Yamaha DT175 Service manual
Contents
1. 111 POOR MEDIUM AND HIGH SPEED PERFORMANCE 111 FUEL SYSTEM ELECTRICAL SYSTEM COMPRESSION SYSTEM 1 111 111 FAULTY GEAR SHIFTING HARD SHIFTING SHIFT PEDAL DOES NOT MOVE JUMP OUT GEAR CLUTCH SLIPPING DRAGGING 112 CLUTCH SLIPPING sohis CLUTCH DRAGGING 112 IMPROPER KICKING OG Fui YR ee eee h SLIPPING n quella HARD KICKING EN KICK CRANK NOT RETURNING 22 FAULTY BRAKE 1 12 POOR BRAKING EFFECT FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION 1 13 OIL LEAKAGE MALFUNCTION INSTABLE HANDLING INSTABLE HANDLING FAULTY SIGNAL AND LIGHTING SYSTEM MALI HEADLIGHT DARK I Cot M BULB BURNT OUT FLASHER DOES NOT LI FLASHER KEEPS ON FLASHER WINKS SLOWER FLASHER WINKS QUICKER HORN IS INOPERATIVE OVERHEATING OVERHEATING TRBL 2 I STARTING FAILURE HARD STARTING SHTG TROUBLESHOOTING NOTE The following troubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to troubleshooting Refer to the relative procedure in this manual for inspection adjustment and replacement of parts STARTING FAILURE HARD STARTING FUEL SYSTEM PROBABLE CAUSE Fuel tank Empty Clogged fuel filter Clogged fuel tank L sDeteriorated fuel or fuel containing water or foreign2. OUT OF SPECIFICATION Wiring circuit from main switch to bulb sock et connector is faulty repair SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM Main switch Brake switch Oil level gauge Flasher relay OIL warning light TURN switch NEUTRAL indicator light HORN switch Tail Brake light Battery Flasher light Fuse Horn 7 29 SIGNAL system ELEC EH TROUBLESHOOTING HORN DOES NOT SOUND FLASHER LIGHT BRAKE LIGHT AND OR INDICATOR LIGHT DO NOT COME ON Procedure Check 1 Fuse main 2 Battery 3 Main switch 4 Wiring connection entire signal system NOTE Remove the following parts before trouble shooting 1 Seat 2 Side cover left 3 Side cover right Use the following special tool in this trouble shooting 1 Fuse main Remove the fuses Connect the pocket tester 0 x 1 to the fuses Check the fuses for continuity CONTINUITY Check the battery condition Refer to the BATTERY INSPECTION sec tion in the CHAPTER 3 Specific gravity 1 280 at 20 CORRECT Pocket tester P N 90890 03112 NO CONTINUITY Replace fuse INCORRECT Refill battery fluid Clean the battery terminals Recharge or replace the battery 730 SIGNAL system ELEC 1 3 Main switch Disconnect
3. POOR CONNECTION CORRECT CDI unit is faulty replace it 738 CHARGING SYSTEM ELEC CHARGING SYSTEM CIRCUIT DIAGRAM se 9 9 GO CDI magneto Rectifier Regulator Battery Fuse 79 CHARGING SYSTEM TROUBLESHOOTING BATTERY IS NOT CHARGED Procedure Check 1 4 Charging resistance 2 Battery 5 Wiring connection charging system 3 Charging voltage NOTE Remove the following parts before trouble Inductive tachometer shooting P N 90890 03113 1 Side cover Pocket tester 2 Fuel tank P N 90890 03112 3 Seat Use the following special tool s in this trouble shooting NOCONTINUITY Replace fus Remove the fuse Connect the pocket tester 0 x 1 to the fuse Check the fuse for continuity CONTINUITY Check the battery condition Refer to the BATTERY INSPECTION sec tion in the CHAPTER 3 INCORRECT Refill battery fluid Specific gravity 1 280 at 20 68 F Clean battery terminals Recharge or replace battery CORRECT 7 20 CHARGING system ELEC 3 Charging voltage Connect the engine tachometer to spark plug lead Connect the pocket tester DC20V to the battery Tester lead Battery terminal Tester lead Battery terminal Start the engine and accelerate
4. 7 26 OUT OF SPECIFICATION NO CONTINUITY Replace bulb and or bulb sock Wiring circuit from main switch to bulb sock et connector is faulty repair LIGHTING system ELEC NO CONTINUITY 3 Taillight does not come on 1 Bulb and bulb socket Check the bulb and bulb socket for continui ty Refer to the CHECKING OF BULBS section Replace bulb and or bulb sock CONTINUITY Connect the pocket tester DC20V to the bulb socket connector 1 Tester lead Blue 2 terminal Tester Black 3 terminal Start the engine Check for voltage 12V on the Blue lead at the bulb socket connector OUT OF SPECIFICATION Wiring circuit from main switch to bulb sock et connection is faulty repair MEETS SPECIFICATION This circuit is good 7 27 LIGHTING SYSTEM ELEC ES 4 Auxiliary light does not come on 1 Bulb and bulb socket Check the bulb and bulb socket for continui ty Refer to the CHECKING OF BULBS section CONTINUITY Tester lead Blue Red lead Tester lead Black lead eStart the engine Check for voltage 12V on the Blue Red lead at the bulb socket connector MEETS SPECIFICATION This cir 7 28 NO CONTINUITY Bulb and or bulb socket are faulty replace
5. CHAPTER 7 ELECTRICAL DT175D CIRCUIT DIAGRAM COLOR CODE ELECTRICAL COMPONENTS CHECKING OF 8 H 5 CHECKING OF SWITCHES H 5 SWITCH CONNECTION AS SHOWN IN MANUAL H 5 CHECKING SWITCH FOR TERMINAL CONNECTION H 5 CHECKING OF BULBS FOR HEADLIGHT TAIL BRAKE LIGHT FLASHER LIGHT METER LIGHT ETC KINDS OF BULBS CHECKING BULB CONDITION IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING CHARGING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING LIGHTING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING LIGHTING SYSTEM CHECK SIGNAL SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING SIGNAL SYSTEM CHECK DT175D CIRCUIT DIAGRAM ELECTRICAL T175D CIRCUIT DIAGRAM ELEC t DT175D CIRCUIT DIAGRAM D CDI magneto CDI unit Ignition Rectifier Regulator Control unit Main switch ENGINE STOP switch Oil level gauge OIL warning light Neutral switch NEUTRAL indicator light Sidestand switch LIGHTS Dimmer switch Headlight Auxiliary light Meter light Tail brake light Flasher light HIGH BEAM indicator light Horn Brake switch 2 Flasher relay TURN switch HORN switch 35 Battery 28 Spark plug Fuse COLOR CODE Blue Yellow R Red W_ White B
6. Connect the ignition checker T as shown Spark plug Start the engine and increase the spark gap until misfire occurs X Minimum spark gap 6 mm 0 24 in OUT OF SPECIFICATION OR NO SPARK 3 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester 2X 1k to the spark plug cap Check the spark plug cap for specificated resistance Spark plug cap resistance 5 46 7 34k2 at 20 C 68 F MEETS SPECIFICATION OUT OF SPECIFICATION Spark plug cap is faulty replace IGNITION SYSTEM 4 Ignition coil resistance Disconnect the ignition coil lead Orange from the wireharness Connect the pocket tester Q x 1 to the igni tion coil Tester lead Orange Q lead Tester lead Ignition coil base Check the primary coil for specificated resistance E Primary coil resistance 0 8 1 20 at 20 C 68 F Orange coil base Connect the pocket tester Q x 1k to the ig nition coil Tester lead Spark plug lead 1 Tester lead Ignition coil base Check the secondary for specificated resistance Secondary coil resistance 4 72 7 08 0 at 20 C 68 F Spark plug lead coil base BOTH MEET SPECIFICATIONS OUT OF SPECIFICATION Ignition coil is faulty replace IGNITION SYSTEM 5 Main swit
7. Gear BAD CONDITION O Continuity Nocontinuity GOOD CONDITION 8 Sidestand switch Disconnect the sidestand switch leads from the wireharness Connect the pocket tester Q x 1 to the side stand switch Tester lead Blue Yellow lead Tester lead Black lead NO CONTINUITY eCheck the sidestand switch for continuity CONTINUITY Replace the sidestand switch 736 Disconnect the CDI magneto leads White Red and Black from the wireharness Connect the pocket tester 0 x 1 to the pick up coil Tester lead White Red 2 terminal Tester lead Black terminal Check the pickup coil for specificated resistance Pickup coil resistance 8 120 at 20 C 68 F MEET SPECIFICATION 10 Source coil resistance Disconnect the CDI magneto coupler from the wireharness Connect the pocket tester Qx 100 to the MEETS SPECIFICATION 11 Wiring connection Check the entire ignition system for con nections Refer to the WIRING DIAGRAM section CORRECT 747 OUT OF SPECIFICATION Replace pickup coil OUT OF SPECIFICATION Replace source coil POOR CONNECTION IGNITION SYSTEM ELEC ES 2 Check the CDI unit for connections coupler and each leads 12 CDI unit
8. High tension of kick clip Seized kick gear Seized kick idle gear Transmission m Die quality High viscosity Deterioration Cylinder piston and piston ni iaman or seized cylinder ip Damaged or seized piston Damaged or seized piston ring L Crankcase and crankshaft Improperly seated crankcase Improperly seated crankshaft Damaged or seized crankshaft Damaged or seized crankshaft bearing KICK CRANK NOT RETURNING PROBABLE CAUSE L Kick axle assembly Damaged kick return spring Kick return spring coming off Kick clip coming off Damaged kick return spring stopper FAULTY BRAKE POOR BRAKING EFFECT PROBABLE CAUSE L Drum brake Worn brake shoe Worn or rusty brake drum Improperly adjusted brake free play Improper brake cam lever position Improper brake shoe position Fatigue Damaged return spring Oiiy or greasy brake shoe or greasy brake drum Broken brake cable 86 FRONT FORK OIL LEAKAGE TRBL 2 I AND FRONT FORK MALFUNCTION sHTG 7 FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE PROBABLE CAUSE Bent damaged or rusty inner tube Damaged or cracked outer tube Damaged seal lip Improperly installed oil seal Improper oil level too much Loose damper rod holding bolt Broken cap bolt O ring Loose drain bolt L Damaged drain bolt gasket MALFUNCTION PROBABLE CAUSE deformed or damaged inner tube Bent or deformed outer tube Da
9. Remove the bulb holder before removing the bulb itself Most of the bulb holder for this type can be removed by turning them counter clockwise Most of the bulbs of and D type can be re moved from the bulb sockets by pushing and turning them counterclockwise Bulbs of the type can be removed from the bolb sockets by simply pulling them out CAUTION Be sure to hold the socket firmly when removing the bulb Never pull the lead Otherwise the lead may be pulled off the ter minal in the coupler WARNING Keep flammable products or your hands away from the headlight bulb while it is on It will be hot Do not touch the bulb unt cools down CHECKING OF BULBS 2 Check the bulb terminals for continuity Checking steps Set the pocket tester selector to the Dx 1 Connect the tester lead to the respective bulb terminals Take for example a 3 terminal bulb as shown left First check the continuity be tween the 1 and 2 terminal by connecting the tester lead to the 1 terminal and the tester lead to the 2 terminal Then check the continuity between the and 3 termi nals by connecting the tester lead still to the 1 terminal and the tester lead to the terminal If the tester shown co in either case replace the bulb 3 Check the bulb socket by installing a proven bulb to it As in the checking of bulbs con nect the pocket teste
10. Shift eem X Transmission CLUTCI CLUTCH H SLIPPING DRAGGING SLIPPING Clutch Transmission oil CLUTCH DRAGGING Clutch Transmission i PROBABLE CAUSE Bent shift shaft Groove jammed with impurities Seized shift fork Bent shift fork guide bar Seized transmission gear impurities Incorrectly assembled transmission PROBABLE CAUSE Improperly adjusted shift lever position Improperly retumed stopper lever Worn shift fork Improper thrust play Worn shift cam groove Worn gear dog PROBABLE CAUSE improperly adjusted clutch cable Loose clutch spring Fatigued clutch spring Worn friction plate Worn clutch plate Low oil level quality Low viscosity Deterioration PROBABLE CAUSE Improperly adjusted clutch cable Improperly adjusted push lever position Improper engagement of push lever and push rod Warped clutch plate Swollen friction plate Broken clutch boss High oil level Improper quality High viscosity Deterioration 85 IMPROPER KICKING FAULTY BRAKE IMPROPER KICKING SLIPPING PROBABLE CAUSE Kick axle assembly Low tension of kick Worn kick axle Worn or damaged kick idle gear Worn or damaged kick gear Damaged kick clip Kick clip coming off Damaged kick clip stopper Transmission SS ee quality Low viscosity Deterioration HARD KICKING PROBABLE CAUSE Kick axle assembly
11. Sky blue lead NOCONTINUITY Check the oil level gauge for continuity CONTINUITY Replace oil level gaug 7 38 3 Oil level gauge Connect the pocket tester Q x 1 to the oil lev el gauge Cheek 2 Tester leadBlack Red 1 lead Tester lead Black 2 lead Check the oil level gauge for continuity Switch Good position conuition Bad condition Upright BAD CONDITION position x x o Up side down Replace oil level gauge GOOD CONDITION 4 Voltage Disconnect the indicator light box coupler from the wireharness Connect the pocket tester DC20V to the OIL indicator light coupler Tester lead Black Red 1 lead Tester lead Brown 2 lead OUT OF SPECIFICATION Check the OIL indicator light voltage OIL indicator light voltage 120v MEETS SPECIFICATION This circuit is good 5 Wiring connection Check the entire signal system for connections Refer to the WIRING DIAGRAM section 7 39 TRBL SHTG CHAPTER 8 TROUBLESHOOTING STARTING FAILURE HARD STARTING 1 10 FUEL SYSTEM 2 0 ELECTRICAL 6 22 rnnt COMPRESSION SYSTEM POOR IDLE SPEED PERFORMANCE 1 POOR IDLE SPEED
12. W Black White 0 Orange Ch Chocolate WIR White Red L Blue Dg Dark green W L White Blue P Pink Sb Sky blue Y R Yellow Red Y Brown White 72 ELECTRICAL COMPONENTS ELEC ELECTRICAL COMPONENTS 1 Rectifier Regulator Control unit Q Sidestand switch IGNITION COIL PRIMARY COIL RESISTANCE 0 8 1 20 at 20 C 68 F cbiunt SECONDARY COIL RESISTANCE 4 72 7 08kQ at 20 C 68 F ELECTRICAL COMPONENTS ELEC ES ELECTRICAL COMPONENTS 2 Wireharness Fuse BATTERY Battery CAPACITY Brake switch 12 Neutral switch Ignition coil SPECIFIC GRAVITY Oil level gauge 1 280 at 20 C 68 F Main switch CHECKING OF CONNECTIONS 75 CHECKING OF CONNECTIONS Dealing with stains rust moisture etc on the connector 1 Disconnect Connector 2 Dry each terminal by an air blower 3 Connect and disconnect the connector two three times 4 Pull the lead to check that it will not come off 5 If the terminal comes off bend up the pin and reinsert the terminal into connector 6 Connect Connector 7 Check for continuity by a tester NOTE there is no continuity clean the terminals sure to perform the above steps 1 to 7 when checking the wireharness When replacing the CDI unit be sure to check its connector For a field remedy use a contact revitalizer
13. avail able on the market Use the tester on the connector as shown CHECKING OF switcHes ELEC 76 CHECKING OF SWITCHES SWITCH CONNECTION AS SHOWN IN MANUAL The manual contains a connection chart as shown left showing the terminal connections of the switches e g main switch handlebar switch bracket switch lighting switch etc The extreme left column indicates the switch po sitions and the top line indicates the colors of leads connected with the terminals in the switch component O O indicates the terminals between which there is a continuity of electricity i e a closed circuit at the respective switch positions In this chart and Br and L W and L R are continuous with the ON switch position B B W is continuous with the OFF switch position B and B W is continuous with the LOCK Switch position and B W and R and L R are continuous with the switch position CHECKING SWITCH FOR TERMINAL CON NECTION Before checking the switch refer to the connec tion chart as shown above and check for the cor terminal connection closed circuit by the color combination To explain how to check the switch the main switch taken for example in the following CHECKING SWITCHES 1 Disconnect the main switch coupler from the wireharness CAUTION o 0 0 Never disconnect the main switch coup
14. the main switch coupler from the wireharness Check the switch component for the continui ty between Red 1 and Brown 2 Refer to the CHECKING OF SWITCHES section Switch Good position condition x x 2 OFF o O Continuity Bad condition INCORRECT x Nocontinuity CORRECT 4 Wiring connection POOR CONNECTION Check the entire signal system for con nections Refer to the WIRING DIAGRAM section CORRECT Check condition of each circuit for signal sys tem Refer to SIGNAL SYSTEM CHECK section 7 31 SIGNAL SYSTEM SIGNAL SYSTEM CHECK 1 Horn does not sound 1 HORN switch Disconnect the handlebar switch left cou pler from wireharness the switch component for the continui ty between Pink 2 and Black Refer to the CHECKING OF SWITCHES section INCORRECT CORRECT Replace handlebar switch left 2 Voltage Connect the pocket tester DC20V to the horn lead Tester lead Brown 1 lead Tester lead Frame ground Tum the main switch to ON Check for voltage 12V on the Brown lead at the horn terminal OUT OF SPECIFICATION MEETS SPECIFICATION 12V Wiring circuit from main switch to horn t
15. to about 3 000 t min Measure the charging voltage S Charging voltage E 13 3 15 3 at 3 000 r min OUT OF SPECIFICATION 4 Charging coil resistance Disconnect the CDI magneto coupler and lead Black from the wireharness Connect the pocket tester Q x 1 to the charg ing coil Tester lead Green White 2 lead Tester lead Black lead Measure the charging coil resistance Charging coil resistance 0 24 0 360 at 20 C 68 F MEETS SPECIFICATION 5 Wiring connection Check the entire ignition system for con nections Refer to the WIRING DIAGRAM section CORRECT Replace rectifier regulator MEETS SPECIFICATION OUT OF SPECIFICATION Replace stator assembly POOR CONNECTION LIGHTING SYSTEM CIRCUIT DIAGRAM LIGHTS Dimmer switch Headlight Auxiliary light Meter light Tail Brake light HIGH BEAM indicator light 7 22 system ELEC EB TROUBLESHOOTING HEADLIGHT HIGH BEAM INDICATOR LIGHT TAILLIGHT AND OR METER LIGHT DO NOT COME ON Procedure Check 1 LIGHTS Dimmer switch 2 Lighting coil resistance 3 Wiring connection NOTE a az Z Remove the following parts before trouble Z Pocket tester shooting 2 P N 90890 03112 1 Side covers 2 Seat 3 Fuel tank Use the following special tool s
16. OMPRESSION SYSTEM Cylinder and cylinder head Piston and piston ring Crankcase and crankshaft Reed valve FAULTY GEAR SHIFTING HARD SHIFTING Clutch Transmission oil PROBABLE CAUSE Improper plug gap Worn electrodes Wire between terminals broken Improper heat range L eFaulty spark plug Faulty CDI unit Faulty source coil eFaulty pickup PROBABLE CAUSE Loose spark plug Broken cylinder head gasket Broken cylinder gasket Loose cylinder head or cylinder L eWorn damaged or seized cylinder improperly installed piston ring Won fatigued or broken piston ring Seized piston ring L Seized or damaged piston Improperly seated crankcase Improperly sealed crankcase Damaged oil seal L eSeized crankshaft Deformed reed valve stopper Improperly adjusted reed valve stopper height Improperly seated reed valve Loose intake manifold Broken gasket L Broken reed valve PROBABLE CAUSE Improperly adjusted clutch cable Improperly adjusted push lever position Improper engagement of push lever and push rod Warped clutch plate Swollen friction plate L Broken clutch plate High oil level Improper quality High viscosity L eDeterioration CLUTCH SLIPPING DRAGGING SHIFT PEDAL DOES NOT MOVE Shift shaft L snit cam and shift Transmission JUMP OUT GEAR j Shift shaft 7 Shift fork
17. ch Disconnect the main switch coupler from the wireharness Connect the pocket tester Q x 1 to the main switch Tester lead Black White 1 lead Tester lead Black lead the main switch to ON and OFF Check the main switch for continuity Switch Good position condition OFF 6 ENGINE STOP switch Disconnect the ENGINE STOP switch leads from the wireharness Connect the pocket tester Q x 1 to the EN GINE STOP switch Tester lead Black White 2 lead Tester lead Black 3 lead Turn the ENGINE STOP switch to OFF and RUN Check the tinuity NGINE STOP switch for con BAD CONDITION Switch Good s position condition Bad condition RUN x I OFF x x o Replace handlebar switch Goop CONDITION 715 IGNITION SYSTEM ELEC 7 Neutral switch Disconnect the magneto coupler 1 from the wireharness Connect the pocket tester Q x 1 to the neu tral switch lead Tester lead Sky blue lead Tester lead Frame ground Shift the transmission in neutral and gear Check the neutral switch for continuity Transmission position condition Neutral o x x
18. ermi nal is faulty repair 7 32 SIGNAL SYSTEM ELEC 2 Disconnect the Pink lead from the horn terminal Connect a jumper lead 1 to the horn termi nal and ground the jumper lead Tum the main switch to ON 3 Horn T Br b HORN IS NOT SOUNDED HORN IS SOUNDED Horn is good Connect the pocket tester DC20V to the horn at the Pink terminal Tester lead Pink 1 lead Tester lead Frame ground Turn the main switch to ON Check for voltage 12V on the Pink lead at the horn terminal MEETS SPECIFICATION 12V Adjust or replace horn 7 33 OUT OF SPECIFICATION Horn is faulty replace it SIGNAL system ELEC ES NO CONTINUITY 2 Brake light does not come on 1 Bulb and bulb socket Check the bulb and bulb socket for continui ty Refer to the CHECKING OF BULBS section Replace bulb and or bulb socket CONTINUITY 2 Brake switch Disconnect the brake switch leads from the wireharness Check the switch component for the continui ty between Black 1 and Black 2 Refer to the CHECKING OF SWITCHES section INCORRECT 7 x Front brake switch B Rear brake switch CORRECT Replace brake switch 3 Voltage Connect the pocket
19. ester DC20V to the headlight and HIGH BEAM indicator light couplers A When LIGHTS Dimmer switch is LO position E When LIGHTS Dimmer switch is HI position Headlight Tester lead Yellow 1 or Green lead Tester lead Black 3 I HIGH BEAM indicator ligi Tester lead Yellow lead Tester lead Black 6 lead id Start the engine Turn the LIGHTS Dimmer switch to LO or HI position Check for voltage 12V on the Green and Yellow lead at bulb socket connectors MEETS SPECIFICATION This circuit is good NO CONTINUITY Replace bulb and or bulb socket OUT OF SPECIFICATION Wiring circuit from main switch to bulb sock et connector is faulty repair 725 3 LIGHTING system ELEC ES 2 Meter light does not come on 1 Bulb and bulb socket Check the bulb and bulb socket for continui ty Refer to the CHECKING OF BULBS section CONTINUITY 2 Voltage Connect the pocket tester DC20V to the bulb socket coupler 1 Tester lead Blue 2 terminal Tester lead Black 3 terminal Start the engine Check for voltage 12V on the Blue lead at the bulb socket connector MEETS SPECIFICATION This circuit is good
20. in this trouble shooting 1 LIGHTS Dimmer switch Disconnect the handlebar switch left and headlight coupler 1 from the wireharness Check the switch component for the continui ty between Green 2 and Yellow Red 3 and Yellow Red 2 and Yellow 4 Refer to the CHECKING OF SWITCHES section INCORRECT Replace handlebar switch left CORRECT 7 23 2 Lighting coil resistance Disconnect the CDI magneto coupler and lead Black from the wireharness Connect the pocket tester Q x 1 to the light ing coil coupler Tester lead Yellow 2 terminal Tester lead Black 3 terminal Measure the lighting coil resistance Lighting coil resistance 0 14 0 220 at 20 C MEETS SPECIFICATION Replace stator assembly 3 Wiring connection Check the entire lighting system for con nections Refer to the WIRING DIAGRAM section POOR CONNECTION Correct CORRECT Check condition of each circuit for lighting system Refer to LIGHTING SYSTEM CHECK section 7 24 LIGHTING SYSTEM CHECK 1 Headlight and HIGH BEAM indicator light does not come on 1 Bulb and bulb socket Check the bulb and bulb socket for continuity Refer to the CHECKING OF BULBS section CONTINUITY 2 Voltage Connect the pocket t
21. itch to ON Check for voltage 12V on the Brown lead at the flasher relay terminal OUT OF SPECIFICATION Wiring circuit from main switch to flasher re lay connector is faulty repair MEETS SPECIFICATION 12V 4 Voltage Connect the pocket tester DC20V to the flasher relay Tester lead Brown White 1 lead Tester lead Frame ground Tum the main switch to ON Check for voltage 12V on the Brown White lead at the flasher relay terminal MEETS SPECIFICATION 12V 5 Voltage Connect the pocket tester DC20V to the bulb socket connector At flasher light left Tester lead Chocolate 1 lead Tester lead Frame ground At flasher light right Tester lead Dark green lead Tester lead Frame ground 7 36 SIGNAL SYSTEM Turn the main switch to ON Turn the TURN switch to L or R Check for voltage 12V on the Chocolate lead or Dark green lead at the bulb socket connector OUT OF SPECIFICATION Wiring circuit from TURN switch to bulb socket connector is faulty repair MEETS SPECIFICATION 12V This circuit is good 4 NEUTRAL indicator light does not come on 1 Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continui ty Refe
22. ity between R and Br at the respective switch position of ON 7 OFF 2 LOCK and P There must be continuity the tester indicating 0 at the ON switch position and there must be no continuity the tester indicating at OFF LOCK or There is something wrong between R and Br if there is no continuity at the ON po sition or if there is some continuity either at the OFF or LOCK or P NOTE Check the switch for continuity several times 5 Next go on to checking of the continuity be tween and B W L W and L R and and L R at the respective switch posi tions as in the same manner mentioned above If there is something wrong with any one of the combinations replace the switch com ponent CHECKING OF BULBS 79 BULBS FOR HEADLIGHT TAIL BRAKE LIGHT FLASHER LIGHT METER LIGHT ETC Check the bulb terminal continuity for the condi tion of the bulb KINDS OF BULBS The bulbs used in the motorcycle are classified shown left by the shape of the bulb socket and B are mainly used for the headlight is mainly used for the flasher light and tail brake light and are mainly used for the meter light and other indicator lights CHECKING BULB CONDITION 1 Remove the bulb NOTE Bulbs of the and type uses a bulb holder
23. l e incorrect oil level Improper oil viscosity inferior oil quality L Brake Dragging brake 8 10 2
24. ler by pulling the leads Otherwise leads may be pulled off the terminals inside the coupler 2 Inspect whether any lead is off the terminal inside the coupler If it is repair it NOTE S S If the coupler is clogged with mud or dust blow it off by compressed air 3 Use the connection chart to check the color combination for continuity a closed circuit In this example the continuity is as follows and Br and L W and L R are continu ous with the ON switch position and B W is continuous with the OFF switch position and B W is continuous with the LOCK switch position and B W and R and L R are continu ous with the P switch position Please note that there is no continuity an open circuit at all for the color combinations other than the above 77 CHECKING OF SWITCHES 78 4 Check the switch component for the continui ty between R and Br Checking steps Turn the switch key to the ON OFF LOCK and P several times Set the pocket tester selector to the Q x 1 Connect the tester lead to the R lead ter minal in the coupler and the lead to the Br lead terminal Use thin probes for checking the continuity Otherwise the probes may contact other termi nals inside the coupler Check the continu
25. maged fork spring Worn or damaged slide metal Bent or damaged damper rod Improper oil viscosity L eimproper oil level 87 3 TRBL INSTABLE HANDLING SHTG INSTABLE HANDLING INSTABLE HANDLING Handlebars Steering Front forks Tires Wheels Swingarm Rear shock absorber L Drive chain PROBABLE CAUSE Improperly installed or bent Improperly installed handlebar crown Bent steering shaft Improperly installed steering shaft Improperly tightened ringnut L Damaged ball bearing roller bearing or bearing race r Uneven oil levels on both sides Uneven spring tension Uneven damping adjuster position Broken spring L Twisted front forks Uneven tire pressures on both sides Incorrect tire pressure L Unevenly worn tires Incorrect wheel balance Deformed cast wheel Loose bearing Bent or loose wheel axle L Excessive wheel run out Frame _ Twisted Damaged head pipe L elmproperly installed bearing race r Worn bearing or bush L Bent or damaged Fatigued spring Improperly adjusted spring preload L Oil leakage Improperly adjusted chain slack 8 8 TRBL 5 FAULTY SIGNAL AND LIGHTING SYSTEM SHTG FAULTY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DARK BULB BURNT OUT FLASHER DOES NOT LIGHT FLASHER KEEPS ON PROBABLE CAUSE bulb many electric access
26. material Fuel cock z Clogged fuel hose Carburetor Deteriorated fuel fuel containing water or foreign material Clogged pilot jet Clogged pilot air passage Sucked in air Deformed float Groove worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Starter plunger malfunction L simproperty adjusted starter cable Lar Clogged air filter 81 2 TRBL STARTING FAILURE HARD STARTING SHTG ELECTRICAL SYSTEM Spark plug ignition coil CDI unit system L switches and wiring COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston rings Crankcase and crankshaft Reed valve PROBABLE CAUSE Improper plug gap Worn electrodes Wire between terminals broken Improper heat range L eFaulty spark plug Broken or shorted primary secondary Faulty spark plug lead L Broken body Faulty CDI unit Faulty source Faulty pick up coil L woodruff key Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty sidestand switch ignition control unit PROBABLE CAUSE Loose spark plug Loose cylinder head or cylinder Broken cylinder head gasket Broken cylinder gasket L damaged or seized cylinder Improperly in
27. ories charging Broken charging coil and or faulty rectifier regulator Incorrect connection Improperly grounded L Bulb life expired PROBABLE CAUSE improper bulb Faulty battery Faulty rectifier regulator Improperly grounded Faulty main and or light switch L Bulb life expired PROBABLE CAUSE Improperly grounded Discharged battery Faulty TURN switch Faulty flasher relay Broken wireharness Loosely connected coupler L Bulb burnt out PROBABLE CAUSE Faulty flasher relay Insufficient battery capacity nearly discharged L Bulb burnt out 8 9 E FAULTY SIGNAL AND LIGHTING SYSTEM TRBL OVERHEATING SHTG FLASHER WINKS SLOWER PROBABLE CAUSE Faulty flasher relay Insufficient battery capacity nearly discharged Improper bulb Faulty main and or TURN switch FLASHER WINKS QUICKER PROBABLE CAUSE Improper bulb Faulty flasher relay HORN IS INOPERATIVE PROBABLE CAUSE Faulty battery Faulty main and or horn switch Improperly adjusted horn Faulty horn L Broken wireharness OVERHEATING OVERHEATING PROBABLE CAUSE Ignition system Improper spark plug gap Improper spark plug heat range L Faulty CDI unit Fuel systems improper carburetor main jet Improper setting simproperty adjusted fuel height Clogged air cleaner element Compression Heavy carbon build up Engine oi
28. r leads to the respective leads of the socket and check for continuity in the same manner as mentioned above 7 0 IGNITION system ELEC ESI IGNITION SYSTEM CIRCUIT DIAGRAM magneto Neutral switch CDI unit Sidestand switch Ignition coil Spark plug Control unit Main switch ENGINE STOP switch IGNITION SYSTEM TROUBLESHOOTING IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE NO SPARK OR INTERMITTENT SPARK Procedure Check 1 Spark plug 7 Neutral switch 2 Ignition spark gap 8 Sidestand switch 3 Spark plug cap resistance 9 Pickup coil resistance 4 Ignition coil resistance 10 Source coil resistance 5 Main switch 11 Wiring connection entire ignition system 6 ENGINE STOP switch 12 CDI unit NOTE Remove the following parts before trouble Ignition checker shooting P N 90890 06754 1 Front cover Pocket tester 2 Side cover left P N 90890 03112 3 Seat 4 Fuel tank 1 Spark plug Check the spark plug condition Check the spark plug type Check the spark plug gap Refer to the SPARK PLUG INSPECTION section in the CHAPTER 3 INCORRECT Repair or replace spark plug Standard spark plug 5 N G K lt Spark plug gap 0 7 0 8 mm 0 028 0 032 CORRECT 7 12 IGNITION SYSTEM 2 Ignition spark gap Disconnect the spark plug gap from spark plug
29. r to the CHECKING OF BULBS section CONTINUITY 2 Neutral switch Replace bulb and or bulb socket Disconnect the neutral switch coupler 1 from the wireharness Check the switch component for the continui ty between Sky blue 2 and Ground Refer to the CHECKING OF SWITCHES section INCORRECT CORRECT Connect the pocket tester DC20V to the bulb socket connector Tester lead Sky blue 1 terminal Tester lead Brown 2 terminal SIGNAL SYSTEM Tum the main switch to ON OUT OF SPECIFICATION Check for voltage 12V on the Sky blue and Brown lead at bulb socket connector MEETS Wiring circuit from main switch to bulb sock SPECIFICATION et connector is faulty repair 5 OIL indicator light does not come on This circuit is good NOCONTINUITY 1 Bulb and bulb socket Check the bulb and bulb socket for contin ty Refer to the CHECKING OF BULBS A Replace bulb and or bulb socket section CONTINUITY 2 Oil level gauge C Sb 2 Remove the oil level gauge from the oil tank 5 al Disconnect the oil level gauge coupler from the wireharness Connect the pocket tester Q x 1 to the oil lev 0 1 el gauge Check 1 Tester lead Black Red 1 lead Tester lead
30. stalled piston ring fatigued or broken piston ring Seized piston ring L Seized or damaged piston seated crankcase Improperly sealed crankcase Damaged oil seal L Seized crankshaft Deformed reed valve stopper Improperly seated read valve Loose intake manifold Broken gasket L Broken reed valve 2 POOR IDLE SPEED PERFORMANCE TRBL POOR MEDIUM AND HIGH SPEED PERFORMANCE SHTG POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE PROBABLE CAUSE Carburetor Improperly returned starter plunger Clogged or loose pilot jet Clogged pilot air passage Improperly adjusted idle speed Throttle stop screw Improper throttle cable play Faulty pick up POOR MEDIUM AND HIGH SPEED PERFORMANCE FUEL SYSTEM PROBABLE CAUSE Fuel tank n Clogged fuel filter Deteriorated fuel or fuel containing water L 0r foreign material Clogged fuel breather hose Fuel cock Clogged fuel hose Carburetor Deteriorated fuel fuel containing water or foreign material Sucked in air Detormed float Groove worn needle valve Improperly sealed valve seat Improperly set clip position of jet needle Improperly adjusted fuel level Clogged or loose main jet L Clogged or loose needle jet Air cleaner Clogged air filter 83 I FAULTY GEAR SHIFTING ELECTRICAL SYSTEM Spark plug CDI unit system C
31. tester DC20V to the bulb socket connector Tester lead Green Yellow 1 lead Tester lead Brown lead 7 34 SIGNAL SYSTEM E 1 Tum the main switch to ON brake lever is pulled or brake pedal is stepped down Check for voltage 12V on the Green Yellow lead at the bulb socket connector OUT OF SPECIFICATION Wiring circuit from main switch to bulb sock et connector is faulty repair MEETS SPECIFICATION 12V This circuit is good 3 Flasher light and or TURN indicator light does not blink NOCONTINUITY Replace bulb and or bulb socket 1 Bulb and bulb socket Check the bulb and bulb socket for continuity Refer to the CHECKING OF BULBS section CONTINUITY Disconnect the handlebar switch left cou pler from the wireharness eCheck the switch component for the conti ty between Brown White 2 and Chocolate and Brown White 2 and Dark green Refer to the CHECKING OF SWITCHES section 2 TURN switch NOCONTINUITY TURN switch is faulty replace handlebar switch left 7 35 SIGNAL SYSTEM Connect the pocket tester DC20V to the flasher relay Tester lead Brown 1 lead Tester lead Frame ground Tum the main sw
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