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1. Turn the change cam cam with hand to make sure that the driving and fork is smooth in operation 4 48 on Assembling and adjustment of engine P 1 Left crankcase 2 Dowel pin 3 Airflow pipe 4 Right crankcase 5 Clutch fastening clip Cu Assembling and adjustment of engine 4 50 Crankcase Right 1 Application e Seal gum Apply to the linking surface of left and right crankcase Seal gum Yamaha bonder No 1215 90890 85505 Note Never allow any seal gum to enter into the lubricati on oil hole 2 Installation Dowel pin 3 Installation Install the right crankcase to the left crankcase N ot L Before installing and fastening the fastening screws of cranrcase be sure to turn the shift cam with hand to check if the transmission functions normally 5 Fastening e Screw crank case Note From the screw marked with the Minnumber tighten up the screws orderly 6 Application e Engine oil of 4 stroke engine Apply to the crankshaft pin bearing and crankshaft hole 7 Inspection e Action of crankshaft and transmission The action is not smooth repair Assembling and adjustment of engine 4 Shift shafl pedal spindle and pedal idle speed gear Shift shaft Circlip Reset spring Washer Retainer Idler pulley Tortion spring Washer Star wheel 11Circlip Start shaft assy
2. 3 26 Periodic inspection and adjustment Periodic inspection and adjustment Brief introduction This chapter ineludes all information necessary to perform recommended inspections and adjustments These preventive maintenance procedures if followed will ensure more reliable machine operation and a longer service life In addition the need for costly overhaul work be greatly reduced This information applies to machines already in service as well as new machines that are being prepared for sale All service technicians should be familiar with this entire chapter Contents Items Routine 1 000 600 or 1 month Check valve clearance adjust if necessa Spark plug Check condition clean or replace if eee Air filter Clean replace if necessary NS Comet Check idle speed starter operation ee adjust if necessary Fuel line Check fuel hose for cracks or damage k replace if necessary Engine oil Rejbace warm engine before draining a Oil filter Clean or replace EN Front brake Check operation brake fluid leakage refer t the HOM Mes remarks Adjust if necessary Check operation Adjust if necessary EE Clutch Check operation adjust if necessary mM Rocker ann vin Check swing arm assy for looseness tig ten if necessary Repair if damaged ear suspending affaheck operation Disassemble to repair if fuleram necessary Check the bearing for looseness repair if Wheel ecessary Disassemble to repair every 12 00D
3. YBR125 JYM125 125 2 Chongqing Jianshe YAMAHA Motor Co Ltd First edition Jan 2003 All rights reserved Copy in any manner in whole or part or use without written authorization of company prohibited Notice This service manual compiled by ChongqingYAMAHA Motor co Ltd is specially used for dealer and maintenance station of Chongqing Jianshe YAMAHA Motor co Ltd It is not possible to include all the knowledge of a mechanic in one manual it is only used for repairing and maintaining JiansheYAMAHA motorcycle and understand the principle of vehicle procedure of maintenance as well as technology of maintenance If without the knowledge on this field the improper ass embly and dangerous condition occaft amp assembly would be happened when repairing the motorcycle Chongqing JiansheYAMAHA Motor co Ltd is continually striving to improve all its models Modifications and si gnificant changes in specifications of procedures will be forwarded to all authorized dealers and will appear in future editions of this manual where applicable Note Design and specification are subject to changes without notice Important Information Particularly important information is distinguished in this manual by the following notations A The safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLED Failure to follow WARNING instructions could result in severe injury of death to the vehicle operator a bystander or a person inspecting
4. Camshaft with bearing Note Disassemble the camshaft with 8 mm bolt 3 Disassemble Rocker shaft e Rocker arm Note Disassemble the rocker arm with sliding hammer bolt and weight block Sliding hammer bolt 90890 01083 Weight block 90890 01084 Disassembly of engine Valve Note Before disassembling the inner parts of cylinder head such as valve valve spring and valve seat check the seal of valve firstly 1 Check e Seal part of valve Leakage of valve seat Checing working face of valv Valve seat and width of valve Refer to section of Check and repair of valve seat Teck k K K k kK k k K k k RK K k K K K K K K K Rk K K kK K k K z K k k K K K K K R K EK Checking procedures e Inject the clean solvent into intake orifice and exhaust orifice Check the seal of air valve There should be no leakage at valve seat OK OK 2K 2K 2K 2K KE 2K KE OK K OK OK OK OK OK OK OK OK OK OK OK OK OK K OK OK OK OK OK K OK K KKK K K K K K OK K K K 2 Disassemble e Lock piece of valve Note When disassembling valve lock piece compress the valve spring with tool Compressing tool of valve spring 90890 04019 Disassembly of engine 3 Disassemble Upper seat of air valve spring e Air valve spring Air valve Oil seal of air valve e Spring Note Mark postions of each part in order to refiting them to oringinal position Check and
5. LUL4 EA ka 7 tm Ci 3 HALO bh PA2h gt RBAL i AFORLERALET PR PERS ee ERPS ES ER b z S e UXkLEULBPsaTismsi pv XM Stes ice ee Lo HT ePake gt dt CO MMA ee H EUXRL ELT S QEWA FUTT CENE EAL EHMAESicoIiEELTUEM ATE we Fakes SOOO Be EXRLULJqEAL L HYOMACERHLET DEA Y B d VAR ULfOf It CHA rok NU rur A prie PAb gt L HTOXSMtLIIT BETET ORE EE Loi i 2 HrponBtLTT eee BULBRFF UPEMMLT KEARSE a heed De zi Pik FOR AO E Pi Vabre EhLos4 kgu oc uii racist USES Sieg eee EELE a ELT CARES Fey b NnLoS4zHBm aii aL J C Pye Ff 0 F Lb E led XT DGeneral information Specification Periodic inspections and adjustment Engine Cooling system Carburetor Chassis 8 Electrical system Troubleshooting Maintenance with engine installed D Filling fluid I2 Grease 13 Special tools I2 Tighten torque q5 Wear limit clearance 16 Engine speed v Stipulation for resistance voltage and current I5 YAMAHA engine oil I9 YAMAHA gear oil Q0 YAMAHA molybdenum disuflide oil Wheel bearing grease B Q2 Lithium soap base grease Q3 Grease with molybdenum Thread sealing agent Q3 Replace new parts when reassembly Index 1 General informatio 2 Specification 5 3 Periodic inspection and adjustment COD Co 4 Engine 5 Carburetor 1D
6. Rear wheel nut 3 Removal e Rear wheel axle bushing Note S When removing the rear wheel axle the bushing will fall down Be careful not to lose it 4 Removal e Rear wheel Rear brake Note When removing the rear wheel axle the clutch hub will fall down Be careful of safety 6 12 Inspection of front and rear wheels CHAS 5 Removal e Shock block If damaged deformed replace Rear brake hub 1 Inspection nner surface of brake drum Oil stain or scrape repair Oil stain Wipe a cloth dipped in the paint diluent or C NC SS p J solvent NW Vis e Scrape Poslish slightly and evenly with a emery cloth Brake hub inner diameter Standard value 130mm Limit value 131mm 2 Measurement e Brake hub inner diameter a Out of specification replace 6 13 Inspection of front and rear wheels CHAS 3 Installation Rear wheel Note The convex part of clutch hub should be inserted into the groove of the shock block 4 Installation e Rear wheel axle Fastening rorque of rear wheel axle 9 1 Kgf m 91 N m 6 14 Drive chain and sprocket CHAS BH Rear drive chain Sprocket cover1 Small sprocket drive Chain press plate Connector of chain Chain drive chain Big sprocket driven Adjuster assy Circlip Retaining press plate Drive chain and sprocket CHAS 6 16 Removal 1 Rest the motorcycle on the c
7. After each grinding wipe off the sanding agent on working face of air valve and air valve seat e Measure the air valve seat width again f the air valve width exceeds specified value repair and grind air valve seat jk ck k k ok ok OK oe oe ok ok o oec o o k o k aie k oe k k S ie o k k o kK oie okt ok coe oe ok ok x Check and repair Air valve and guide pipe of air valve 1 Measure Clearance between air valve rod and guide pipe Clearance between air valve and guide pipe Inner diameter of air valve guide pipe air valve rod diameter Exceeding specified value range Replacing guide pipe of air valve Clearance between air valve rod and guide pipe Intake 0 01 0 037 mm Limit valve 0 08 mm Exhaust 0 025 0 052 mm Limit valve 0 10 mm SEM Using limit 5 000 5 012mm 5 042mm 9 000 5 012mm 5 042mm Note After replacing guide pipe of air valve repair the sur face of air valve seat 2 Clean e Carbon deposit clean from working surface of air valve Check and repair 3 Check e Working face of air valve Corrosive pitting or wear polishing the surface Air valve rod end Mushroom shape or diameter more than other part of air valve rod replacing 4 Measure Run out tolerance air valve rod Exceeding specified value range Replacement Run out tolerance Less than0 01 mm Air valve spring 1 Measure Free lengtkKLa air valve spring Exceeding
8. Note Eject and push piston ring with piston to make the ring vertical to cylinder surrounding Check and repair 3 Measure e End clearance Note When measuring the oil ring end clearance do not measure at parting slip of cup ring of oil ring Only can measure the end clearance of upper and lower guard rails If the clearance is too large replace all the three rings End clearance 1st ring 0 15 0 30 mm Using limitation 0 4 mm 2nd ring 0 30 0 45 mm Using limitation 0 55 mm Oil ring 0 2 0 7 mm Crankshaft 1 Check e Runout tolerance of crank Runout tolerance limitation of crank 0 03 mm Exceeding limitation Replacement Note Rotate the crankshaft gradually to measure 2 Check e Side clearance of big end Standard side clearance 0 15 0 45 mm Using limitation 0 8 mm Exceeding limitation Replacement Check and repair 3 Measure e Crankshaft width measure with square calliper Standard width 46 95 47 00 mm Exceeding standard Replacement 4 Check e Sprocket of crankshaft Damage wearing Replacing crankshaft e Bearing Abnormal noise unstable rotation loosening Replacing 5 Check Oil way of crankshaft Jamming gt Clean by compressing air Check and repair Balance device 1 Check e Driving gear of crankshaft Driven gear of balancer Wearing damage Replacement 2 Check e Balancer Wearing damage Replaceme
9. Obvious buckle or bending of electrode plate of insulator Note 2 LL4AA9 To new battery the primary charging must be cond ucted before using to assure its best performance and service life The battery electrolyte is damgerous lt contains sulpharic acid which is poisonous and corrosive Must obey following preventing measures e Avoid to contact electrolyte because it will cause serious burn and permanent damage of eye e Protect your eyes when operating or working near battery 3 28 Check of battery Method for detoxication external Skin Wash with water Eyes Wash with water for 15 minutes and see a doctor immediately Method for detoxication internal Drink plenty of water of milk Then take oxidized milk with egg or rapseed oil and see a doctor immediately The battery will produces explosive gas Following protecting measures must be taken Conduct chatging at ventilated place far away from welding equipment lighting cigaret etc Do not smoke when charging or work at battery The battery or electrolyte should be placed far away from children Chapter 4 Disassembly of engine Disassembly of engine Disassembly of exhaust pipe and lead Wire c cece cece c ec ee eee ee rekr netrn eases mI m meme emnes des Disassembly of carburetor clutch cable speedometer cable and driving chain sess qeu Disassembly of CNGING
10. Special tools Special tools in maintenance Use proper special tools to check adjust disassemble and install so as to avoid machinery damage Name of tools use 90890 01084 90890 01135 90890 01274 90890 01275 90890 01278 90890 0408 1 90890 01294 90890 01326 90890 01311 90890 01312 90890 01362 90890 01367 90890 01368 Removing tool for rocker arm Removing bolt for rocker arm shaft Weight Removing tool for crank Tools for separating crankcase and crank Combination sleeve Dfor crank Combination bolt for crank Joint of different diameter tube Spacer of crank Tools for combining crank and crankcase Shock absorber bar fixtare T shape holder Slide stopping tool in disassembling amp reassembling cylinder of front fork Air valve adjuster Adjusting tool for air valve Fluid level meter Tools for measuing oil level of carburetor Removing tool for rotator Removing tool for rotator Installing tools for oil seal of front fork Installing tools for oil seal CD Installing tools for oil seal 1 5 Special tools in maintenance Name of tools use 90890 01268 90890 01403 90890 01701 90890 03079 90890 03081 90890 04082 90890 03112 90890 03113 90890 04019 90890 04086 90890 06754 Tools for reasembling disassembling nut of steering shaft and exhaust pipe Tools for reassembling and disassembling nut of steering shaft Torque spanner
11. cc cece cee ee ec ee eee III I I meme heme e nemen heme sre e she ese rese ese esee ns 4 2 Disconnectin of engine ssssssssssssssssesss eI Ie Ie me he he he ee he re ee n esi se se se re re renes 4 3 Disassembly of cylinder head cylinder and piStOn c cece eee ee cece eect eee Immer red Bassembly of starting motor clutch and oil pump sssssssssssssssssssss s ese nsns 4 7 Disassembly of starting axle and idle Geal 0 cece cece cece cence eee eee n ceca tense Im I me me sr enses 4 10 Disassembly of shift BIB cux oam ea dx e Eug ona com UE ER URDU EROR HU DX LU Ee paced DRE cU DE MR POENI ARR t DisassemDIy Of r9 lio eserse encase csc snc ee DEI 4 11 ISCOMMECHOMN of Chalk Case sercis e e Ee aeaa TRA 4 12 Disassembly of balance device transmission and shift rod lues 4 19 Disassembly OF crank balalce DIOBR cose sese oa PUT PC ETERVE EIE siradan bnn TEES Fu REEVEFE YO Pr PIAFERKAE MU OR ENS deque Disassembly of swaying armam axle ceo eile Recu nac ke aaa ex ak aces alm EAS RR Ape aalReEdas 4 15 Disassemblyof air valve sssssssssssssssssssessse eee e me me me ne he he ee ee ees sss sess se te re resin 4 16 Cheek and repair Cylinder head MERE T EEE EEE 4 18 PII VAING GOAL er a E S a Er E PIA UEPLEPR PUER EG DES 4 19 Air valve and guide pipe of air ValVe 0 cece ccc ence cence cece een n ee ence ena e senate ena
12. Wear or damage Replacement 3 Check e Guide rod of shifting yoke short on left long on right e Shift cam Deformation scratch wear damage Replacement 4 Check e Action of shifting yoke Uneasy action Replacing shifing yoke or guide rod Do not try to align the bending guide rod Check and repair 5 Measure e Run out tolerance driving axle and main axle Exceeding specified value range Replacement Do not try to align bending axle 6 Check Gear teeth of gear Blueing corrosive pitting wear Replacing matching gear Rounding of edge fracture dislocation Replacement 7 Check e Shift axle Damage bending wear Replacement e Torsion spring retainer lever e Reset spring reset axle Damage Replacement f 5 Check and repair Kick starter 1 Check Teeth of kick starter gear e Teeth of kick starter over gear Damage or wear Replacing two gear by pair 2 Measure Tension of work carrier of kick starter Exceeding specified value range replace to Use spring balance Tension of work carrier of kick starter 0 8 1 2 kg Engine oil pump and oil filter 1 Measure Gear tip clearanceA Between inner rotator and outer rotator eSide clearance B Between outer rotator and pump case Exceeding specified value range Replacing oil pump e Clearance C of outer amp inner rotator and pump case Thickness difference of inner amp outer rotator a
13. e oosen the screw at position as shown in Fig po sition in circle e Firstly loosen each screw 1 4 turn then remove all screw e f there is several bolts and nuts generally loosen them according to opposite angle order Loosening order from outside to inside Eg 4 Disassembly of engine 2 Disassemble eStar shape gear ocating pin Note Disassemble the crankcase from right side e Disassemble the shift cam star shape gear Be careful not to damage the matching surface of crankcase Balance device transmission and shift rod 1 Disassemble e Guide rod of shifting yoke short Guide rod of shifting yoke long Shifting yoke C Shifting yoke R Shifting yoke L e Shift cam Disassembly of engine 1 Disassemble eMain axle e nner pushing rod of clutch 2 eDriving axle eWasher ePushing rod of clutch 3 Disassemble e dle switch Disassembly of crank and balance 1 Disassemble Balance block eCrank Disassemble with disassembling tool of crank Disassembling tool of crank 90890 01135 Note LC e Tighten up the supporting bolt of disassembling tool but ensure the tool body vertical to crank When nessary screw a screw back ward a little to ca librate the tool body state Never beat the crank directly with hammer etc Disassembly of engine Rocker arm and camshaft 1 Disassemble e Lock pressure plate 2 Disassemble
14. liner of brake pad 4 Installation e Driven gear of meer e Installing meter cable Speedometer cable head 5 Installation e Brake assy Note The convex part on the inner side of the gear assy should be engaged with various surfaces each other the concex part of hub amp Should be jammed into the clutch 6 6 8 Inspection of front and rear wheels CHAS Installation of front wheel 1 Installation Front brake cable Meter cable e Nut front wheel axle 2 Installation Front wheel Note The convex seat on the front fork should be engaged with the locating slot of the brake padplate correctly 3 Cable e The action of brakepad If the action is not smooth repair Nut torsgue 3 5 5 6kgfm 35 56N m 4 Installation Meter cable e Clip When installing the meter cable don t bend it 6 9 Inspection of front and rear wheels CHAS Rear wheel Driven chain gear Adjusting nut Rear wheel Pin Spring Rear brake assy S plit pin Q3 Shock absorber Tension rod 42 Oilseal Self locking nut 43 Bushing Bearing Chain adjuster assy 9 1 Kgf m 91 N m Inspection of front and rear wheels CHAS Rear wheel Brake shoe Brake arm Indicator Cam axle 6 11 Inspection of front and rear wheels CHAS Rear wheel Rest the motorcycle firmly so as to avoid it turn over 2 Removal Adjusting nut e Tension rod e Nut Spring e Brake pull rod
15. replace MEN Do not attempt to straighten the bending handle bar otherwise it will decrease the operation function of the handle bar causing danger 6 29 Steering axle and handle bar CHAS 6 30 Inspection of front steering axle 1 Clean the roller holding bracket and bearing race 2 Inspection e Roller holding bracket Bearing race Worn damaged replace kkkkkkkkkkkkkkkkkk kkkkkkkkkkkkkkkkkkkkkkkk Procedres for replacement e As shown on the fig remove the bearing race with a lon rod and hammer take it out from the cencave groove of fork pipe of steering joint e As shown on the fig remove the bearing race of steerin rod with plain chisel and hammer Install the new dust seal parts roller holding bracket and bearing race kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Note e The roller holding bracket bearing race and dust seal parts are always replaced as a complete set f the roller holding bracket and bearing race are installed at a slant the frame will be worn so install them in horizontal condition Never beat the roller and rod surface Installation of steering axle Conduct installation according to the reverse procedures of Removal 1 Oil filling Roller holding bracket upper and lower Bearing race Lithium base lubrication grease 2 Installation Ring nut lower Ring rubber pad Ring nut upper Limit clip Conduct adjustment after installing th
16. then install the bolt of cushion into every hole seperately finally tighten the nut Bolt torque see fig 1Kgf m 10N m Inspection and adjustment of air valve clearance AD ES Engine Inspection and adjustment of air valve clearance Note The valve clearance must be adjusted when the engine is cool Adjust the air valve clearance when the piston is at the Top Dead Center T D C on compression stroke 1 Remove the following parts Side cover left right Cushion Fuel tank Refer to removal and installation of cushion fuel tank and cover alike 2 Remove the following parts Side cover of cylinder head bolt e Spark plug Rocker arm cover Intake e Rocker arm cover Exhaust 3 Remove the following parts Cock with O ring Cock with O ring Inspection and adjustment of air valve clearance 4 Turn the rotator counter clockwise align the T D C mark of rotator with the T D C mark b on the cran kcase cover 5 Conduct the following inspection e Air valve clearance Standard air valve clearance IN 0 08 0 12 mm Ex 0 10 0 14 mm Conduct adjustment for the valve under standard value kkkkkkkkkkkkkkkkkkkkkkkkkkkkkk kkkkkkkkkkkk Adjusting sequence e Loosen fix nut e Insert feeler gaug amp Q Install the air valve adjusting tool on the adjuster Air valve adjusting tool 90890 01311 Turn the adjuster util the standard value is obtained To avoid the
17. 1 3 2 4mm C seat width IN 1 2 1 4mm EX 0 9 1 1mm D margin thickness IN 0 4 0 8mm EX 0 8 1 2mm Valve stem outside diameter IN 4 075 4 000mm 4 950 EX 4 960 4 975mm 4 935 D ud Guide tube inside diameter Valve stem to guide tube clearance Valve twist limit Valve seat width Valve spring Free length Set length valve closed Spring compressing force Direction of winding Piston Piston clearance Piston outside diameter D Measuring place H Inside diameter of piston pin hole Outside diameter of piston pin hole Clearance between piston pin and hole Piston ring First ring Shape Size B T Split clearance installed Side clearance installed Second ring Shape Size B T Split clearance installed Side clearance installed Oil ring Size B T Crankshaft Crank width A Runout limit C Big end side clearance D Clearance of big end diameter Transmission Main shaft deflection Drive shaft deflection Inspection specification Standard value 5 000 5 012mm 5 000 5 012mm 0 010 0 037mm 0 025 0 052mm 1 2 1 4mm 0 56 1 64mm 39 62mm 25 6mm 132 236N RH 0 02 0 034mm 53 997 54 028mm 4 5mm 15 002 15 013mm 14 99 15 000mm 0 002 0 022mm Drum type 1 0 2 1mm 0 15 0 30mm 0 035 0 07mm Trapezoid 1 0 x 2 1mm 0 30 0 45mm 0 02 0 06mm 2 05 2 25 46 95 47mm 0 03nm 0 15 0 45mm 0 095 0 073mm S
18. 2 8 18 28 Tighten torque 2 For noraml tighten torque tighten screw and nu can decide tighten torque according to diameter of thread width of two faces and space of thread except appointed tighten torque see the table n the right side Width of two faces x Da ad i Pitch of thread Dia of screw width of two faces vishrendorad x Space of thread g q M5 8mm x0 8 34Nm 0 3 0 4kg m M6 10mm x1 0 5 8Nm 0 5 0 8kg m M8 12mm x1 25 12 19Nm 1 2 1 9kg m m M10 14mm x1 25 24 39Nm 2 43 9kg m M12 17mm x1 5 45 72Nm 4 57 2kg m Tioht F st 1 Tight the nut of to30 35N m 2 Then turn the steering bar 2 3 times by leftward and rightward In turing binding and loosening of bearing race is not allowed 3 Loosen nut of by1 4turn and then tighten it with tighten toque of 20 24N m 4Turn the nut of to close to flat washer of 5Put the special washer and stop pawl of into groove of nutof and fitis not aligned with groove turn the nut of to ensure the alignment Position to be applied lubricant Position to be applied lubricant Engine 8 a ales 1 MM 3 Boimereve ooo 9 Ce meeamensum id u wem BB ieseana BB Position to be applied lubricant DET NN wn Se ee TRA a TER Le Gmemesuesee ime MBA ee TER Ce Gmemesemecemseuees TM Cr weewemeaeeeenam MBA ee nrc NL DECUIT NN ee wu we 0000 e y o ommen o TMBME De memeesensen
19. 23mm 0 06 O 10mm 0 1 4mm 0 06 0 10mm 0 1 4mm Ball bearing with holder mE 120mm 337mm 330mm 154 5em 156mm 10W or equivalent 0 2mm 90mm 239 5mm 235mm Spoke die casting 18x 1 60 W Steel belt alluminium alloy Inspection specification 9 Rear wheel TS Spoke casting wheel Rim dimension Rim material 1 85x18 W Rim runout radial lateral Driving chain Type manufacturer DID1480H No of links 118 Twist quantity 20 30mm Front brake Type Disc brake Disc outside diaxthickness 245x4 Use limit of disc thickness Thickness of brake pad Inside Outside Master cylinder inside dia o 12 7mm Long pincers cylinder inside dia p 35mm Appointed brake fluid DOT3 or DOT4 Type Drum type Inside diameter of brake drum 130mm Thickness of brake shoe 4mm Free length of brake shoe spring 36 5mm Rear brake Type Model of brake drum Drum type Inside diameter of brake drum 130mm Thickness of brake block 4mm Free length of brake shoe spring 36 5mm Brake lever and brake pedal Free play of front brake 5 5 10 5mm 10 15mm disc drum Free play 20 30mm Clutch lever Clutch lever free play 10 15mm Inspection specification Ignition system Ignition timing B T D C Advanced timing Advancer type Electrical C D I CDI magneto Pickup coil resistance color 290 330 0 20 C Red white Ignition charging coil resistance color 810 20 Brown green Ignition coil Primary winding re
20. 31 Rear shock absorber and rear atm sess nnn 6 32 sino TT P A 6 33 TAS SC OID E E dace E S TES E A E SA T O EE EEA 6 33 Chapter 7 Circuit General drawing OF CirCUIt cvs cnsdeacnsdncdwcuaenreebadeadserexacchraeinewiesiceueeuaese reid s aM E 7 1 zeige pte OMG AIS TIT T tees AEAEE E 1 3 inspection of socket COF II GE OI escaitieniccicc ce casecrsiesccusdenocunsswacedmemeceunstwcameseeneeicudins 7 5 Inspection of SWIG RERO 7 6 TAI TIOW SY SU caede cea E E MRPPSRRU IRE MAU SUME ME ODE NUMINUM NEU MM EEE 7 8 SLANG SY SLC Meese A E AE A EE E A E E E 12 ejr UIS 9 WIV LON NR T RTT 17 Charge Suslellfenseserieptestmepsot epi ux Rd SUN EA DN S terr Tapa Mor Papin A PNG IRUUAG SY ii cian APRI TET TESA EEN ETUR EEE ETEEN 26 Signal Sy SIGMA cete cra rer ESe eov boP Pereira boot dvel PT E roo Potete rd epe UbDE 31 Chapter 8 Troubleshooting Troubleshooting of engine Chapter 1 General information Motorcycle identification PEREAGRENEEES he ae tee ee BINE E Motorcycle identification code 1 Points for attention in maintenance opecial tool n Mee 5 Motorcycle identification General information Motorcycle identification Motorcycle identification code Motorcycle identification code is stamped on the right side of steering bar It consists of three portions First portion the first 3 digits is the identification code
21. 4 51 Assembling and adjustment of engine Ae O Q Os Jo ez Tou 4 52 Shiftcam 1 Installation e Dowel pin 2 Installation e Star wheel Note mem When installing the star wheel pay attention to install the pin hole on the star wheel and the pin hole a on the cam correctly 3Installation Retainer e Spring Bolt Retainer 1 0kgf m 10Nm Note The retainer and the shift start wheel should be eng aged each other 4 nstallation eShift shaft Note When installing the shift shaft be sure to jam the tortion spring on the dowel pin Assembling and adjustment of engine rg COL mT OPS 4 53 Pedal shaft and pedal idle speed gear 1 Installation e Drive shaft e Hoop e Spring Note __ The projecting part should be installed on the a po sition of crankcase and the fastening of spring should be down only after it turns 1turn 2 Installation Circlip Washer e Idler pulley Washer e Circlip Assembling and adjustment of engine Clutch oil pump Spring Clutch hub 13Drive gear 19Paper pad of oil Press plate Retaining washer 140il filter Push plate Main driven gear 15Dowel pin Push rod Steel ball 16Drive gear of oil pump Friction liner 11Push rod 17Drive gear of oil pump Clutch plate 12Push rod assy 180il pump case 454 Assembling and adjustment of engine 4 55 Oil pump 1 supplement of oil e 4 stroke
22. 6 Chassis S 7 Electrical system 8 Troubleshooting E OO GEN INFO Z 77 1 Go ADJ r Z Q I zd On CA JJ CHA ELEC D r q p TRB SHT Chapter 1 Chapter 2 Chapter 3 General information Motorcycle identification Motorcycle identifcation code Points for attention in maintenance sss RI Rr rrr Special tool Specification Main specification Inspection specification Electrical system Main tighten torque SpeCifiCatiOn 0 cece cece e eee e eee eee acne ee nm mmn Position to be applied lubricating oil and kinds of lubricating Oll cccceee eee e eee Engine lubrication diagram Layout of cable pipeline Periodic inspection and adjustment Brief introduction Contents of periodic INSPECTtION 0 cece cece cece cence eeeeeeeeeeeeeeeees Removal and installation of cushion fuel tank and cover alike Inspection and adjustment of alwe ClEArANCE 0 ccc cece cece e cece ence eeeeeeeaeeeeaeeeeaees Adjustment of idle speed Drainage Check and adjustment of free play of throttle cable susuuuesue Check of spark plug Check of compression DNCSSUN xiii cn ct ca tetcnsccadees cage atte XP UsUe es ud se Ee ss De qdE sta MES Check of lu
23. 8 000 or 12months if appropriate Wheel bearing Check bearingassembly forlooseness da Replace if damaged Check the balance damage runout tighten sp repair if necessary Front fork Check operation oil leakage Repair if nece ear shock absorb r amp heck operation oil leakage Repair if weh Steering bearing O O O Items Routine 1 000 600 or 1 month Check TT ndo Adjust if necessary TT ndo and lubricate T Check all chassis fittings and fasteners Fittings fastenerS Correct if necessary Main and side stan l Check operation Repair if necessary eden chain Check prior to driving Check specific gravity of electrolyte Check breather Battery for proper operation Correct if necessary It is recommended that these items be serviced by YAMAHA authorized service station or dealer Heavy duty or medium truck wheel bearing grease Lithium soap base grease Remark Replace brake fluid 11f disassembling brake master cylinder or long pincers cylinder the brake fluid must be replaced Check the under normal conditionand refill if necessary 2 The oil seal of brake master cylinder or long pincers cylinder must be replaced every two years 3 The brake hose must be replaced every 4 years or immediately if any crack or damage is found Periodic inspection and adjustment AD Re Removal and installation of cushion fuel tank and cove alike 1 Side cover left Open with the key then pu
24. VAINO eere E 4 40 Swaying arm Calne hearts sce cenecerenatrotemmesoneqtenenevares 4 4 Crank palanca te VIGBiuascepeide sits nentes eunin Eina Ed ER UE E 4 43 Bane SO RR D ee ee 4 45 Shift cam shifting yoke eee s 4 46 AAKG IOO een ee ee 4 40 Shift axle starting axle idle g ar 0 eee 4 5 Cuch endine ol Moll ee ee ee ee eee 4 54 Timing pheunmalleSusteldieeusopoiu n nenep t eee eee renee ee 4 59 Rotator starting chain guide plate idle pulley 4 60 Piston and piston ring T 4 6 Cylinder and piston ccceceee cece eee eee eee ee eee eae ener reni 4 63 easi 4 64 Cam axle and locating KG yoeteson pde tas ades qudd qx Tode Cr ROpros E riei 4 65 Disassembly of engine Thorough repair of engine Disassembly of engine 1 Disassemble e Side cover Cushion e Fuel tank Refer to section of Disassembly of cushion fuel tank and side cover Engine oil 1 Oil draining Engine oil Refer to section of Replacement of engine oil in Chapter3 Exhaust pipe 4 1 Disassemble e Exhaust pipe e Fixing bolt Carbauretor 1 Disassemble Carburetor Cable and guide wire 1 Disconnect Guidewire of neutral switch Guidewire of stator coil e Guidewire of charging coil Guidewire of pulser coil Disassembly of engine 3 Disconnect Guid wire of
25. adjuster turn together fix the adjusting tool before locking the set screw Locking torque of set screw 7 5Nm 0 75kg m Confirm the air valve lf it is out of standard value readjust it Idle speed inspection adjustment NSP 3 ADJ Idle speed adjustment 1 Start and warm the engine for several minutes 2 Install the following parts e Rpm meter of engine nstall Rpm meter of engine on the wire of high pressure spark plug wire Rpm meter of engine 90890 03113 3 Confirm the following items e Standard idle speed rpm Standard idle speed rpm 1300 1500rpm Adjust if out of standard value 4 Conduct the following adjustment e Standard idle speed rmp Adjusting sequence Turn the P S adjusting screw to the end slightlg Note Do not lock it tightly Ratate to standard rpm turns Standard rpm turns of P S adjusting screw 2 0 Start the engine Rotate idle speed adjusting screw leftward and right ward until the standard idle speed rpm turns are obtained Screw in ncrease the engine Screw off Decrease the engine speed Drainage and adjustment of freeplay of throttle cable AD Re 5 Remove the following parts e Rpm meter of engine Adjustmehof co content at idle speed 1 Install the following measuring meter measuring meter with detector for normal temperature and rpm meter of engine 2 Warm the engine until the oil temperature reachs to s
26. amp 6 68 G0 Press down the horn CD Flexible shaft of speedometer Q Guide frame of cable 3 Guide frame of cable A Fix the wire of handle bar switch and clutch switch 2 19 Disc type with fairing L 2 N p m9 ER MSS Layout of cable pipline DGuide frame of cable at the right side of headlight support 4 Brake cable for condition of cable see next page in fig A Guide frame of cable at the left side of headlight support Clutch cable for condition of cable see next page in fig A 3 Throttle cable 6 Cable A Pass the flexible shaft of speedometer through guide frame Disc type without fairing are i ws a ot Y ee CUA Conditions with fairing DWire of right turning light A To headlight C Band the main cable and fairing Z Wire of left turning light B After connecting the cable band them support at this position and cut the at this position and cut the spare portion spare portion Disc type with fairing Layout of cable pipline spec i Wire of front brake switch Wire of left turning light Brake cable Wire of clutch switch Wire of right turning light Wire of left handle bar switch Throttle cable Clutch cable Wire of right handle bar switch Chapter 3 Peridoc inspection and adjustment Brief introduction Contents of periodic inspection e 3 1 Removal and installation of cushion fuel tank and cover alike nn 3 3 Check and adjustment of air valve cl
27. and high beam indicator of headlamp are not lit 1 Bulb and socket Check if the bulb and socket are conducted J Conduction Replace the bulb or socket No conduction 2 Voltage Connect Min multitester DC20V to branch connector of headlamp and to that of indicator Headlamp Positive guide wire of multitester Yellow or green guide wire Negative guide wire of multitester Black guide wire High beam indicator of headlamp Positive guide wire of multitester Yellow guide wire Negative guide wire of multitester Black guide wire D When the dimmer switch of headlamp lies in lowe beam poisition D When the dimmer switch of headlamp lies in high beam position Turn the switch to ON Out of normal value Turn the garden light switch to ON Turn the dimmer switch of headlamp to HI or LO Check if the voltage of socket connector between the green and the yellow wire gets to 12V Poor lagout from main switch to the socket yes normal valur 12V This circuit is normal The repair is needed 2 The instrument light is not lit No conduction 1 Bulb and socket Check if the bulb and the socket are conducted Conduction Replace bulb or socket 1 29 Lighting system 2 Voltage Connect min Multitester DC20V to the branch connector of socket Positive wire of multitester Yellow binding post Negative wire of multitester Black binding post Tu
28. cdenesenwesttnedenesiecseeenax Air valve spring CambshalfL ee Rocker arm and rocker arm shaft sess sente aka pagum E anra cane cacdwaccceadddeceus Timing chain sprocket Cylinder and piston guide plate of chain chain tensioner Lsueesuuses 3 22 3 23 3 24 3 25 3 26 4 1 4 1 4 3 4 4 4 7 4 10 4 11 4 11 4 12 4 13 4 14 4 15 4 16 4 18 4 19 4 21 4 22 4 23 4 24 4 25 4 26 4 27 4 28 4 29 4 31 4 31 4 33 Chapter 5 Chapte 6 Kick starter Engine oil pump filter dria eR Bearing oil seal Elastic CINCID OW ASIC oes vseratterzvi d vERRUERFU CHE Ea Ver Fo cen Inr EVodP IUE UFEFWRIYT E debP ho art eM Trpo n Assembly and adjustment of engine Assembly and adjustment of CNGIN ccccce cece cece ee cease eee rnrn teat sean menn Air valve Rocker IINSIEEAECUTET TIT TTE n Crank Dalanc QOVICE NETT TETTE Transmission Shift cam shifting fork Crankcase Shift axle starting axle idle GAN ccc cece cece cence cence eens tena ee eea mmn mens Clutch engine il pump TING SOR SUNIAUIC SYS CAN em m Disassembling of carburetor General drawing of carburetor cs io o ea o EEux eae E FRE SEE ESAE edF a guck a Sona eux a sKreaE ESSE decus Removal of carbure
29. check when asse mbling 2 Remove e The front bracket e pad e he rear bracket 3 Remove e Electric button e Magnet wheel e Electric brush Inspection and repair 1 Check e Commutator Dirt on the comutator polish it with 600 sand paper 2 Measure e Diameter of the commutatof A Out of normal value Repace the starting motor Wear limit value of commutator 21mm Starting system 3 Measure The depth of mica sheet sla Out of normal range grind it with hand saw to make it fits to normal value Depth of the mica slot 1 5mm Note The insulated mica sheet of commutator must has slot which can sure the normal work of the com mitator 4 Check Electric coil insulation conduction If there is default replace the starting motor kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk kkkkkkkk Inspection procedure Connect min multitester for the test of conduction and insulatiom Measure the resistance value of the electric button Resistance value of electric button coil Conduction test 0 017 0 021Q at 20 C 68 F Insulation test more than 1MO at20 C 68 F If the resistance value is abnormal replace the starting moi kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk kkkkkkkk 5 Measure Electric brush length_a Out of normal value Replace the electric brush as a s Lengh limit value of the electric brush 3 5mm 0 14in Note When replacing the electric brush pay more atte ntion to one side which
30. front fork Removal of front fork 1 Removal e Cover bolt and O ring 2 Oil drain 3 Removal e Spacer e Spring seat e Spring 6 20 Front fork CHAS e Dust cover 4 Removal e Clip Note Be careful not to damage the surface of inner pipe 5 Removal e Nut Grip the shock absorber rod loosen the bolt with T lever and shock absorber fixture T flat handle 90890 01294 6 Removal Bolt Washer 7 Removal Q5 2 e Oil seal Note When removing the oil seal be careful not to scrape the pipe wall of outer fork 6 21 Front fork CHAS Inspection of front fork 1 Inspection e Bending of inner pipe Bending limit 0 2mm Never attempt to straighten the bending inner piper otherwise the pipe will be damaged seriously 2 Measurement e Free length of front fork springC Free length of front fork spring 336 9mm Min free play 330mm Out of specificationo replace 3 Inspection Damper rod Shock aborbor piston Scraped damaged bent replace e Spring Plug rod of oil stocking Worn damaegd replace Pollutant blow off all oil holes with compressed air Note Never attempt to straighten the bending damper rod otherwise the damper rod will be damaged seriously 6 22 6 23 Front fork CHAS Assembling of front fork Conduct according to the reverse procedures of disass embling pay attention to the following it
31. is welding 7 19 7 20 Starting system 6 Measure e Elastic force of the electric brush spring Fatigue or out of the normal value replace it as a set Elastic force of the electric brush spring 560 840g Assemble According to the contary procedure of Remov 1 Install e Electric brush spring Electric brush Note e When assembling the electric brush the electric brush wire should wrap the outer side of proje ction of electric brush spring clamp When assembling the eclectric brush the binding post of electric brush wire should slightly touch the projection lying in the side of electric brush spring clamp 2 Install Electric button Note When installing the electric button press down the electric brush with min screw driver to avoid da maging the electric brush Starting system 3 Install e O ring Note Replace new one 4 Install e Magnet wheel Note The matching mark on the magnet wheel shoeld be align with that on the rear bracket then the installation is done 5 Install e Pad e Front bracket Note e The installation is done after the project of washer is align with the groove of front bracket e Make the matching mark on the magnetic yoke be align with that of front rear bracket Bolt 0 5Kgf m 5N m Installation 1 Install The starting motor 2 Install he starting motor Wire of starting motor Botl 0 7Kgf m 7N
32. of world manufact urer identification WMI Second portion 6 digits is vehicle definition section VDS Third portion 8 digits is vehicle indication section VIS Engine series No Engine series Nos is stamped on the crankcase Engine stamping code JYM154FMI 00000001 Note Design and specification are subject to changes wit hout notice 1 1 Points for attention in maintenance 1 Points for attention in maintenance 1 Key points for efficient and safety performance 1 Washing motorcycle e Clean the mud and dust on the chassis and engine to prevent from entering into the motorcycle in performance 2 No smoking e Don t smoke close to maintenance worksite ic s Ais LT A mae s rui Fr D Sn PIS r 3 Use proper tools e Use special tools on necessary portion to prevent parts from damaging e Use suitable tools and measuring instr ament to conduct maintenance propeyly Avoid to use fixed spanner etc as much as possible philips spanner and socket spanner should be used 4 Use genuine parts e Use YAMAHA genuine products or recommended ones for parts and oil never use the part of other brand 5 Replace the easily worn out parts the parts with mark e Replace the sealing shim gasket O ring Split pin circlip and locking washer etc 1 2 Points for attention in maintenance 6 Pay attention to safety operation e Pay att
33. or repairing the vehicle CAOTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE Provides key information to make procedures easier or clearer How to use this manual Manual Organization This manual includes many chapters which explain the main contents of each title individually First title An abbreviation and symbol in the upper right corner of each page indecates the current chapt Second title This title is shown in the left of section symbol of upper right corner of each page Third title It is a title of the smallest unit which is compiled step by step and matched with relevent pictur Exploded Diagram In order to understand the parts and treatment procedure the exploded diagram is provided at the beginn of each exploded chapter 1 A clear exploded diagram is used for disassembly and reassembly of the motorcycle 2 In the exploded diagram the numbers as symbols is used for explaining the removing procedure f there around the numbers it is the explanation of disassembly procedure 3Symbol in the exploded diagram is the explanation of work and key points For the meaning of each symbc page 4 There is work indication table under each exo diagram which provides such informations as work proce name of parts key pionts of work etc 5 For other informations concerning work there is detailed explanation on progressive steps besides explod and work indication table yy MTM itin
34. positive and negative electrode of batt Guid wire of starting motor 4 Dsconnect Cable of clutch Shift pedal and driving chain 1 Loosen e Nut of rear wheel shaft Note Loosen the nut of chain adjusting device and increase the slackness of chain 2 Disassemble e Shift pedal 3Disassemble e Small chain gear Driving chain Kick starter 1 Disassemble eNut e Kick starter Disassembly of engine 1 Place a proper support under frame and engine or support the main stand and make it stable 2 Disassemble Mounting bolt support of lower part of front side and engine Mounting bolt support of lower part of front side and frame Disassembly of engine 3 Disassemble Mounting bolt nut lower side 4 Disassemble e Mounting bolt rear part of engine and frame o Disassemble e Mounting bolt upper part of engine and support mounting bolt upper support and frame Disassembly of engine Cylinder cover cylinder and piston 1 Disassemble e Spark plug 2 Disassemble ntake divided manifold connecting pipe of cylinder andcarburetor 3 Disassemble Timing rotating plug Disassembly of engine 4 Disassemble Air valve cover intake eAir valve cover exhaust o Disassemhle e Side cover of cylinder cover 6 Timing adjustment Make the mark on rotator aiming at the fixing needle on crankcase cover KKE KK K K K K K K K K KK KK KK KK KK
35. specified value range Replacement Free length of air vlave spring Standard 32 28 mm Limitation 31 90 mm Check and repair 2 Check Vertical angel degree of air valve spring Side angle limitation a 1 2 mm 3 Check e Contacting face of air valve spring Above2 3 of outer circle are not in horizontal conta cting state Replacement Camshaft 1 Convex part of cam Corrosive pitting scratch blueing Replacement 2 Measure Convex part A and B of cam Exceeding specified value range Replacement Length of convex part of convex part of cam Intake A Standard 25 881 25 981 mm Limitation 25 851 mm B Standard 21 195 21 295 mm Limitation 21 165mm Length of convex part of cam Exhaust A Standard 25 841 25 941 mm Limitation 25 811 mm B Standard 21 050 21 150 mm Limitation 21 02 mm 3 Check Bearing Jamming swaying Replacing Rocker arm and rocker shaft 1 Check e Contacting face of rocker arm and convex part of cam Adjusting device surface Wearing corrosive pitting scratch blueing Replacement Then check lubrication system 2 Measure Inner diameter of rocker atm a Standard value of inner diameter of rocker arm 10 000 10 015 mm Using limitation 10 030 mm Exceeding specification Replacement Check and repair 3 Measure Outer diamet t b of rocker shaft Outer diameter of rocker shaft St
36. the foreign matter and dirt on the rotor 6 Locking Nut Fastening torque 7 OKgf m 7ON m Note Fasten the rotor with slide retaining tool lock the rotor with a nut with washer Slide retaining tool 90890 01701 7Installation Dowel pin e Paper gasket new product Left crankcase cover Y Fastening torque of crankcase cover 1 0Kgf m 10N m Note C222221f222 40020 2 2 20 2 0 The left crankcase can be installed only after the lo cking nut of main drive gear of right crankcase has been installed Assembling and adjustment of engine 4 62 Piston and piston ring 1 Installation of piston ring Oily plate Oil scraping plate 2nd ring st ring _COF __ x When installing the 1st ring and 2nd ring pay atte ntion to the upper and lower directions The surface with sign should be assemblied upward When installing the ring first installing the lower oil scraping plate then install the oily plate finally install scraping plate e After assembling make sure that the piston rings can turn smoothly between each other here should bea 120 angle difference for the interfaces between the rings the splits of upper and lower oil scraping plate of oil ring should stragger about 20mm on the left and right sides of oily plate split 2 hstallation e Piston Piston pin ePiston pin hoop Note e The arrow mark a gt on the piston should be
37. the spark plug clearance Refer to the 3 chapter Inspection of the spark plugf Spark plug clearance 0 6 0 7mm Abnormal Normal Correct and replace 2 Inspection of the spark Spark plug cap High pressure coil voltage gauge Voltage gauge wire of high pressure coil Spark plug Turn the main switch to ON for checking if the spar gets to the normal value above When pressing the starting switch check if the spafkKja gets to normal value above Min spark clearance of spark plug 6mm The spark gets to normal value above Ignition system normal No spark 1 8 3 Resistance of spark plug cap Remove the spark plug cap Connect the multitester test frequencyx 1K to spark plug cap Remark Don t pull down the spark plug from the high pressure wire Turning in counter clockwise when removing Turning in clockwise when installing When assembling the spark plug cap check the hig pressure wire first Cut off the front end of high pressure wire about omm before installing Resistance of spark plug cap 5KQ 20 20 C 4 Resistance of primary coil of ignition coil Remove the high pressure coil ignition coil Connect the multitester test frequencyOx1 to the terminal of ignition coil Resistance value of ignition coil primary 0 304 10 20 C 7 9 out of specification The spark plug is failure replace it 5 Resistance of secondary c
38. tow ard the front side of engine e Before installing the piston pin hoop cover the cra nkcase with clean towel or cloth so as to prevent the piston pin hoop or other articles falling into the cr ankcase 3 Installation Dowel pin Paper pad Assembling and adjustment of engine P Cylinder and piston Cylinder Piston O ring Piston pin Paper pad Dowel pin Piston ring Piston pin hoop 4 63 Assembling and adjustment of engine Cylinder head Bolt Cylinder head Copper washer Dowel pin Inner hexagonal bolt Steel pad Valve cover Intake O ring O ring 11Side cover of cylinder head Valve cover Exhaust 12Spark plug 1 25 Kgf m 12 5 N m 1 75 Ko 4 64 Assembling and adjustment of engine Cam shaft and locating key Paper pad Tensioner Chain guide plate intake Timing sprocket Timing chain Chain guide plate exhaust 2 0 Kgf m 20 N m 1 0 Kgf m 10 Nam 4 65 Chapter 5 Disassembling of carburetor General drawing Ol Cal DLIFPelOE saiccisenarcicaavanindnanrstarencepedintinninlairacbansttaGhenudennediatsnediaaaauediniid Removal of carburetor Adjustment of fuel level CARB Carburetor Adjusting screw of throttle cable Circlip 49Startspanner 28 Rubber pad 37Needle valve 460 ring Rubber sleeve 11Needle washer 20 Wave washer 29 Washer 38Firm clip Throttle cable guide pipe 42Needle 21 Screw 30 Spring 39 Bolt Rubber washer 43Plunger 22 Ru
39. valve into cylinder cover 3 Push and press the air valve to air valve seat through guide pipe of air valve thus to get clear trace 4 Measure the width of this mark which is width of air valve seat No matter wherever the air valve seat contacts working face of air valve blue colour will never disappear 5Jf the air valve seat is too wide too narrow or not in the middle it must be repaired OK OK 2K 2K 28 2K 2K ok 28 ok ok 2K OK ok OK OK OK OK OK OK OK KK ORK RRR RRR KOR OK 28 OK OK OK OK OK OK Check and repair 4 Grind e Working face of air valve Air valve seat Note After replacing air valve and guide pipe of air valve grind the air valve seat and working face of air valve TKCKCKCKGKCKCKCKGKCKCKCKCKCKCKCKCKCKCKCKCKCKCKCKCKCKCKCKCKCKCK KKK OK OK OK OK OK OK Grinding procedure Paint rough abrasive sand on working face of air valve Note Do not let the abrasive sand enter into slit between air valve rod and guide pipe of air valve Paint disulfide containing moly on surface of air valve rod Fit the air valve into cylinder cover e Rotate the air valve until the working face of air valve and air valve seat polish evenly Then wipe off all san ding agent Note In order to get better grinding effect when rotating the air valve forward and backward with hands you may beat the air valve lightly Paint fine sand agent on working face of air valve Then repeat above procedures Note
40. 5 B450 7 4 Inspection of socket connector 7 5 Inspection of socket connector The dirt rust and moisture on the socket connector should be removed 1 Remove e Socket connector 2 Dry every connector with air 3 Evey socket connector should be connected and dis charged for 2 3 times 4 Check if the wire is come off with hand 5 If the binding dost is pulled out by hand bend he pin and insert the binding post into the socket co nnector again 6 Connect e Socket connector T Check if the circuit is conducted with multitester Note e f the non conduction of circuit is found clear every binding post e When checking the bale of wire the procedure of inspection must be done according to above 1 7 steps e When replacing the CDI every socket connecter mustbe checked he inspection should be done by inserting the multitester to the socket connector seefigure Inspection of socket connector Inspection of the switch Inspection method of the switch Check the conduction of terminals with multitester If any poor condition is found replace the switch im mediately Multitesler 90890 03112 Note e Start the switch several times to cheak e Before checking turn the multitester to O e When checking the used voltage gauge should be set to proper position for check The conduction inspection of every switch should be done by Ox1 Every switch terminal in the manual Inner connect
41. 7kg Engine Engine type Cylinder Displacement Bore x stroke Compression ratio Compression pressure Starting system Lubrication system Machine oil type Engine oil Periodic oil change Total amount Air cooled four stroke SOHC Forward inclined single cylinder 123cm 54 0 x 54 0mm 10 1 1 200KPa 12Kg cm 171psi Electric and kick starter Wet sump YAMALUBE four strokeSAE20WAOSF or SAE10W30SF machine oil 20C 10C oc 10c 20 30C 1L 1000cm 1 2L 1200cm Wet type filter core Fuel type Fuel tank capacity Fuel reserve amount 90 gasoline unleaded gasoline 121 1 4L oo SPECI Main specification JYMI25 JYM125 2 VM22SH MIKUNI CR6HSA Co 0 6mm 0 7mm Wet multi piece Transmission o Primary reduction system Secondary reduction system C Reson OOOO NN E T 3rd gear 25 19 1 316 Chassis o 264 00 0 King pin rear caster angle 26 4 a De E TENEEMMMEMEZMEN Tire pressure o Drive with one person S 196kPa 2 0kgf c n Drive with two person S d 245kPa 2 Skgl em Brake 0 0 Right hand operation Drum brake persion 0 Operaiton Right foot operation 2 2 Main specification spec 2 Main spcification JYM125 JYM125 2 Suspension Front Retractable sleeve type Rear Rocker arm type Shock absorber Front Coil spring oil damper Rear Coil spring oil damper Wheelbase 1290mm Electrical system Ignition system C
42. DI Generator system A C magneto Battery type Immediately use Battery capacity 12V5Ah Headlinght type Bulb type Headlight bulb type Incandescent bulb Bulb voltage wattxquantity Headlight 12V 35W 35x1 Brake light tail light 12V 21W 5Wx1 Meter light 12V 1 7Wx4 14V 1 2Wx 1 Position 12V 4Wx 1 Neutral light 14V 3Wx 1 Highbeam indicator 14V 3Wx 1 Steering indicator 14V 3Wx 2 Steering light 12V 10Wx4 Inspection specification SPEC 2 Inspection specification Engine Item Standard value Cylinder cover Twist limit 0 03mm 0 03mm Cylinder Bore size Twist limit 54 060mm 54 075mm Camshaft Cam dimension Intake cam A Intake cam B Intake cam C 5 081mm 4 78 1mm Exhaust cam A 25 841mm 25 94 mm lt 25 817 gt Exhaust cam B 21 097mm 20 097mm lt 21 027 gt Exhaust cam C pe B 5 041mm 4 741mm Camshaft runout limit 0 03 25 881mm 25 981mm 25 85 21 194mm 21 294mm 21 165 Cam chain Cam chain type NO of links DID25 88 Cam chain adjustment method Automatic Rocker arm Swaying arm shaft Rocker arm inside diameter 10 000mm 10 015mm 10 03mm Rocker arm shaft outside diameter 9 981mm 9 991mm 9 95mm Arm to shaft clearance 0 009mm 0 034mm Valve Valve clearance cold IN Intake 0 08 0 12mm EX Exhaust 0 10 0 14mm Valve dimension pg p A valve head diameter IN 25 9 26 1mm EX 21 9 22 1mm B face width IN 1 4 3 0mm EX
43. K KKK KK KKK KKK KK K K K K K K Timing adjusting procedure Rotate the crank counterclockwise with wrench Make mark on rotator aiming at fixing neede b on crankcase cover When mak aiming at fixing needle the piston is on upper dead center T D C At the same time the calibration mark c of cam chain gear should aim at calibration m rR d on cylinder cover The swaying arms on both sides must form valve gap If there is no gap rotate the crank counterclockwise to meet above requirement 2k 2k 2k 2k K K K K 2k K K ok K K K K 2k K ok ok K ok ok K ok ok ok ok KK Kook ok ok ok KK KK ok K Disassembly of engine 7 Loosen Cover bolt chain tensioner device 8 Disassemble Chain tensioner device 9 Disassemble Bolt Cam chain gear Note Fix the timing chain with protective steel wire to prevent the chain dropping into crankcase 10 Disassemble Bolt e Cylinder head Note L C M Firstly loosen each bolt 1 4 turn After loosening all bolts remove them Loosen them successively from Min number The reverse order of the number st amped on cylinder means the order of tightening the bolts Disassembly of engine 11 Disassemble e Guide board of chain e Locating pin e Cylinder pad e Cylinder 12 Disassemble Locating pin e Papper pad 13 Disassemble Elasric circlip of piston pin e Piston pin
44. NSPECTION f SOCKEFCONMECION aaeseseseeduseacibestvevavtezivesadequavapicrtoTssexIMU ta pn Pssapueqvi SECTE TRESTE usbiqubeKi lacere yo Eie RE Em Ignition system Starting system Starting motor Charge system Lighting system Signal system 1 1 1 3 7 5 7 6 7 8 7 12 7 17 1 22 1 26 1 31 Circuit Drawing 1 1 Circuit ELEC Magneto 2 Instrument Rectified adjuster Fuel signal sender Battery 6 Horn Starting relay 7 Left lever switch Starting motor 8Flash relay Positive wire 9 Front brake switch Negative wire 20 Rear brake switch Main switch 2 Neutral switch Right lever switch 2Headlamp Clutch switch 23 Tail lamp 3 CDI unit assy 2 Ignition coil 3 Diode OA Front left turning lamp 5 Front right turning lamp 26 Left right turning lamp Jj Right left turning lamp Brown BR Black White Black Red mw BrownWhite Green Green White Green Yellow Bue wh Whefelue Orange B W B R W L R White Red W sky blue B Y Black Y ellow Red UE write 0 qo 1 2 2 O O Electric components 5 Rectifying adjuster 1 Battery 6 Fuel sensor 2 Rear brake switch 7 Three keys assy 3 Starting relay 8 Main cable 4 Fuse plate o v 4 o N q 4 T 2 u 1 3 Circuit ELEC Electric components 1 lgnition coil assy 4 Flash relay assy 2 Spark plug cap assy 5 CDI unit 3 Neutral switch assy 6 Horn 5 A c 5VL141
45. PEC MA Use limit 5 042mm 5 042mm 0 08mm 0 10mm 0 01 mm 1 6mm 1 6mm 0 03mm 0 8mm 0 08mm 0 08mm Inspection specification oo SPECI Clutch Friction plate thickness Quantity Clutch plate thickness Quantity Free length of clutch spring Quantity Clutch seperating method Kick starter Type Carburetor Model Main jet MJ Main air jet M AJ Jet nozzle JN Low speed air nozzle PAJ Low speed mixed air outlet PO Low speed nozzle PJ Adjusting blot of low speed mixed air PS Oil level Idle speed Intake negative pressure Machine oil pump type Clearance between inner rotator and outer rotator Clearance between outer rotator and rotator chamber Clearance between rotator surface and rotator chamber surface Steering system Steering bearing type Front shock absorber Front shock absorber travel Free length of front fork spring Oil quantity Oil level Type of shock absorber oil Bending limit of inside tube Rear shock absorber Rear shock absorber travel Free length of spring Front wheel Type Rim size Rim material Rim runout limit radial lateral 2 9 3 00mm 2 8mm 4 1 55 1 65mm 0 05mm 3 29 29mm 31mm 4 Inside cam pushing Kick starter and mesh type mu VM225H 1977 5 o 0 9 5EJ49 2 L250 0 o 1 4 o 1 0 15 21 2 3 4fig 7 1 x 0 05mm 1400 100rpm 31 9 2 7kPa Trochoidal pump Less thanO 15mm 0
46. Push plate e Washer e Nut 6 Installation Press plate e Spring eScrew Screw installing torque 0 6 kgf m 6 N m Note ___ Tighten up the bolts orderly according to the diago nal order 4 57 Assembling and adjustment of engine 7 Confirmation e The aligning identification of push rod assy and crank case e Turn the push rod assy counterclockwise to the end make sure the projecting part of push rod a is identifiec with the aligning identification convex part b If not identified adjust aAdjustment e Aligning identification of push rod 3 and crankcase e Unlock the nut turn the push rod counter clockwise to the end eTurn the push rod 1 left and right until a aligns with e After adjusting lock the nut Yy Nut fastening torque 0 8kgf m 8 N m 9 Installation Paper gasket new product eft crankcase cover Crankcase cover installing torque 1 0kgf m 10N m 10Installation e Kick start rod Installing torque of kick start rod 5 0kgf m 50 N m 4 58 Assembling and adjustment of engine Timing chain Woodruff key Guide plate of chair Rotor Locating shaft Stator Idle start gear1 11Paper gasket Press plate 12Dowel pin Washer 13Left crankcase cover Starting gear 2 T a L3 a 7 0 Kgf m 70 N m m 7 N m 1 0 Kgf m 10 N m 4 59 Assembling and adjustment of engine 4 60 Rotor and
47. The circuit is normal socket connector repair is needed 7 34 Signal system 3 Blinker turn signal lamp indicator no work 1 Bulb and socket Check if the bulb and socket are conducted No conduction Conduction Replace the bulb or the socket 2 Turn signal switch Abnormal Remove the branch connector of handlebar switc left from bundle conductor Check if the switch between Brown white amp Dark The turn signal switch is failure replace the brown and Brown white amp Dark green is conducted handlebar switch left Condutction Connect min Multitester DC20V to the relay on the blinker device Postitive guide wire of multitester Brown guied wire Negative guide wire of multitester Frame ground Out of normal value Turn the switch to ON Check if the voltage of Brown guide wire at the ee netDo DUSPONDUUKGIENI GEN SEO Te There is poor layout from the main swotch to the rela binding post of blinker device the repair is needed Meet mormal value 4 Blinker relay Connect multitester test frequencyDC20V to blinker relay Guide wire Brown white terminal guide wire Body ground Turn the main switch to ON Turn the blinker to left or right Out of normal value Measure the voltage of brown white guide wire 12lV Meet normal value Replace the blinker relay 7 35 5 Turn indicator Connect min Multitester DC20V to socket connector Connect
48. ake out the chain from solvent and dry it Lubricate it quickly to avoid rust Note Never use lubricating grease when lubricating chain Check of front fork 1 Place the motorcycle on flat place 2 Check e Inner tube Scar or damage Replacement Oil seal Serious oil leakege Replacement 3 23 3 Keep the motorcycle in vertical parking state and acti vate front brake 4 Check Activating state Make the front fork sliding up and down certain times Blocking in activating gt Repair Refer to section of Frohtfork in Chapter 6 Adjustment of rear shock absorber Warning Always adjust the preload value of each shock ab sorber identical to set constant value Uneven adj ustment will worsen the operation and reduce reliability Support the motorcycle firmly to avoid turning over 1 Adjust e Spring preload Turn the adjusting device indirection a or b Turn in direct a Spring preload value increases Turn in direct b Spring preload vlaue reduces Adjusting device position Standard 3 Min 1 Max 5 Note meee The adjusting device should not be trned exceeding Max or Min position Check of tire 1 Measure Tire pressure Exceeding specified valueadjustment Pressure of cold tire Load below 175kPa 19 amp Pa 0 90 kg 1 75kgfcm 2 0Kgf cnt Front wheel Rear wheel Max load 196kPa 100kg 2 Kgf cm Load means total weight of cargo driver and a
49. andard value 9 981 9 991 mm Limitation 9 95 mm Timing chain sprocket guide plate of chain and chain tensioner 1 Check e Timing chain Hardening or crack Replace the whole set of timing chain and chain wheel 2 Check Sprocket Hardening or crack Replacing the whole set of timing chain and sprocket 1 4tooth Correct assembly Roller Sprocket 3 Check Guide plate of chain exhaust side Guide plate of chain intake side Wearing or damage Replacement Check and repair 4 Check e Free movement of timing chain tensiener Checking procedure e Press the tensioning device lightly with finger and screw the tensioning device rod to dead with small screwdriver e When pressing screwdriver lightly with finger to loosen the screwdriver confirm that the tensioning device come out smoothly Otherwise replace the tensioning device assy Cylinder and piston 1 Clean Carbon deposit from top of piston and ring groove 2 Check Side wall of piston Wearing scratch damage Replacement 3 Check e Cylinder wall Waring or scratch Reboring cylinder or replacing 4 Measure e Clearance between piston and cylinder Measuring procedure Measure cylinder diameter and C with cylinder gauge at D3D4position 40 mm to cylinder top Note _ Measure cylinder diameter C from parallel and ver tical direction to crank Then caculate the average value Standard valve of cylinder inner diamet
50. arm up the engine for several minutes and stop it Place an oil container under the oil drain plug 3 Remove e Filling in cock of engine oil e Drain cock e Gasket installed on drain cock 4 Drain oil 5 Add the engine oil from filling in cock 6 Install e Filling oil cock of engine oil Gasket installed on drain cock Drain plug Torque of drain cock 20N m 2kgkm Check of oil pressure 1 Remove oil pressure inspection bolt 2 Start and run the engine for several minutes in idle speed 3 Check e Machine oil condition of overflowing hole Overflow of machine oil oil pressure is normal Machine oil can t overflow oil pressure is insufficient Note If the oil still does not over flow after one minute stop the engine immediately to prevent it from being da maging 3 12 Adjustment ofclutch adjustment of front brake Adjustment of clutch 1 Check e Freeplay of clutch cab e a out of specified range adjust Free play 10 15mm Measure at end portion of clutch lever 2 Adjust Free play of clutch cable Adjusting steps 1 Confirm that adjusting device and locking nut have been fully tightened 2 Loosen the lock nut 3 Screw in or screw out adjusting nut until the specified free play has been obtained Screw in free play increased Screw out free play decreased 4 Tighten locknut Note If the free play is improper use adjusting device a part of clutch lever
51. ation damage under burning damage under burning for deposits replace the pollutant and deposit clean with spark plug det ergent or steel wire brush 2 Conduct the following check Check the clearan amp a between center electrode and side one Clearance between electrode 0 6 0 7mm Out of specified value adjust side eclectrode Standard spark plug NGK CR6HSA Check of compression pressure e When compression pressure A Poor air valve contact will cause compressio leakage B Adjustment of air valve clearance is poor C Piston cylinder and piston ring will be worn out When compression pressure is too high A The burning room of cylinder head will have carbon deposit B Piston head will have carbon deposit Note Insufficient compression pressure wil result in the performance loss 1 Check e Air valve clearance adjust Refter to adjustment of air valve 2 Start and warm the engine for several minutes 3 Stop the engine 4 Remove spark plug 5 Install e Pressure manometer Joint Pressure manometer 90890 03081 Joint 90890 04082 6 Check e Compression pressure DK OK OR K OK OS K OK OK EK K K OK OR K OK K GE OK K K K GE OK OK OK OK CE OK OK GE Measurement steps Crank over the engine with the electric starter or kick starter with the throttle wide open until the compression reading on the manoeter reach to the max value then read the max one Check readings with specified leve
52. ation of front fork Conduct according to the reverse procedures of removal 1 Installation Front fork Tighten up the fixing bolt tempotarily Note When installing align the inner pipe end with bolt head end 2 Fastening e Bolt Bolt Cover bolt Torque of position 2 8Kgf m 28N m Torque of pisition Kgf m 23N m Cover bolt torque 2 3Kgf m 23N m 6 26 Steering axle and handle bar CHAS Handle bar holder Dust cover Handle bar Steering axle Right handle bar assy 1 Bearing race upper Handle bar seat 2Roller holding bracket upper Limit clip 13Roller holding bracket lower Ring nut 4 Bearing race2 middle Ring rubber pad 5 Bearing race Lower Ring nut 2 3 Kgf m 23 N m 2 3 Kgf m 23 N m DN 3 5 Kgf m 35 N m 6 27 Steering axle and handle bar CHAS Handle bar 1 Removal e Remove left and right lever switches 2 Removal e Handle bar holder e Handle bar Handle bar seat 3 Removal Front wheel 4 Removal e Front fork 6 28 Steering axle and handle bar CHAS 5 Removal e Limit clip e Ring nut e Ring rubber pad 6 Removal e Ring nut e Remove with steering nut wrench Steering nut wrench 90890 01403 Remove only with wrench 7 Removal Bearing race 2 Roller race 2 e Roller holding bracket upper e Steering axle Roller holding bracket Lower Inspection of handle bar 1 Inspection Handle bar ns If bent cracked damaged
53. aying arm pin intake Air valve spring rod exhaust 12Swaying arm pin exhaust 0 8 Kgf m 8 N m 4 39 Assembling and adjustment of engine Assembly of engine and adjustment of air valve 1 Deburr e End of air valve rod Polish the end of air valve rod with oil stone 2 Paint e Molybdenum disulfide lubrication oil Painting on air valve rod and oil seal of air valve e 4 stroke engine oil Painting on air valve rod top 3 Assembly e Spring seat of air valve Oil seal of air valve eAir valve e Air valve spring e Upper seat of air valve Note L M Make the side of large pitch a upward and mount the air valve spring b small pitch 4 40 Assembling and adjustment of engine 4 41 4 Mount ock piece of air valve N ot a L L u When mounting the air valve lock piece compress the spring with compressing tool of air valve spring Compressing tool of air valve spring 90890 04019 5 Beat lock piece of air valve lightly with soft hammer to fix it on air valve rod Note Do not boat it forcedly to advoid damaging the air valve Rocker arm and camshaft 1 Lubricate e Molybdenum disulfide lubricating oil Painting on the confacting face of rocker arm hole and camshatt e 4 Stroke engine oil Painting to rocker shaft and O ring 2Mount e Rocker arm e Roc
54. bber cap 31Ps adjusting screw 40Float Top cover cap 44 Carburetor 23 Guide seat 32 Idling fuel 41 Float pin Circlip 15dle speed adjusting scr M Starting pluger 833 Needle valve jet 42Gasket Rubber washer 46 Spring 25 Spring plate 34 Main jet 43Float cover Plunger spring 47Washer 26 Firm plate 35 O ring 44 Bolt Needle pressure plate 48Rubber pad 27 O ring 36 Needle valve seat 45Spring CARB Carburetor 1 Removal Throttle cable Caburetor Disassembly 1 Loosen e Oil drain screw 2 Removal Plunger 3 Removal e Starting wrench e Starting plunger 4 Removal e Float chamer 0 2 Carburetor 5 Rmoval e Float pin Float e Needle valve e Needle valve seat 6 Removal e Main jet Needle valve jet O ring 7 Removal e Idling fuel jet 8 Removal e P S adjusting screw Inspection 1 Inspection Mixing chamber case of carburetor If polluted clean 5 4 CARB Carburetor 3 Inspection Float e f damaged replace 4 Inspection Needle valve Needle valve seat O ring If worn or damaged replace Note The needle valve and its needle valve seat should be replaced as a complete set 5 Inspection e Main nozzle Main jet e O ring e dling fuel jet If polluted clean Note Blow the jets with compressed air CARB Carburetor Assembly Conduct according to the reverse procedures of removal No
55. bricating oil quantity of engine lsssseesseesse mm Replacement of engine lubricating oil Check of lubricating oil pressure Check and adjustment of CIUICI uiuo chc ox Unt duue eA E ERE exci sup edi a ORu tena o kxx exu ed ERR iaMKDS Check and clear of air filter Adjustment of front brake drum rype soesssessesse mmm Check of front brake pad Check of front brake disk type 0 ccc cece cscs eee e eee eeceeeeeeaeesaeeseeesanersneesnerenetanes Check the brake liquid quantity Exhausting Qll c ccc ccc cece eee e eee e eee eeaeeeaeeeaeeeaeeeas Replacing brake fluid Check and adjust rear brake Check and adjust brake light SWIIGI uii nire soon a reta rhe Eo ua o ERE TR Parure EE RR eRC Mao RAE Check and adjust driving chain 1 1 1 1 1 2 1 5 2 1 2 4 2 6 2 8 2 9 2 12 2 13 2 14 2 16 3 1 3 3 3 5 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 16 3 16 3 17 3 18 3 19 3 20 3 21 3 21 Chapter 4 Check of front fork Adjustment of rear shock ADSOrDAL c ccc eee eee cece eee e esse eeeeeeaeeseeeeaeeseeesaeesaneags Check of tire Check of steering XeVvibB ssi sci seman ne EX E DRE exe Sa ERE En ke Eas emu ka dk Ru Ex beekesdeesdcsecas Electrical system Check of battery Disassembly of engine Dissassembly of engine Disassembly of exhaust pipe and lea
56. can be used together Stop rotation tools for slide wheel Stop slide tools for rotor Clearance measure Tool for meassuring air valve clearance Cylinder pressuer measuring tool Joint Tools for measuring compressed pressure of cylinder A VO meter Tool for measuring voltage resistance and current of electric parts RPM meter of engine Tool for measuring RPM of engine Compresser of air valve spring Disassembly and reassembly tool for air valve and air valve spring Fixed tool for clutch Ignition checker 1 6 Chapter 2 Specification W lzigksier te dile li e12 ELSE Er 2 1 Inspection spediflealiBipeissesueeioossatur Peres pondere RN upSG 2 4 EG MiG eree consane seen pense a E E EEEE E EE 2 4 EE E E E E TE 2 6 Electrical system ees 2 8 Main tighten torque specification 2 9 Position to be applied lubricating oil and kinds of lubricating oil 2 12 Engine EEE 2 12 aei a E IRI ee eee re E eee 2 13 Engine lubrication diagram 2 14 Layout et cable DIDellliGserweeententtvuriasat E er ee 2 16 Main specification coec 9 Main specifiation Model code opecification JYMI25 JYMI25 2 SVL Dimension Overall length Overall width Overall height Seat height Wheelbase Min ground clearance Min turning radius 1 980mm 745mm 1050 1120 mm 785mm 1 290mm 160mm 1 850mm Weight full fuel tank 11
57. ccessaries Specification of front wheel 2 75 18 42P Specification of rear wheel 90 90 18 51P 2 Check eTire surface Wear damage Replacement Min depth of tire thread front amp rear wheel 1 0 mm Repth of thread Side wall Wear indication layer Driving the motorcycle with worn tire is dangerous Replace the tire immediately when the tire is worn to line You would better not to mend the broken tire tube with rubber Mend the tire tube especially carefully if you have to do so And replace it with high quality substitute as soon as possible e When using tiretube type tire be sure to mount correct tire tube 3 24 3 25 Check of steering device Check of steering device 1 Conduct following device Support the front wheel and sway the lower part of front fork to check if the steering axle is loose Check if the steering bar can be turned to left and right smoothly Loose steering axle unsmoothed turning adjusting nut of steering axle 2 Conduct following adjustment Steering nut Adjusting procedures e Disassemble steering handlebar Refer to Chapter 6 Steering handlebar e Disassembling steering handlebar seat Lock the nut with steering nut wrench The locking procedures and method refer8 11 Mount steering bar seat Mount steering handlebar 3 26 Check of battery Check of battery 1 Disassemble Side cover left Reter to section Disassemb
58. charge coil from bundle conductor Connect the min Multitester Ox1 to the charge Coil Measure the resistance value of charge coil Positive wire of multitester White wire Negative wire of multitester White wire Out of normal value Resistance value of charge coil 0 40 20 20 C Two test value meet If the charge coil is failure replace it the normal value Charge system 5 Connecting condition of wire Check the whole connecting condition of charge Poor connetion system Refer to section circuit Diagram Reinstall the rectifier adjuster 7 25 D T op gt gt v O C C JO Lighting system Circuit diagram pis 7 26 za O o oO gt Ao k D ad Q E o ce E o amp o qc L Lr S GS Lighting system Exclusion of troubleshooting Headlamp high beam indicator of headlamp tailamp and instrument garden light are not lit Remark Before excluding the following components should be removed Side cover Cushion Hood The following specific tool should be applied when excluding Min multitester Part number 90890 03112 No conduction 1 Bulb and socket Check if the bulb and socket are conducted Conduction If the bulb or socket is failure replace it No conduction Remove the fuse Connect the min multiteste Ox1 to the fuse Check if the fuse is conducted Refer to Inspectio
59. check e Support the motorcycle with main stand Check the slackness a of driving chain Exceeding specified value range adjustment Slackness of driving chain 20 30mm 2 Adjust driving chain Adjusting procedures oosen the lock nut of axle e Loosen the lock nut of adjuster Screw in or out the adjusting device until reaching the specified slackness 2G Screw in Slackness reduction Screw out Slackness increment 3 21 Checking adjusting driving chain Check of fronk fork 3 22 Checking adjust driving chain Note There is graduation mark on chain adjuster When adjusting should ensure the identical graduation value on driving chain adjusters of two sides of rear arm After the left and right adjuster is adjusted properly tighten up the lock nut of adjuster and lock nut of axle Lock nut of axle l 91 N m 9 1kgfm Lubrication of driving chain The driving chain includes many cooperating parts They will be worn rapidly without proper maintenance So per iodical checking and repair should be conducted which is especially important when driving under dusty condition 1 Spraying type lubrication oil may be used Get rid of all dirts and mud on chain with brush or cloth Spray the lubricating oil onto the position between two side plates of chain and middle roller 2When washing chain remove the chain from the moto rcycle and immerse it into solvent to clean it as far as possible T
60. ckle carbon deposit Wear choke damage ae E ud T Wear choke damage Troubleshooting of engine Trouble Intake and exhaust system Fuel pipe Choke crack or fold e Pollution or choke Improper adjustment e No timing Exhaust pipe e Choke e Crack or damage Carbon deposit Neadle valve of measuring hole e Improper adjustment Incorrect position Starting plunger Out of work When starting idle speed PS adjusting screw Improper adjustment Inproper adjustment of fuel level When idle speed and 1 Broach out starting Measuring hole of idle speed Choke PT e Choke DEN high speed e Improper size Improper size Loose e Loose When idle speed and starting Float bowl e Incrustation and dropsy Wear damage
61. d wire ssssessssssssseeeeennre Disassembly of carburetor clutch cable speedometer cable and driving chain Disassenbly O OnmgdlliB ieran eee ne oe een eet one eee Pee EROE Disconnection of CNGING ccccc ese eece cece cece cece esse sees eee eeeeeeesanesgnesgnesgnesenennens Disasembly of cylinder head cylinder and PistONn ccccece cece eee e eee eeeeeeeeeeeeeeeeees Disassembly of starting motor clutch and oil DUMP 0 cece eee cece eee eeeeeeee eee eaeees Disassembly of starting axle and idle Qeal 0 ccc ccc cece cece eect eee e eee eeeeeaeeeneeeaeees DEASSEMDIY of shift SXIe eicere pierde trea en Ea aeo Raus Ure e tubs edewidesdedsedrscepsetiestateede Disassermbly OLIOIBIE usdesieistusuekacti sr netibec detractis toic uitadtevestubs us ELS aput ia RUE Disconnection Of crankcase ioees qr ccs voce crak OI DNE EI DEI iir e ntl ooiervrcrurrexud sie Es Disassembly of balance device transmission and shift rod cc cece cece cence eeeee ees Disassembly of crank balance DIGG a eredi rale mado d arie Sex vinis aeensdaestucseasdadess Disassembly or rocker arm Camis Dell uide saeiut ence ea e cae Co poo UIN DERE CRIT E VPEI ERU ER DUE DisassembDIy of Tcl NRI ee ee anne eee eee Check and repair Cylinder head Air valve seat Air valve and guide pipe Of air ValV8 s once ctcceacissecsatad doesesstace
62. e Piston Note Before disassembling the cirlip of piston pin cover a piece of clean cloth on crankcase to prevent the elastic circlip dropping into crankcase Before disassembling the piston clean the groove and pin hole of circlip If it is difficult yet to disas semble the piston after doing that use disassembing tool of piston pin Disassembly of engine Disassembling tool of piston pin 90890 01304 Left crankcase cover starting motor 1 Disconncct e Neutral light switch 2 Disassemble Left crankcase cover Locating pin Seal papper pad 3 Disassemble eStarting motor Clutch oil pump 1 Disassemble Kick starter device 2 Disassemble Crankcase cover right Seal papper pad Locating pin Note Firstly loosen each bolt 1 4 turn according to cross curve order then remove all bolts Disassembly of engine 3 Disassemble e Bolt e Clutch spring e Pressing pan e Friction wafer e Clutch wafer Pushing rod1 e Steel ball Note Firstly loosen each bolt 1 4 turn according to order of opposite angle then remove all bolts 4 Flatten Smoothen the tongue of lock washer o Loosen e Nut Note When loosening nut convex seat of clutch fix the clutch hub with clutch jig Universal clutch jig 90890 04086 Disassembly of engine o Disassemble eNut e Lock wacher e Clutch hub e Spline washer e Main driven gear Washer e Ela
63. e adjustment method is conducted as stated in chapter Steering shaft and handle bar CHAS d 6 31 Installation of the handle bar 1 Install e Handle bar e Handle bar clamp Coupling torque 2 3Kgf m 23N m Note e The bolt ahead must be fastened first e When assembling the steering the projection of handle bar clamp is in front of installation direction 2 Install e Front brake lever e Clutch lever 3 Install ever switch When installing locating pinC of the lever switch sh ould be inserted into the locating hol b of the handle bar Rear shock absorber and rear arm Rear shock absorber Nut Rear rocker arm Connecting rod Chain shield 40 Kgf m 40 N m 1 9 Kgf m 19 N m Rear shock absorber and rear arm CHAS Removal 1 Rear shock absorber The motorcycle should be supported firmly to avo id turning 2 Remove e eft right rear shock absorber 3 Remove e Rear wheel 4 Remove Chain o Remove e Nut Connecting rod e Chain shield e Rear rocker arm Inspection 1 Check Slackeness of rocker arm If it is loose screw up the axle nut or replace bush Vertical movement of rocker arm If itis unflexible bend and there is rough part replace the bush 2 Check e Rear shock absorber If it is leak deformation replace it 6 33 Chapter 7 Circuit General drawing Of 2 21 Same ae Onna NE dom Mu Pre OPT MM MED M eM UM BONS ON Mia EE TETTE I
64. e of multitester Brown guide wire Negative guide wire of multitester Frame Turn the main switch to ON Check the voltage at the binding post of horn brw guide wire gets td 2V ipeo normal value 12V Connect the min multitester DC20V to Pink binding post of horn Positive guide wire of multitester Pink guide wire Negative guide wire of multitester Frame ground Turn the main switch to ON Check if the Pink guide wire voltage at the binding post of horn gets to 12V Out of normal value No function of the horn Adjust or replace horn If the horn is failure replace it 1 33 Signal system 2 The brake lamp is not lit 1 Bulb and socket Check if the bulb and the socket are conducted No conduction Replace bulb or socket Abnormal 2 Brake switch Remove brake switch guide wire from the bundle connector Check if the switch between the Yellow amp Brown and Black amp Black is conducted If the brake switch is failure replace it 3 Voltage Connect min Multitester DC20V to socket connector Positive guide wire of multitester 5 Yellow guide wire Negative guide wire of multitester Black guide wire Turn the main switch to ON Pull brake lever or step brake pedal Check if the voltage of Yellow guide wire at the Out of normal value socket connector gets to 12V Meet normal value There is poor layout from the main switch to the
65. earance este e eter e eect eee e eee ee eens 3 5 Adjustment of idle speed Los ee ee ee ee ENG RES SEES EU EN IDEE Gus a ee EU GU EpsUE ied ee 3 Drainage Check and adjustment of free play of throttle cable 3 8 CHEEK OF SBOrK DIUG eanna arene E E EE E E EEEE 3 9 Check of compression pressure E a bar E E a oe ee mci dicli d A E E A E E A E 3 1 0 Check of lubricant guantity Of engo sence tectenen certs sneis ebd qu 3 11 Replacement of engine lubricant Check of lubricant pressure se 3 12 Check ma adiusimenbofelutabbeeie et aE urhe tnos 3 13 Check aler of air filter IHH I I III IIR 3 14 Adiusimentor frome brake drum ype essssasotd censet uees torso aereo ttes det erai cad deese 3 16 Check of front brake shoe e HII I HII III 3 16 Cheskortohtbrake dise ype eee ree eee 3 17 Check the brake liquid quantity Exhausting air cece eee errr teeters 3 18 Replacing brake guide enir inin et ere 3 19 Checking adjusting rear brake 3 20 Checking adjusting rear brake light SWIEGEI usse iip siia ioni ordi dina facilia tei 23 04 GiarseleceeelUsueneuMichei ee oe ens 3 94 Check of front fork cccccccceeceeteeeteeeneeeeenneteeeneeeeengatetegeeeeengetetengnteenganeees n Adjustment Of rear shock abSOIDGE sis siissaa Rua eo REeisoPRIPR PE ARR iieii REGIE RAPR PAGS 3 23 Check o TO T TI ee ee ee TT 3 94 Check of steering deviee Hee 3 25 Electrical system Check of battery
66. ebar to make the brake liquid pipe filled with brake liquid Note sa Supply the brake liquid at the same time Do not let it below the lower limit a muwi 3 20 7 Operate the brake handlebar until no bubble sends out from the small hole of brake liquid vat and the brake handlebar is felt powerful 8 Release air 9 Assemble according to reverse procedures after adjus ting Check and adjust rear brake 1 Conduct following checking 2 Check brake and free play of front end part of pedal cx Free travel of frontend part of brake pedal 20 30mm Unconformable to specified value Adjustment 3 Conduct following adjustment e Free play of brake pedal Adjusting order Adjust the free play to specified value with adjuster Screw in Reduction Screw out Increment Check of rear brake shoe 1 Check Needle wear indicating plate The needle has reached wear limit line Replacing brake shoe Note The tension spring must be replaced when replacing brake shoe Q Checking rear brake light switch Checking adjusting driving chain Checking rear brake switch 1 Conduct following checking e Brake light Check if the brake light comes on when treading down the brake pedal 30mm Brake light does not come on adjustment Rotate the adjusting nut for adjustment Rear brake light switch Adjusting nut Checking adjusting driving chain 1 Conduct following
67. em MM Bie ae OW C YAMAHA toke engine oil LSB Light weight lithium soap base grease We Molybdenum disuflide grease Engine lubricating diagram spec 2 Lubrication diagram Rocker arm intake Centrifugal filter Rocker arm shaft Oil pump Rockerarm exhaust Pushing rod Cam shaft Filtering web R E We PE 4 Lh Y d NI Engine lubricating diagram epgc 2 D Cam shaft Driving shaft 2 Centrifugal filter Clutch assy 3 Crank 4 Spindle jo z r Sunes ATE mal B Lad S T Teo EI TECH 71 ERG E yc l c lal Le D Clutch steel cable Front brake cable Switch cable of left handle bar Cable clip Fuel tube CDI Foul Osafery 5 Fuel sender Start relay A Cable must pass cable clip position E B Cable and all wires must pass through rear side of headlight and connect the wire at the interior of headlight F C Fix the white mark of cable at the cable clip of frame D Insert the flowing tube of carburetor from cable clip of G battery box Drum type without fairing o pr f A SEC lf Layout of cable pipline Flash relay CDFlexible shaft of speedometer Flowing tube of carburetor 3 Overflow tube of carburetor 4 Positive pole wire of battery Main cable Wire of starting generator shall pass through the inte rior ofbattery Flowing guide tube of battery shall pass through the interior of battery Fix the wire of ma
68. ems Note When reassembling the front fork use the follow ing new components Oil seal e Dust cover Before reassembling make sure that all compon ents are cleaning 1 Installation e Spring e Shock absorber piston 2 Lubrication nner pipe Outer surface Shock absorbor oil 10W or equal 3 Installation e Shock absorber rod e Plug rod of oil stocking nner pipe Outer pipe 4 Installation Washer Bolt shock absorber rod Front fork CHAS 5 Fastening Bolt damper rod Bolt 2 3Kgf m 23N m Note Fasten the bolt of damper rod with T handle wr ench and damper rod fixture T tool 90890 01326 Shock absorber rod fixture 90890 01294 6 Installation Oil seal 7 Installation Clip New Outer pipe 6 24 Front fork CHAS 6 25 8 Inspection e Stretch of inner pipe If the stretch is not smooth Inspect again after disase mbling 9 Oil filling e Measuring glass Oil amount 156mm 10W shock absorber oil 10 After filling oil move the front fork up and down slo wly so as to let the oil spread into the pipe 11 Installation e Spring Note When installing let the end of front fork spring with small play to toward the cover bolt side Install the O ring on the cover bolt 12 Installation Cover bolt e O ring Note Be careful not to damage the surface of inner pipe Front fork CHAS SAS Install
69. engine oil supply to the oil hole in the crankcase and oil hole in the oil pump 2 hstallation e Oil pump Oil filter 1 Installation Drive gear of oil pump e Centrifugal filter Note Install the dowel pin of centrifugal filter into the retainning groove of crankshaft b Main drive gear 1Installation Main drive gear Dowel pin Washer Nut Note L C CC When locking the nut in order to avoid the rotation of crankcase the rotor must be fixed No articles such as alumium sheet cloth strip of copper sheet between gears They prevents the crankshaft from rotating Assembling and adjustment of engine Clutch 1 Installation e Main driven gear Retaining washer Clutch hub Retainingasket e Nut 2 nstallation Nut Note L Fasten the clutch hub with clutch fixture lock the nut and bend the retaining gasket Clutch fixtrue 90890 04086 Nut torque 60N m 6 Okgf 3 Installation e Friction linertotal of 4 pieces 9 Clutch plate total of 3 pieces Note mee e Apply the engine oil of 4 stroke engine on each plate of clutch then install it e Install the clutch plate and friction liner alternatively to the clutch hub starting from friction liner and ending with friction liner 4 56 Assembling and adjustment of engine 4 Installation e Steel ball NIST PAX SOM I 5 Installation ePush rod 1 e
70. ention to safety operation in mainte nance so as to avoid a burn by the heat of engine exhaust pipe and muffler etc e In maintenance always use proper tools con sider proper operation proper fixing position and the operation position to facilitate using force and keeping body stability 7 Keep proper procedure in disassembly and Sort out removed parts immediately e The procedure of loosening screw shall be Loosen in twice or three times along diagonal direction from outside to inside e In disassembly check and measure the impo rtant parts keep the record for reference in reassembly e Put the disassembled parts according to each portion in proper order to prevent from mixing or lost e After disassembling the engine and transm ission clean each parts with oil and dry it with compressed air 8 In reassembly confirm the operation according to manual then conduct the performance e The procedure of tightening screw shall be Tighten in twice or three times along diagonal direction from outside to inside e In reassembly conduct the performance as con firm the repaired result and the data before dis assembly e Don t let such foreign matters as dirt stick on the parts Conduct reassembly according each portion as confirm the operation Apply machine oil on the place of rotation and slide apply grease on the oil seal and O ring Obey the specified tighten torque e When two person conduct t
71. entral stand Rest the motorcycle firmly to avoid turnover 2 Removal e Sprocket covef 3 Removal e Drive sprocket 4 Removal e Chain joint clip e Press plate of chain e Chain e Driven chain Inspection of drive chain 1 Inspection Drive chain jam If jammed Lubricate after cleaning or replace 2 Inspection Drive chain e Drive chain As shown on the fig the clearance after extruding right cannot exceed 2 gear If out replace Drive chain and sprocket CHAS 3 Measurement a aaqG d 6 6 D dO d The length of 10 linksCa drive chain Out of specification replace nii E E OB RRO OE Re eh Oa Oo Length limit of 10 links 119 5mm Note eMeasure after pulling the chain with fingers e As shown on the fig measure the length of 10 links within the range from link roller to the inner side of the roller 3 e Measure the length of 10 links at diffrient parts for 2 3 times 5 Cleaning e Clean with neutral detergent e After cleaning apply a plenty of chain lubrication oil of SAE10 w 30w YAMAHA 4 stroke engine oil Never clean with the volatile matters such as steam gasoline solvent etc Inspection of clutch hub 1 Inspection e Clutch hub If worn damaged cracked replace 1 Installation e Driven gear e Retaining press platd d Nut Nut torque 2 6K gf m 26 N m Note Lock orderly 6 17 Drive chain and sprocket CHAS 6 18 2 Installation e In
72. er 94 024 54 056 mm Exceeding standard range Replacement Che ck and repair Piston measurement 1 Measure Measure diameter of skirt section of piston with micr ometer at the point 5mm to bottom edge of piston Outer diameter standard of piston 93 997 54 029 mm Clearance between piston and cylinder Inner dia neler or Clearance cylinder i m Standard clearance of piston and cylinder 70 020 0 034 mm Exceeding specified value Replacement Piston pin 1 Check Piston pin Blueing or becoming groove Replacing then checking lubrication system 2 Measure e Outer diametet a of piston pin Exceeding specified value range Replacing Outer diameter of piston pin aa LAT Mufa T DAAA 14 991 15 000 mm Limitation 14 969 mm Check and repair 3 Measure e Inner diameter of piston pin hdie b Inner diameter of piston pin hole 15 002 15 013 mm Using limitation 15 043 mm Exceeding limitation Replacement Piston ring 1 Measure Side clearance Exceeding specified value range Replacing the whole set of piston and piston ring Note Before measuring side clearance get rid of carbon deposit in piston ring groove and each ring Side clearance 1 ring 0 03 0 07 mm Using limitation 0 12 mm 2 ring 0 02 0 06 mm Using limitation 0 12 mm 2 Measure e Push the piston rirg a into cylinder at point 5mm to to
73. gneto and brake switch at the wire clip Pass the brake cable and flexible shaft of meter though guide frame SPECI Layout of cable pipline D Throttle cable O Wire of rear brake switch Zilgnition coil Flowing tube of carburetor 3 High pressure wire 8 Flowing tube of crankcase Clutch cable 9 Overflowing tube of carburetor Rear brake switch dOFlowing tube of battery A Fix ground wire and ignition coil together B Pass the overflowing tube of carburetor and flowing tube of battery through suspending upper portion of crankcase and engine sup port of frame Drum type without fairing Serio j a as ee a X eee Layout of cable pipline D Left handlebar switch A Pass the wire of the cable brake cable brake switch and handle bar switch through 2 Clutch switch guide frame 3 Prontbrubeswitel B Pass the wire of clutch cable handle bar switch and clutch switch through guide frame C Fix the wire of left handle bar switch and clutch switch with bands D Fix the wire of right handle bar switch and brake switch with bands 4 Right handle bar switch Drum type without fairing D Clutch cable A Pass the flexible shaft of speedometer and 2 Cable brake cable through guide frame Drum type withoutTflt fairing Wire of handle bar switch Wire of front brake switch Throttle cable Guide frame of throttle cable Front brake cable brake oil tube Fixing clip of front brake cable gt 9
74. he performance they shall closely cooperation 9 Service manual and parts catalogue shall be always at hand e In order to ensure the performance with efficiency reliability and safety it 1s neces sary to bring with them 1 3 Points for attention in maintenance GEN 1 Gaskets oil seal and O ring 1 Replace all gaskets oil seal and O rings when over hauling the engine All gasket surfaces oil seal lips and O rings surface must be cleaned 2 Properly oil all mating parts and bearings during reassembly Apply grease to the oil seal lips Lock washer lock shim and split pin 1 Replace all lock washer shim D and split pins after removal Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification Bearing and oil seals Install bearings D and oil seals so that the manafac turer s mark or numbers are visible When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips The bearings should be lubricated generously when installing Criclips 1 Check all circlips carefully before reassembly Always replace piston pin clips after one use Replace distorted circlips when installing a circlipCD make sure that the sharp edged corner 2 is positioned opposite the thrust it receives see sectional view Qis shaft Note Do not use compressed air to spin the bearings dry This will damage the bearing surfaces 1 4
75. ing terminal abbreviated drawing of switct such as main switch handlebar switch brake switch ar lighting switch etc see left figure often appear in this manual The switch position is recorded in the left columr of terminal connection table which the wire color connec ting terminal is written down at the upper column O O means the conduction between the terminals is formed that is the sealing conduction circuit of every switch is formed on it s position conduction is formed at ON position which is between the Brown term inal and theRed one 7 6 D 4 v gt Y c OQ c D Circuit of ignition system Maganeto dJCDI unit d2lgnition coil spark plug Main switch 1 1 Inspection of socket connector Exclusion of trouble shooting Ignition system failure No spark or discontinuous spark Inspection procedure 5 Resistance of pulse coil 1 Spark plug 6 Resistance of spark charging coil 2 Checking spark 7 Main switch 3 Resistance of the spark plug cap 8 Circuit terminal loop of ignition system 4 lgnition coil Remark Before excluding the troubleshooling the following parts side cover cushion fuel tank should be removed The following specific tool should be used before excluding Min multitester Ignition tester 90890 06754 90890 03112 Spark plug type CR6HSA 1 Spark plug Check the spark plug condition Check the spark plug type Check
76. int Remark When excluding the following components should be When excluding the following specialtol should be used removed Multitester Side cover Cushion 90890 03112 Check if the fuse is conducted Conduction 2 Battery Check the battery condition Voltage 12 5V Poor conduction Replace the fuse Abnormal Special gravity of electrolyte 1 280 20 C Supplement electrolyte distilled water Normal Clear the binding post of battery 3 Main switch Remove the branch connector of main switch from bundle conductor Check if the switch between the Red and the Brown is conducted Charge of replace battery Abnormal Normal 4 Reconnection condition of guide wire Check the socket connector of whole signal syste The main switch is failre replace it Abnormal Refer to circuit Diagram section Normal The correct should be done Check every circuit condition signal system Refer to Inspection of signal system section 1 32 Signal system Inspection of signal system 1 No function of the horn Abnoraml 1 Horn switch Remove the branch connector of handle bar switch left from the bundle conductor The horn switch is failure the lever switch left Check if the switch between the Pink and the should be replaced Black 2 Voltage Connect min multitester DC20V to guide wire of horn Positive guide wir
77. ion at the left blinker Positive guide wire of multitester Brown guide wire Negative guide wire of multitester Frame groun Connection at the right blinker Positive guide wire of multitive Dark green guida wire Negative guide wire Frame ground wire Tum mailewiteh io SON Out of normal value Turn turn signal switch to left lt or right position Check if the voltage of brown guide wire of dark 6 Circuit joint geeen guide wire at socket connector gets tQV Check if there is break at connection part of loop Meet normal value of signal system Refer to connection diagram of loop of signal syste Layout of signal loop is normal 4 Neutral indicator no work No conduction 1 Bulb and socket Check if the bulb and the socket are conducted Replace the bulb or socket Abnormal Conduction 2 Neutral switch Remove guide wire of neutral switch from bundle condctor Check if the switch between the sky blue and the ground wire is conducted The neutral switch is failure replace it Normal 1 36 Signal system 3 Vitage Connect min Multitester DC20V to socket connector Positive guide wire of multitester Brown guide wire Negative guide wire of multitester Sky blue guide wire Turn the main switch to ON Check if the voltage of brown guide wire at socket Out of normal value connector gets to 12V Meet normal value There is poor
78. ithout fitting filter core of air filter It will cause over wear of piston cy linder 3 16 Adjust of front brake Adjust of front brake drum type 1 Check Free travel a of brake cover Exceeding specified range adjustment 2Adjustment Free travel of brake lever Adjusting procedure lever side Loosen the lock nut Screw in or screw out the adjusting nut until reac hing specified free travel Screw in Free travel increment Screw out Free travel reduction e Toghten up the lock nut Note Should confirm no blocking of brake after adjusting Adjustment brake drum side eScrew in or screw out the adjusting nut until reac hing specified free travel Screw in Free travel reduction Screw out Free travel increment Check of front brake pad 1 Check Needle wear indicating plate e Needle reaching the wear limit line of indicating plate Replacing brake pad Check of front brake Check of front brake disk type If feeling loose and soft braking the bad brake effect may be caused by oil leakage or mixing with air You should check brake liquid capacity and lock brake steel cable or eliminate air 1 Conducting following check e f there is vibration when turning leftward or rightward or driving you should check if the brake nose contact other part Contacting correcting 2 Check the free play of the front end part of brake handle ree
79. ker shaft Aim at screw hole of cylinder head to mount until the rocker arm can not be seen Note Be sure to make the mouth part of screw outward to mount Assembling and adjustment of engine P 3 Mount e Camshaft 4 Mount Pressing plate e Bolt 4 42 Assembling and adjustment of engine P Crank and balance device Crank pin Crank bearing Crank left Semi round key Connecting rod Balancer Roller bearing of end side Balancer bearing 4 43 Assembling and adjustment of engine Mount of crank and balance axle 1 Mount e Crank Shielding hood of crank assembly 90890 04081 Sleeve of crank assembly 90890 01274 Bolt of crank assembly 90890 01275 Template pipe joint 90890 01378 Note Keep the connecting rod on dead piont When mounting never contact crankcase Never use hammer to beat crank 2 Mount e Balance axle e aim the engraving mark a of driving gear of crank at engraving mark b balance axle gear then mount them 4 44 Transmission assembly Driving chain wheel Oil seal Bearing Driving gear 5gear Driving axle Assembling and adjustment of engine Driving gear 2 Driving gear 3 Driving gear 4 Driving gear 1 Bearing 4 45 11Bearing 16Main axle 12Drive gear 5gear 17Circlip 13Drive gear 2gear 1 earing 14Drive gear 3gear 15Drive gear 4gear Assembli
80. l gallge needle s action Needle of fuel gauge Showing E Normal The loop connection of signal system is normal 7 38 Chapter 8 Troubleshooting Trouble shooting of engine Electric appliance Sy stem COC COC PED OED ETE SET FOSTER OD SET SCT ROTTED OTE STS EER OOF OET SOC EH OEE SEES OS HOH STO OTE DESH EE EHO STEED PETER HD DODD Compressure system ee Intake and exhaust system CO E E E E 999 eeeeeeeeeo 9599 999 690909 0944 see 995 9 5 9062046 0 925 9955 999 0699 96 6 9 49959 9 9 9 9 5 090906 206 429595999 seseeeeeeee eee eee eee Troubleshooting of engine a Troubleshooting of engine Electric Appliance system Check all socket connector of guide wire Ignition coil refer to page 7 8 Short circuit of main switch Damage of short circuit of main coil or secondary coil Failure of high pressure guide wire Failure of spark plug cap Break or short circuit of guide wire Spark plug Apparent carbon deposit Moisture of electrode Tm sie Pulse coil refer to page7 p Damage of winding Incorrect ignition timing Lighting coil ignition charge coil refer to pagE Starter motor rdfer to page 14 Ads l dis 7 7 7 22 7 7 22 Damage or failure of starter motor Failure of starter relay Damage of winding Failure of starter cultch Failure breaking relay 8 1 Troubleshooting of engine Y Compressure system Inadequate tight force Bu
81. layout from the main switch to 5 Needle of fuel gauge no work 1 Fuel level sensor e Remove the fuel level sensor from the fuel tank Connect min Multitester Q x 10 to the branch connector of fuel level sensor Positive guide wire of multitester Green binding post D Negative guide wire of multitester Black binding post Check the resistance value of fuel level sensor and compare it with normal value Resistance value of fuel level sensor upper position 4 10 Q at 20 C 68 F Out of normal value Resistance value of fuel level sensor lower position 90 1000 at 20 C 68 F Meet normal value Replace the fuel level sensor 1 37 2 Voltage Connect min Multitester DC20V to branchconn nector of fuel gange at the side of bundle conduc Positive guide wire of multitester Green guide wire D Negative guide wire of multitester 5 Body ground wire 2 Check if the brown wire voltage at the fuel gauge binding post at the side of bundle conductor gets Out of normal value to 12V Meet normal value Check all socket connectors of singal system 3 Fuel gauge Connect fuel level sensor to circuit joint e Move the float up and down Remark Firm the float bowl on the 1 or 2 position respectively for over 3 minutes to confirm the needle of fuel gauge Turn the main switch to ON e Move the float to Max upper postion or Poor function max Lower position to check the fue
82. ll out set pin of side cover finally take out side cover along the direction pio nted by arrow 2 Side cover right Take out bolt at position with screwdriver then pull out set pin of side cover finally take out side cover along the direction pointed by arrow 3 Side cover of guide flowing right Take out the bolt of seperate the connecting block which connects side cover then pull out the set pin of side cover finally take out the side cover along the direction pointed by arrow 4 Side cover of guide flowing left Take out the bolt of separate the connecting block which connects side cover then pull out the set pin of side cover finally take out the side cover along the direction pointed by arrow 5 Cushion Take out bolt as per fig indicated position one each at left and right side then take off the cushion forward Periodic inspection and adjustment AD ES 6 Fuel cock eSwitch the fuel cock off Note First close the fuel cock on the fuel tank at the position 0 then take off the fuel pipe T Fuel tank Bolt Shim Rubber pad Fuel tank 8 Installation Conduct as per reverse procedure of removal operation pay attention to the following 1 Installation Fuel tank e Torque Bolt torque see upper fig 2Kgf m 20N m 2 Installation e Cushion Note _ First insert the convex tip position at the rear portion of cushion into insert hole on the frame
83. ls Standard compression pressure 1200KPa 12kg cm 7 nstall e Spark plug spark plug cap 3k ak ake 2k aK ok 2k 2k ok oe 2k ke o 2k K ake ok ok ok oe ok oe o 2k ok ak 2k ok ok 2k Check of lubricant quantity of engine Recommended lubricant oil Replace engine lubricant oil Check of lubricant quantity of engine When inspecting the motorcycle should be rested at flat position and in vertical condition 1 Conduct the following check e Lubricant quantity of engine Run the engine with idle speed for 2 3 minutes then stop the engine for 2 3 minutes keep the machine in vertical position and take out cock Check the oil level on the cock if itis between and Lubricant quantity of engine Recommended lubricant oil When normally replacing Wide isti ie rui E SAE10W 40 When repairing the engine 1 2 1200mL ee eee eee SAE20W 50 EIE 20 10 0 10 20 30 40 Refer to the indication in the fig select the proper engine lubricating oil which suits for viscosity code of local temperature Recommended engine oil YAMAHA four stroke lubricating oil 3 11 AD ie Replacement of engine lubricating oil check of lubricating oil pressure Replacement of engine oil Note Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase 1 Rest the machine on a level place 2 W
84. ly of side cover 2 Check Electrolyte level The electrolyte level must be between upper mark line and lower mark line e f the electrolyte level is too low supply the electrolyte properly Note Only distilled water can be supplied The tap water contains mineral which is harmful to battery 3 Check Terminal of battery Dirty terminal cleaning with steel wire brush Bad connecting correction Note Paint a layer of little lubricating grease after cleaning terminal 4 Check Airflow hose Jamming Eliminating Damage Replacement Note Be sure to arrange the way of airflow hose correctly when checking battery Be careful not to let electrolyte of bubble contacting frame or other part to avoid cor rosion 3 27 Check of battery 5 Connet Airflow hose Must confirm firm connection and correct way of air flow hose 6 Check e Specific gravity Smaller than1 085 Recharge Charging current 0 5A 10h Specific gravity 1 28 at20 680 F Replace the battery when finding following condition e During charging the votage can not reach the specified value or no bubble rises One or several battery unit elements are suphidized The electrod plate becomes white or substance gathers on bottom of battery unit element Recharging becomes slow after a period of time The specific gravity reading of one battery element is lower than others
85. m 5 Main switch e Remove the branch connetor of main switch from the bale of wire Check if the switch is conducted between the red amd the brown Abnormal If the main switch is failure replace it Normal 6 Neutral switch Remove the wire of neutral switch from the bundle conductor Check if the switch is conducted between the sky blue wire and the ground wire Abnormal If the neutral switch is failure replace it 7 15 Starting system 7 Clutch switch Remove the branch connector of clutch switch from the bale of wire Check if the clutch switch is conducted between the black and the black Abnormal If the clutch switch is failure replace it Normal Poor connection break 8 Wire joint Refer to the loop wire of starting system Correct or replace 7 16 Starting system Starting motor Starting motor assy Magnet wheel Rear bracket Electric button Electric brush spring Adjusting pad Electric brush assy io bracket O ring O ring Length limit value of electric brush A 3 5mm Wear limit value of commutator 21 0mm Hexagon slot 1 5mm Resistance value of electric button coil 0 017 0 021020 C 7 18 Starting system Removal 1 Remove e Wire of starting motor e Starting motor assy Stripping 1 Before stripping make the identifiable mark on the frond and rear brack to be easy to
86. m 1 21 D T ep 2 V D Lum S am O 1 22 O p z O 14 O C D O ad CDI magneto Starting relay Charge system Circuit Diagram Charge system Exclusion of trouble shooting No charge on the battery 1 Fuse 4 Lamp switch 2 Battery 5 Double beam lamp switch 3 Main switch Remark Refore excluding the following components should be removed Side cover Cushion The following specific tool should be applied Multitester 90890 03112 No conduction 1 Fuse Check if the fuse is conducted Replace the fuse Conduction 2 Battery Check the battery condition Voltage 12 5V Abnormal Specific gravity of electrolyte 1 280at 20 C 68 F Normal Supplement the electrolyte distilled wate Clear the binding post of battery Charge or replace the battery 1 23 3 Charge voltage Connect the induction tachymeter to the wire of the spark plug Connect min multitester DC20V to the battery Positive wire of multitester positive binding post of battery Negative wire of multitester Negative binding post of battery Check the charge voltage after the engine is accelerated to 5000r min Charge voltage Normal value 14 0V at 5000r min Remark Battery charged fully should be applied The charge circuit is normal Out of normal value 4 Resistance value of charge coil Remove the branch connector of
87. n of fuse section of the 3 chapter If the fuse Is broken replace it 3 Baltery Abnormal Check the battery condition Refer to Inspection of battery section of the3chapter Specific gravity of electrolyte Supplement eletrolyte distilled water Clear the binding post of battery Charge or replace the battery 1 280 at 20 C 68 F 1 27 Lighting system 4 Main switch Remove the branch connector of main switch fro the bundle conductor Check if the switch between the red and the Abnormal brown is conducted Normal o Garden light switch If the main switch is failure replace it e Remove the branch connector of handle bar sw itch right from the bundle conductor e Connect min Multitester Ox1 to the binding post of handle bar switch right e Check if the switch between the brown and the blue black is conducted Abnormal Normal 6 Dimmer switch of headlamp Garden light switch is failure replace the handlebar switch right e Remove the branch connector of handle bar switc left from the bundle conductor e Connect min Multitester Ox1 to the binding post of handle bar switch right Check if the switch between blue black and yello Abnormal and blue black and green is conducted Normal Headlamp dimmer switch is failure replace the handlebar switch left 1 28 Lighting system Inspection of lighting system 1 Headlamp
88. nd pump case Gear tip clearanceA 0 15 mm Side B 0 06 0 10 mm Thickness difference C 0 06 0 10 mm 4 37 Check and repair 2 Check Centrifugal eigine oil filter Crazine damage Replacement Dirty Washing 3 Check Engine oil filter net Crazine damage Replacement Dirty Washing Crankcase 1 Rinse the combinating face of the crankcase thoroughly with a little warm solvent 2 Wash all matching surface of gasket and crankcase th oroughly 3 Check e Crankcase Crack ordamage Replacement e Oil hole Jamming Blowing with compressed air 4 38 Check and repair Bearing and oil seal 1 Check e Bearing Wash and lubricate it then rotate the inner ring with fi nger Uneven Replacement Note Do not dry it by making the bearing rotating by itself through blowing in compressed air Otherwise will cause damage of bearing surface 2 Check Oil seal Damage or wear Replacement Elastic circlip and washer 1 Check e Elastic circlip e Washer Damage loosening bending Replacement Assembling and adjustment of engine Assembly and adjustrment of engine Air valve swaying arm and cam axle Air valve rod intake 130 ring Lock piece of air valve Lock nut 14Guide pipe of air valve f air val i Upper seat of air valve spring Adujsting bolt Cam axle Oil seal of air valve rod n Swaying arm 16Pressing plate Air valve spring Air valve spring seat 11Sw
89. ng and adjustment of engine P Shiftcam shifting yoke Guide rod of shifoing yoke long Shifting yoke 3 Shifting yoke 1 Cam Star shape gear Guide rod 2 of shifing yoke short 4 46 Assembling and adjustment of engine Installation of thransmission change cam and change fork 1 Installation e Clutch push rod 2 2 Installation Main shaft Note Before installing the main shaft first installing the push rod in the clutch into the inner hole of main sh aft then installing it 3 Inspection Installing width of main shaft gear a ox tandard installing width of main width 82 25 83 45 mm 4 Installation e Garket e O ring Install the O ring into the installing groove of firm bracket of sprocket of drive shaft avoid damage of oil sealing lip after installing the drive shaft take out the O ring e Drive shaft 4 47 Assembling and adjustment of engine 5 Installation e Change cam The convex point on the change cam should align the contact point in the neutral switch of crankcase Change camL The surface signed L is toward clutch Change fork R The surface signed with R is toward clutch Change fork C The surface signed with C is toward clutch e Change fork guide rog Change fork guide rod 6 Inspection Operation of change cam The operation of change cam The operation is unsmooth reinstall Note CCC
90. nt Clutch 1 Check e Driving gear of spindle e Driven gear of spindle Wear or damage Replacing two gears Loud noise while running Replacing two gears 2 Check e Friction wafer Damage or wear Replacing the whole set of friction wafer 4 31 Check and repair 3 Measure Thickness of friction wafer Exceeding specified value range Replacing the whole set of friction wafer Measuring at four points of upside lowside leftside and rightside Thickness of friction wafer 3 0 mm Using limitation 2 8 mm 4 Check e Clutch wafer Damage Replacing the whole set of clutch wafer 5 Measure Buckling of clutch wafer Exceeding specified value range Replacing the whole set of clutch wafer e Should use flat plate and thickness gauge Friction limitation value Less than 0 05 mm 6 Check The length of clutch sprir g a Damage Replacing the whole set of spring Spring length of clutch 33 0 mm Limitation 31 0 mm Check and repair 7 Check e Retainer of main amp driven gear Scratch wear damage Deburring of replacing Clutch hub Scratch wear damage Replacing clutch hub 8 Check e Steel ball e Pushing rod e Pressing plate Wear damage Replacement Transmission and shift rod 1 Check e Driven part of shifting yoke cam eShifting yoke jaw Scratch bending damage Replacement Check and repair 2 Check e Shift cam groove
91. nternal hexagonal cylinder head bolt M amp x 1 10 02 1022 Hexagonal flange faced bot Hexagonal fange facedbot yip 2 10202 10 22 NL Jg 14 Oil drainage bolt 90340 12097 Bolt 2X0 5 20 5 16 Silencer assy finished vehicle 9581N 08020 Hexagonal flange faced bolt 2 2 0 2 22 2 9502L 06030 Hexagonal flange faced bolt small head M6x DUI TITEUWEEEZETTNE TE pepe eem flange faced bolt small head M6x1 0 EOE SEE aee nos eem ama 2 emen f qm oso21 og0a5 Fervora tange acea tonemarneadh ponto 9 10202 102 9502L 06045 Hexagonal flange faced bolt small head M6x1 0 0 0 10 2 Kick starter assy 90179 12813 Nut M12x1 0 O41 50 10 22 Hold down of idler 9851L 06012 Cross recess pan head bolt M6x1 0 Hexagonal flange faced bolt small head M6x1 0 Pe ae De La sena arainanoie ene neal crnerteesbor perts 3 soma ms 26 Howdown 2 swesmroo Emsiewrew wea 4 0602 ez Tighten torque SPECI 16 Tighten torque Tiighten parts Part No Name Dimension Qty Handle bar seat and inner tube M8x1 2 18 28 C1 e C1 N O N N oO N IN oO co 24 25 Pulling rod and reararm 90109 08848 Hexagonal flange faced bolt M8x1 25 1 15 23 Fuel tank and fuel cock 90149 06801 l neag S faced bo M6xtO 4 5 8 Meri z TE nam M10 1 26 2588 TEE nan Mont 2548 Mesas 1523 Brake pan and front wheel pan 90111 08805 M8x1 25 ES 1 8
92. of bent replace Never attempt to repair the wheel by yourself even the small repair 3 Inspection and fastening of spoke 1 Inspection e Spoke If bent and damaged change If the spoke is slack tighten up 2 Fastening e Spoke Note L After repairing be sure to adjust the slackness of the spoke evenly 6 4 GS SN V E Inspection of front and rear wheels CHAS N 6 5 4 Inspection e Turn the wheel rim slowly to inspect the radial and ax ial runout Over of limit replace Rim runout limit Radial 1mm Axial 0 5mm 5 Inspection e Wheel bearing If the bearing inside the hub hawindage unsmooth rotation slackness abnormal sound replace e Oil seal If worn or damaged gt replace opeedometer gear assy 1 Removal Cable head of speedometer e Driven chain of meter e The speedometer cable should be free from bending Meter clutch 1 Inspection Meter clutch e f deformed damaged replace Inspection of front and rear wheels CHAS e Drive chain of meter e Driven chain of meter Front brake 1 Inspection e Friction liner surface of brake pad Smooth area polish e Polish with rough sand Note After polish with sand clean off the grainsof polishing material 2 Measurement Friction liner thickness of brake pad Out of specification replace The friction liner thickness of brake aC Thickness 4mm Limit 2mm No
93. oil of ignition coil Connect multitester test frequency 1k to terminal of high pressure coil Resistance value of ignition coil 3 160 I 10 20 C Abnormal The resistance of two coils meets the normal value 6 Resistance of pulse coil g Divide the adapter of the pulse coil with wire g Connect the multitester testOx1000 to the adapter q pulse coil for measure of coil resistance lead wire of voltage gauge Red terminal lead wire of voltage gauge White terminal Normal resistance 3100 20 20 C Out of normal value Replace the pulse coil 7 10 Inspection of socket connector 7 Resistance of ignition charge coil a Remove the ignition charge coil g Connect the multitester te dx 1000 to the terminal of charge coil Connecting method Lead wire of voltage gauge Green terminal lead wire of voltage gauge Brown terminal Resistance of charge coil 8600 20 20 C Out of normal value Replace the ignition charge coil Normal 7 Wire joint Refer to the loop connection of ignition system Normal Change CDI unit assy Poor connection Correct or replace 7 11 c D ep gt v O amp 2 i Y Circuit of starting system Neutral switch Starting relay Starting motor Main switch C O 0 5 l E o z 2 o gt 2 D 2 O 7 12 Starting system Exclusion of troublesh
94. ooting No work of starting notor Inspection procedure 1 Battery 5 Starting relay 2 Fuse 6 Starting switch 3 Starting motor 7 Neutral switch 4 Main switch 8 Clutch switch Remark Before excluding the following components should be removed Side cover Cushion The following specific tool should be used when excluding Min multitester 90890 03112 No conduction 1 Fuse g Remove fuse a Connect min multitester Ox1 to the fuse Check if the fuse is conducted If the fuse is broken replace it Conduction 2 Battery a Check the battery condition Abnormal a Refer to the third chapter Battery Voltage 12 5V Electrolyte specific gravity 1 280 at 20 C 68 F a Supplement the electrolyte a Clear the binding post of battery Charge or replace the battery Normal 7 13 Starting system The capacity of the cross bond must be equal to or 3 Starting motor larger than that of the battery wire otherwise the Connect the positive binding post of battery l cross bond will be burnt to the cable of starting motor with cross bond See figare Out of work If the starting motor is failure replace it Check if the starting motor work Work 4 Starting relay Remove the adapter of starting relay from the bundle conductor Connect the battery to the wire of starting relay wit cross bond See figure Out of work If the starting motor is failure replace it 7 14 Starting syste
95. pecified value Specified oil temperature 55 6 3 Confirm idle speed value 1400 pm 4 Install the measuring meter for CO content 5 Check the CO density Standard co density 1 5 4 596 Out of standard value adjust P S adjusting screw match with adjusting idle screw Inspection adjust the free clearance of throttle cable 1 Conduct the following inspection e Free clearan e a of surrounding of throttle cable Free clearance of surrounding of throttle cable mm Out of specified value adjst 1 Conduct the following adjustment e Free clearance of surrounding of throttle cable Adjust sequence First step Throttle steel cable oosen the locking screw e Adjust the adjuster Screw in increase the clearance Screw off decrease the clearance Tighten the locking screw Adjustment of frdd play of throttle cable and check of spark plug Note When the adjustment could not done by the steel cable at throttle handle bar it could be done by the adjuster at the carburetor Second step carburetor Loosen the locking screw Adjust the adjuster Screw in Increase the dearance Screw off Decrease the dearance e Tighten the locking screws After adjustment start the engine turn the steering handle bar leftward and rightward confirm that the idle speed of engine will not increase Check of spark plug 1 Conduct the following check Check electrode pollution of insul
96. play of front end part of brake handle 5 5 10 5mm Note This play is ensured by manufacturing No adjustment is needed Checking brake pad 1 Conduct following checking e Check the wear condition of brake pad If the wear indicator hardly contactin brake round disk replacing whole set of brake pad Q Check the brake liquid quantity Exhausting air 3 18 Check the brake liquid quantity 1Conducfollowing checking e Brake liquid level Check the liquid level when the brake liquid level cover is in horizonal state The liquid level should be above in figure f the liquid level is below the lower position sup ply the brake liquid until above the lower limit position Appionted brake liquid genuine YAMAHA brake liquid DOT4 Note Do not mix and use brake liquid of different brand DOT3 oil can be used if there is no No DOT4 oil The brake liquid will corrupt the painting surface and pla stic part wipe off it inmedinately when splashing Exhausting air When disassembling related parts of braked liquid you must confirm that other parts are locked and sealed Then the air can be released Proceduresof releasing air 1 Remove the cover of brake liquid vat 2 Remove the diaphragm of brake liquid vat 3Mount plastic rubber pipe on front end of oil draining Screw and place a oil container at the front end of plastic rubber pipe 4 After braking several times loosen the oil draining screw about 1 2 tu
97. repair Cylinder head 1 Clean e Carbon deposit Clean from burning chamber Use round head scraper Note Do not use sharp tool for avoiding the damagement of the spark plug thread and air valve seat 2 Check Cylinder head Scratched marks damage Replacement 3 Measure e The tilt of cylinder Check if there is skew at 6 directions of combinating faces with cylinder Gradient Less than 0 03mm 4 Repair the surface e Cylinder head KKK KK KK KK KK KK KK K K KK KK ok ok ok ok KK KK KKK KKK ok ok OK ok KOK Repairing procedure Place a wet sand paper about 400 600 on flatform and grind the surface according 8 toshape Note Move the cylinder head several times to avoid too much wearing on one side OK OK OK 2K K K K OK K K K K OK K OK K KK KK KK KKK OK OK OK OOK OKO OK OK OK OK OK OK OK OK K K 4 18 Check and repair Air valve seat 1 Clean e Carbon deposit Clean from working face of air valve and air valve seat 2 Check e Air valve seat Corrosive pitting or wear Repair the air valve surface 3 Measure Width of air valve seba Exceeding specification both are usable value range Repairing air valve seat Width of air valve seat Intake 0 9 1 1 mm Exhaust 0 9 1 1 mm OK OK 2K 2K 2K 2K 2K OK 2K OK OK 8 OK 2K OK OK OK OK OK 5 OK OK OK OK CKCKCKCKCKCKCKCK cene Meauring procedures 1 Paint blue dykem on working fae b of air valve 2 Fit the air
98. rn the main switch to ON postition Turn the garden light switch to ON position Out of normal value Check if the voltage of Brown wire on socket cnng gets to 12V Meet normal valre 12V If layout from the main switch to the socket connector is poor repair it The circuit is normal 3 The tail lamp 1 Bulb and socket Check if the bulb and socket are conducted Conduction 2 Voltage Connect min multitester DC20V to socket No conduction Replace the bulb or the socket connector Positive wire of multitester blue binding post Negative wire of multitester black binding post Turn the main switch to ON position Turn the garde light switch to ON position Check if the voltage of blue wire on socket Meet normal value 12V The circuit is normal 7 30 If the layout from the main switch to socket connector is poor repair it Signal system Signal system Circuit Diagram Main switch 3 Tai lamp brake lamp Starting relay 2426 Front left right turning lamp Battery 9Front brake switch Rear brake switch i ud Instrument assy orn Flash relay Q Neutral switch Left handle lever switch assy 0597 Rear left right turning lamp 5Fuel signal sender 7 31 Signal system Exclusion of trouble shooting Blinker brake lamp or indicator are not lit and the horn does not work Inspecttion procedure 1 Fuse 3 Main switch 2 Battery 4 Wire jo
99. rn when gripping brake handle then tighten it up again quickly Note Do not release the brake handle before tightening up the oil draining screw again 5 Repeat above procedures until the bubble is eliminated completely Note CC COO O C Supply the brake liquid at the same time Do not let it below the lower limit Q Exhausting air Replacing brake liquid Grip the brake hadlebar to check brake liquid leakage Wipe off the brake liquid sprayed on brake disk tire and rim 6 Refit the diaphragm of brake liquid vat 7 Refit the cover of brake liquid vat Replacing brake liquid 1 Make the main liquid vat in horizontal state and disass emble the cover of liquid vat 2 Fit the plastic rubber hose on front end of oil drain ing screw and prepare oil continter at the front end of plastic rubber hose Loosen the oil draining screw and repeat that several times until no brake liquid is drained by oil draining screw Wipe off the brake liquid sprayed on brake disk tire and rim 3Lock the oil draining screw Oil draining screw 6 Nm 0 6 kg m 4 Remove the diaphragm of brake liquid vat 5 Fill the brake liquid until above lower limit Appointed brake liquid genuine YAMAHA brake liquid DOT4 Note LL C Do not mix and use brake liquid of different brand DOTS3 oil can be used if there is no DOT4 oil 6 Pull the brake handl
100. sistance 0 40 20 20 C Secondary winding resistance 7 1k Q 20 20 C Spark plug gap Type Resin type Resistance 5 2096k Q 20 C Rctifier regulator No load regulated voltage Rated voltage14 2 x 0 5 Capacity 5A Withstand voltage 240V min Battery Specific gravity of electrolyte 1 280 0 01 20 C Electric starting system Type Mesh type Start motor Output 0 4KW Rotator coil resistance 0 171 0 209 Carbon brush length 10mm Spring pressure of carbon brush 0 9 20 N Starting relay Rated current 30A Coil resistance 4Q 10 20 C Horn Type Max Current Fuel meter Resistance of sensor Full 100 20 Empty 900 20T Relay of turning light Type Capacitor type Flash frequency 60 120 times min Circuit breaker Type Main circuit Reserve circuit Tighten torque Tighten torque Engine Tighten torque Ser No Tighten parts Part No Name Dimension OM D Kem Wm Kgm Nm 90105 08742 _ Hexagonal flange faced bolt M8xt25 4 22202 DEMENS 9131N 06090 Internal hexagonal cylinder head bolt M6x1 0 EN 1 040 2 YX2 Bolt of oil drainage port 90153 06803 Cross recess hexagonal head holt M6x1 0 0 7 0 2 Spark plug 94700 00372 M10x1 0 1 25 40 25 12 5 2 5 Side cover 3 of cylinder head 9502L 06020 Hexagonal flange faced bolt M6x1 0 1 00 2 10 2 fe fros oom semmana fanene 0 wits r fraas aa a WA aman M e renaras sonos mean Wis 2 orson rsrs I
101. stall as shown on the fig e Bend the jaw part of limit prers plate in of b as shown on the left fig after bend deformattion stick the side of the nut firmly Installation of drive chain 1 Installation e Drive chain e Chain tensioner Chain press plate 2 Installation Chain joint clip Note As shown on the fig pay attention to the installing direction of chain joint clip 3 Adjustement e The slackness of drive chain Refer to the section Adjustment of drive chain slack ness of chapte Note If the slackness of drive chain is too small it will cause the engine and other main components to overload The chain slackness should be kept within the sp ecified limit 4 Installation e Axle nut Bolt Front fender Plug Bolt O ring Spacer Spring seat Spring Dust cover Clip 6 19 Front fork CHAS Bolt 43 Washer 2 Plug rod of oil stocking 3 Damper rod 2 Inner pipe 5 Spring 6 Oil seal Outer pipe Front fork CHAS Take out the front fork Rest the motorcycle firmly to avoid turnover 1 Rest the motorcycle on the flat ground 2 Place a proper bracket under the frame and the engine to surpport the front wheel 3 Removal Front wheel Front fender hii Yer T S NC Wi fo NULL LY Loosen the bolt Qu 9 P Cover bolt NIB j TTTY 4 Loosen Note 2272C C C CCCCCCCOODODOODOUV When removing the front fork remove the 2 bolts for fastening the
102. stat mechanism 1 Inspection Check the gear conditions of start gear 1 and 2 a bc Rag scrap unsmoothness abrasion replace 2 nspection Start gear 2 linking surface Corrosive pitting abrasion damage replace kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Inspection procedures Install the starter gear to the clutch of starterand grip the clutch When turn the starter gear clockwise A the starter cl utch should be engaged with its gear Otherwise it indicates that there is some trouble with thestarter clutch and it should be replaced When turn the starter gear counter clockwise B the clutch gear of starter should turn freely Othewise it indicatesthat there is some throuble with starter clutch and it should be replaced kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Chain guide plate and idler pulley 1 Installation e Timing chain e Chain guide plate Installing torque 1 0Kgf m 10N m Note 22222227240000 2 2 2 1 2 24 1 O 2 x 2 The guide plate can be installed only after the timing chain has been installed 2 nstallation e Starting the idler pulley Pressure plate Installing torque 0 7Kgf m 7N m 3 Apply e Engine oil of 4 stroke Apply the shaft neck and starter drive mechanism Assembling and adjustment of engine 4 61 AInstallation e Washer e Starting gear alnstallation Woodruff e Rotor Note Before installing clean off
103. stic washer 6 Disassemble Primary driving gear nt Note LL e Do not place cloth strip aluminium plate and copper bar etc between main driven gear and primary driving gear see a Fix with sleeve at position of rotator fixing nut then disassemble primary driving gear nut Disassembly of engine 1 Disassemble Primary driving gear eKey e Engine oil filter Engine oil pump 1 Disassemble e Bolt e Engine oil pump e Gasket Driving gear of engine oil pump Starting axle and idle gear 1 Disassemble e Elastic circlip e Flat washer e idle gear e Flat washer e Elastic circlip 2 Disassemble e Resetting spring eStarting axle assy Disassembly of engine 4 Shift axle 1 Disassemble eShift rod e Resetting spring Bolt eStop device Rotator 1 Disassemble e Nut Note Fix the rotator with rotator jig then loose nut Rotator jig 90890 01701 2 Disassemble e Rotator Half round key Note __ Push the fly wheel backward with disassembling tool of fly wheel then may disassemble the fly wheel Disassembling tool of fly wheel 90890 01362 Ea Disassembly of engine 3 Disassemble e Starting idle gear 1 e Washer 4 Disassemble Pressing plate of gear e Starthing idle gear2 5 Disassemble Chain guide board e Timing chain Crankcase right 1 Disassemble e Screw crankcase Note
104. te _ c Before reassembly clean all parts with clean gas oline Adjustement of fuel level 1 Measurement e Fuel level a Over the specification value adjust Fuel level a 6 6 7 6mm The fuel level should be at the middle postion of the float chamber on the lower side of the carburetor case edge Measurement and adjustment procedures of fuel level Rest the motorcycle on the flat ground and make sure that the carburetor is in vertical condition e Connect the fuel level dipstick with oil drain pipe 4e Fule level dipstick 90890 01312 5 6 Carburetor Loosen the oil drain screw __ run the engine for se veral minutes to raise the temperature e Keep the fuel level dipstick in vertical condition and make it approach to the engrave line of float chamber Measure the fuel level with fuel level dipstick Note The records of the fuel level dipsiticks of the pipes on two sides of the carburetor should be equal If the fuel level is not correct adjust it e Remove the carburetor Check the valve seat and needle valve e f they are all in good condition adjust the fuel level by bending the rear part of the float slightly Install the carburetor Check fuel level again Chapter 6 Chassis Inspection of front and rear wheels ooo ccc cece eee cece III III e eme e heme eene ens 6 1 PION WGC MNT 6 1 Inspec
105. te If any brake pad is found to be worn to the wear limit replace the complete sets of brake shoes 3 Measurement e Inner diameter of brake drums Out of specification replace Inner diameter of brake drum Stardard value 130mm limit valve 131mm 6 6 Inspection of front and rear wheels CHAS 6 7 4 Inspection here is oil stain or scraping mark on the inner surface of brake drum changeand repair Oil stain Wipe with a cloth dipped in the paint diluent or solvent e Scrape Polish slightly and evenly with a emery cloth 5 Inspection Cam axle Damaged replace When installing the cam axle and the central shaft apply a small amount of lubrication grease and clean off the surplus lubrication grease Assembly 1 Installation e Cam axle e ndicator kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk kkkkkkkkkkk Procedures of installation e Let the convex part on the indicataf a pass throughthe concave groove on the cam axfe b and install it well e Align the indicating needle with wear indicator kkkkkkkkkkkkkkkkkkkkkkkkkkkk kkkkkkkkkkkkkkkkk 2 Installtion e Brake arm Installing bolt 1 0Kgf m 10 N m Inspection of front and rear wheels CHAS 3 Installation e Brake Pad e Spring N ote When installing never use the pliers to deform or damage the hook of spring Never apply the ludrication grease onthe friction
106. te eee ee enateegateegateeganenaes 4 21 Air valve spring oessseietevtores ra tbreropr nrtererb iterum opta Tere cenvoragotinisesaeivaus gaecbeabhiereviediatas ue dhavecdensanises 4 22 SAU RR RR 423 Swaying arm and swaying arm exIpuus ncmo uidaesemmiutuu as kate erui ne so gece ps DUERME pu Md RUM A nM MDI 4 24 Timing chain chair wheel guide plate of chain chain tensioner ccccc cece cece eee ee cease eneeeesaeeeas 4 25 cylinder andn 1 9 RITE EID TT 4 26 PIS OM lM S osnesiieteced insani iocus ob epi time M MI P M PN E UIDI PEL ML AR 4 27 NEIN T TT Meme m 4 28 Sn RTI TT 4 29 Balance deviCG sissrskv eade exe E kd re eto ic pa webs Eck dac pw EV E a o C EN TER Ee ber ia d e E d 91 Tranmission shift rod ccccccccccceccuccecuccecceccccccucuceuceucuscuceucuecuceuececsseuetacaseusencaseusencaeensenss 4 33 ael rS UR UNI OTT ee eee A ee eee 4 36 Engine ell pU TIE ccs svar anstanenenimi concn nreauatinae E PEIDEREETOEEEE To ree EE VOL PERVURIUN e Erek eniT Nesenai 4 36 CTC AS RITE EE EE REC T 4 37 Bearno Oil Sedlene ranr i teem acct E aA E EE E EEEE EEEE t 38 Elastic circlip washer cssee m m e em mre he rre nenne re rer re rer n erre rrr r erre rn 4 38 Assembly and adjustment of engine Assembly and adjustment of engine Luuuuuss 4 30 A
107. tion of front wheel isssseessvp oben ana tup aua wat Die kaatico Ua Yoqk iau award DES badud eee bunt etiedeosnieeies 6 4 Speedometer gear ASSY seseexesespteresetacsdexebixsexsEeseshupaseseueuedoE Unc a eras Race Ute UR N RE ESI IND eds 6 5 misse qq 6 6 luicsureasoukieimu Mc 6 9 xc v merr w 6 10 scili o N 6 13 Drive chain sprocket LotenonsoencedsebS axes Seb ri ppEoUEisEudaa C DXud om oR Aen Sadvbd vended den ssdsunokuddsesunetonueeewed 6 15 Big sede c PR e EE NOE ICO ne E rrt 6 15 inspection of drive chain RR 6 17 Insierzeuepusieslisiit a 6 17 installation of drive Chain c T 6 18 Front fork Removal of front fork ssesssessssssesssesssseresssressseresssressseressereesseresseereseeressseresereeeseeresereeesee 6 19 inspection ol MONTOK ccc 6 22 Fron iok aS Semy errer ieie rue ous EE E E EEE E 6 23 Steering shaftand handle ssserssircsrrentiotrikesrt nrs kis orni EENES REEERE EEEE AES EEE Epi onu REE 6 27 PROMOVA NONE sipenge r repie E E EEE E E EEE EET 6 28 inspeccion of handie ARR RR ERR 6 29 Inspection of front steering shaft uusessssssssrrrrunnussssssssrrrrereresssrssrrrererreesssrssrrrrrereesssss gt 6 30 Install ing of steering shaft 2 cccncesexcwaahesieavaoeovencohsosnnisndieawentevcakaudsitecamisecuoreeaseruciseponnateuno
108. to adjust the free play of clutch cable 5 Loosen locking nut 6 Screw in or screw out the adjusting device until the proper free play has been obtained Screw in free play increased Screw out free play decreased f Tighten locking nut core 2 on filter y AD Re Clear of air filter Clear of air filter Note There is check hose at the bottom of the air filter If dust or water collects in this hose clean the air filter core and case 1 Remove e Side cover right e Cushion e Case of air filter 2 Remove Core of air filter Note The engine should never be run without the air filter otherwise unfiltered air will get into the engine thus excessive wron out or damaging the engine will be resulted In addition the operation of carburetor will be influenced and engine may be overheated if running without core of air filter Blown dry with air 3 15 Clean of air filter 3 Check Filter core of air filter Damage Replacement Dusty Blowing off dust on net with compressed air Remove the filter cores1and 2 and clean them by blowing with high pressure air If the filter core 2 is too dirty it may be washed with neutral solution It must be blown dry after washing Coution The filter core may not be painted engine oil Coution It should be confirmed that the filter core has been fixed correctly in filter case Coution It is strictly forbidden to run engine w
109. tor Adjustment of fuel level 00 cc ccc ecc cece cece eeeeeeee sees esse esse sees n enne nme mene Motorcycle body Inspection of front and rear wheels Front wheel Inspection of front wheel Speedometer gear assy Front brake Installation of front wheel sssssssseee IIR RR tert ttrttt t ttt rris Rear wheel Drive chain sprocket Drive chain Inspection of drive chain Rear Drake 810 s MERERI 4 36 4 36 4 37 4 38 4 38 4 39 4 40 4 41 4 43 4 45 4 46 4 49 4 51 4 54 4 59 4 60 4 62 4 63 4 64 4 65 5 1 5 2 5 5 6 1 6 1 6 4 6 5 6 6 6 9 6 10 6 13 6 15 6 15 6 17 Inspection or cute BED orecncvitedtampagesssntaeaconneadan Eo an ERE li don E Eae ut bb n 6 17 instalation of dve Cha MR TETTE TET 6 18 Front fork Removal of ONTO RECETTE DEEP 6 19 IS DE CUOMO MONE TON de 6 22 FONCION AS Se IONIC essit gau EE EEEN E KE REPRE DE 6 23 Steering shaft and MANIC s eiouu uius cano birra siue uie ae EMEN TEPUNF OU RE Eea ONERE 6 27 Removal of WN ERROR m 6 28 Inspection of NANG MERITI TTD 6 29 Inspection Of front steering SOA vcs ccencistwecewdedersdeudy era ubous Dus Prob aka lae eR a ced Ua aia 6 30 Installation of steering SIL seeds dini tos id Ud ES Pas bYRR at ERE D Fauni tanen koutU sa dpud mas tad 6 30 Installation of NANdIlE DAM cece cece een eee e eee mmm me nnn 6
110. uss 6 30 istallato of handie Dar c EEE 6 31 Rear shock absorbor and rear NN RR OTIO 6 32 RAMOVI MUTET TERT 6 33 lacis RET ae E ene ee eT ee S E ere eer er eee 6 33 Inspection of front and rear wheels CHAS Front wheel Self locking nut Meter gear assy Front wheel axle Bushing Front brake assy Bushing Front wheel 4 55 Kgf m 45 5 N m 6 1 Front wheel Brake pad Washer Meter clutch Meter drive gear Brake arm Indicator Cam axle Inspection of front and rear wheels Bushing Washer Meter driven gear Q O ring 20 l seal 1 0Kgf m 10 N m 6 2 Inspection of front and rear wheels CHAS Removal 1 Rest the motorcycle on the flat ground 2 Place the motorcycle on its central stand 3 Place the proper articles under the frame or eng ine to lift the front wheel Front brake 1 Removal e Front brake cable Note Before taking out the cable release the brake 2 Removal e Speedometer cable D Note The clip should be taken out first 3 Removal e Self Locking nut 6 3 Inspection of front and rear wheels CHAS 4 Removal Front wheel axle e Front brake assy e Bushing Front wheel Inspection of front wheel 1 Inspection e Front wheel axle inspect with pencertage meter If bent replace Never attempt to straighten the bent front wheel axle The twist limit of front axle 0 25mm 2 Inspection e Wheel If deformed damaged

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