYSTEM/ CHARGING SYSTEM IGNITION SYSTEM, CHARGING SYSTEM AND TACHOMETER SYSTEM CIRCUIT DIAGRAM TROUBLE SHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE. (NO SPARK OR INTERMITTENT SPARK) Note : PROCEDURE Remove the required parts before trouble shooting. CHECK 1. Spark Plug 1) Side covers (LH and RH) 2.
  • Page 190 ELEC IGNITION SYSTEM / CHARGING SYSTEM PROCEDURE STEPS Standard Spark Plug 1. SPARK PLUG CR7HSA - NGK • Check the spark plug condition • Check the Spark Plug type • Check the Spark Plug gap Spark Plug Gap : 0.6~0.7 mm •...
  • Page 191 ELEC IGNITION SYSTEM / CHARGING SYSTEM æ Multimeter (+) lead Ÿ Black/Blue Terminal ¿ Multimeter (-) lead Ÿ Green Terminal À 3A. IGNITION COIL RESISTANCE (Primary) • Disconnect the Ignition Coil Connector From the Wire harness • Connect the Multimeter to the Ignition Coil. •...
  • Page 192 ELEC IGNITION SYSTEM/ CHARGING SYSTEM Mutimeter (+) lead ŸWhite/Blue terminal ¿ 5. SENSOR COIL RESISTANCE Multimeter (-) lead Ÿ Earth À • Disconnect the sensor Coil Coupler from the Wiring Harness • Connect the Multimeter (Ω X 100) to the À...
  • Page 193 ELEC IGNITION SYSTEM / CHARGING SYSTEM æ Multimeter (+) lead Ÿ Battery (+) terminal ¿ 7. RECTIFIER CUM REGULATOR UNIT Multimeter (-) lead Ÿ Battery (-) terminal À • Check the Charging Voltage À Procedure Steps ¿ • Connect the Tachometer to Spark plug lead •...

  • Page 194: Charging System

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

  • Page 195: Lighting System

    ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM : AC TROUBLE SHOOTING IF THE HEAD LIGHT, HI BEAM INDICATOR LIGHT, TAILLIGHT AND METER LIGHT DO NOT WORK PROCEDURE Note : CHECK Remove the following parts before trouble 1. Lighting Coil resistance shooting.
  • Page 196 ELEC LIGHTING SYSTEM 1. LIGHTING COIL RESISTANCE Multimeter (+) lead Ÿ Yellow terminal ¿ Multimeter (-) lead Ÿ Black terminal À • Remove the C.D.I. Magento Coupler from the wiring Harness • Connect the Multimeter (Ω X 1) to the Light- À...
  • Page 197 ELEC LIGHTING SYSTEM æ 4. LIGHTING VOLTAGE Multimeter (+) lead Ÿ Blue terminal ¿ • Connect the Tachometer to Spark Plug Multimeter (-) lead Ÿ Black terminal À lead. • Disconnect the Taillight coupler from wire harness • Connect the Multimeter (AC 20 V) to tail- ¿...
  • Page 198 ELEC LIGHTING SYSTEM æ 6. INDIVIDUAL LIGHTING CIRCUITS A. If the Headlight and Highbeam Indicator Light do not work 1. BULBS AND BULB SOCKETS • Check the Bulbs and Bulb sockets for continuity. NO CONTINUITY CONTINUITY 2. LIGHTING VOLTAGE Replace Bulb and/or Bulb Socket. •...

  • Page 199: Signal System

    ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM : DC TROUBLE SHOOTING IF THE FLASHER LIGHT, BRAKE LIGHT AND INDICATOR LIGHTS DO NOT WORK IF THE HORN DOES NOT WORK PROCEDURE Note : Remove the following parts before trouble shooting. CHECK 1) Side covers (LH/RH) 1.
  • Page 200 ELEC SIGNAL SYSTEM 1. FUSE Refer to “FUSE INSPECTION SECTION “ in Chapter 3, Page 3-30 NO CONTINUITY CONTINUITY 2. BATTERY Replace fuse • Check the Battery condition Refer to “BATTERY INSPECTION SEC- TION” in Chapter 3, Page 3-28 INCORRECT CORRECT •...
  • Page 201 ELEC SIGNAL SYSTEM 5. INDIVIDUAL SIGNAL SYSTEMS A. If the Horn does not work. 1. HORN SWITCH NO CONTINUITY • Disconnect the Handlebar Switch Coupler from Wireharness. • Check the continuity between the “Pink” and “Black” with switch in Pressed Position. Replace the Switch Handle (LH) CONTINUITY Multimeter (+) lead Ÿ...
  • Page 202 ELEC SIGNAL SYSTEM B. If the Brake Light does not work. 1. BULB AND BULB SOCKETS • Check the Bulb and Bulb sockets for con- NO CONTINUITY tinuity. CONTINUITY Replace Bulb and/or Bulb socket. 2. BRAKE SWITCH FRONT / REAR •...
  • Page 203 ELEC SIGNAL SYSTEM C. If the flasher light and/or turn indicator light fails to blink. 1. BULB AND BULB SOCKET • Check the Bulb and Bulb Socket continuity NO CONTINUITY CONTINUITY 2. TURN SWITCH Replace the Bulb and/or Bulb socket •...
  • Page 204 ELEC SIGNAL SYSTEM æ Multimeter (+) lead Ÿ Brown/White Terminal ¿ 4. FLASHER RELAY Multimeter (-) lead Ÿ Black Terminal À • Connect the Multimeter (DC20V) to the flasher relay coupler • Turn Main switch to ‘ON’ • Check for voltage (12V) on “Brown/White” ¿...
  • Page 205 ELEC SIGNAL SYSTEM D. If the neutral indicator lights fails to operate. 1. BULB AND BULB SOCKET • Check the bulb and bulb socket for conti- nuity. NO CONTINUITY CONTINUITY Replace the Bulb and/or Bulb Socket 2. NEUTRAL SWITCH • Disconnect the neutral switch lead. •...
  • Page 206 TRBL SHTG CHAPTER 8 TROUBLE SHOOTING STARTING FAILURE/ HARD STARTING ........8-1 POOR IDLE SPEED PERFORMANCE ........8-2 POOR MEDIUM AND HIGH SPEED PERFORMANCE .... 8-2 POOR SPEED PERFORMANCE ..........8-3 CLUTCH SLIPPING / DRAGGING ..........8-3 FAULTY GEAR SHIFTING ............8-4 OVER HEATING .................

  • Page 207: Starting Failure/ Hard Starting

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

  • Page 208: Poor Idle Speed Performance

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

  • Page 209: Poor Speed Performance

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

  • Page 210: Faulty Gear Shifting

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

  • Page 211: Front Fork Malfunction

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

  • Page 212: Faulty Signal And Lighting System

    TRBL SHTG FAULTY SIGNAL AND LIGHTING SYSTEM FAULTY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DIM FLASHER BLINKS SLOWER • Improper Bulb • Faulty Flasher Relay • Too many electric accessories • Insufficient Battery capacity (nearly dis- • Hard charging charged) • Faulty rectifier/regulator •...
  • Page 213 YAMAHA MOTOR INDIA PVT. LIMITED 19/6, Mathura Road, Faridabad - 121 006 INDIA PRINTED IN INDIA 5YY (FAZER) 1Y16(WM-01)-204-10-04-E...

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