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Yamaha Crux S, Workshop Manual

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Yamaha Crux S Workshop Manual Download Page 39

SPEC

L-38

CABLE ROUTING

¿ Clamp

À Rectifier regulator

Á Flasher relay

 Flasher light lead

A Clamp the battery positive (+) lead to the batterybox.

B Insert hose Air Bent to holder of frame.

¿

À

Á

Â

Ã

Ä

Å

Æ

B

A

Á

à Stop/tail light lead

Ä Wireharness

Å Battery

Æ CDI unit assy.

Â

2-24

Summary of Contents for Crux S

Page 1: ...WORKSHOP MANUAL ...

Page 2: ...tanding of mechanical concepts and procedures inherent to Motorcycle repair technology Without such knowledge attempted repairs or service of this model may render it unfit for use and or unsafe Yamaha Motor India Private Ltd continually strives to improve all its models Modifications and significant changes in specifications or procedures will be informed to all Yamaha Motor India Private Ltd Aut...

Page 3: ...ach page 2nd title 2 This title indicates the Section of the chapter and only appears on the first page of each section It is located in the centre of the page 3rd title 3 This title indicates a Subsection that is followed by step by step procedures accompanied by corresponding illustrations EXPLODED DIAGRAMS To help identify parts and clarify procedure steps there are Exploded Diagrams at start o...

Page 4: ...ion and adjustment 4 Engine 9 Filling fluid 11 Special Tool 15 Resistance Voltage Current 12 Torque 13 Wear Limit Clearance 10 Lubricant 14 Engine speed Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text 16 Apply engine oil 17 Apply gear oil 18 Apply molybdenum disulfide oil 19 Apply wheel bearing grease 20 Apply lightweight lithium soap base grease 21 Apply ...

Page 5: ... 4 INDEX GENERAL INFORMATION GEN INFO 1 TROUBLE SHOOTING TRBL SHTG 8 ELECTRICAL ELEC 7 CHASSIS CHAS 6 CARBURETION CARB 5 ENGINE ENG 4 PERIODIC INSPECTION AND ADJUSTMENTS INSP ADJ 3 SPECIFICATIONS SPEC 2 ...

Page 6: ... NUMBER 1 1 IMPORTANT INFORMATION PREPARATION FOR DISASSEMBLY 1 2 ALL REPLACEMENT PARTS 1 3 GASKETS OIL SEALS AND O RINGS 1 3 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 SPECIAL TOOLS SPECIAL SERVICE TOOLS 1 4 SERVICE INSTRUMENTS 1 7 SPECIAL SERVICE MATERIALS 1 8 ...

Page 7: ... and sepecifications are subject to change without notice MOTORCYCLE IDENTIFICATION MOTORCYCLE IDENTIFICATION Do not tamper with any of these numbers It may lead to legal action Year of Production 2 Digits standing for last two digits of year Eg 0 0 2000 0 1 2001 Month Code One alphabet standing for Month Eg A January B February M December I Not Used for Month Starting Serial Number 5KA 000101 X 5...

Page 8: ...ncludes gears Cylinder Piston and other mated parts that have been mated through normal wear Mated parts must be reused as an assem bly or replaced 4 During the Motorcycle disassembly clean all parts and place them in trays in the or der of disassembly This will speed up as sembly time and help assure that all parts are correctly reinstalled 5 Keep Motorcycle and its parts away from any source of ...

Page 9: ...ips and O rings contact must be cleaned and Lubricated LOCK WASHERS PLATES AND COTTER PINS 1 All Lock Washers plates and Cotter Pins must be replaced when they are removed Lock tab s should be bent along the Bolt BEARINGS AND OIL SEALS 1 Install the bearing s and Oil Seal s À with their manufacturer s marks or numbers facing outward In other words the stamped letters must be on the side exposed to...

Page 10: ...o when re moving or installing the Magneto Securing Nut 1 Magnet o Holder This tool is used to adjust Valve clear ance 5 Valve Clearance Adjusting Tool YSST 606 This tool is used to replace Piston Pin 6 Piston Pin Replacer This tool is used to remove the Magneto 2 Magneto Puller with Spacer YSST 602 This tool is used to to remove and install Valve Spring Assemblies 3 Valve Spring Compressor YSST 6...

Page 11: ...w Driver small YSST 609 This tool is used to hold the Driving Sprocket when removing or installing Driving Sprocket Nut 11 Driving Sprocket Holder YSST 605 This tool is used to loosen or tighten the Cam Shifter Segment Screw 13 Torx Bit T 30 YSST 611 This tool is used to loosen or tighten the Steering Ring Nut 16 Steering Nut Socket YSST 621 This tool is used for scraping the sealent from Crankcas...

Page 12: ...peedometer Gear Nut YSST 237 This tool is used to adjust spring preload of Rear Shock Absorbers 17 Rear Shock Absorber Adjuster YSST 221 This fixture is used to hold the Engine for its disassembly and assembly 22 Engine Stand This tool is used to install Oil Seal in Crank Case Cover 2 23 Oil Seal Installing Tool YSST 622 This tool is used to remove install the Center Plug from Crank case Cover 1 L...

Page 13: ...er 0 25 mm 50 75 mm 7 CO Gas Analyser 8 Hydrometer This instrument is used for checking ignition timing This instrument is used for checking the engine compression This instrument is used for checking the electrical system This instrument is used for measuring length width thickness of components This instrument is used for measuring Piston size Valve stem size etc This instrument is used for meas...

Page 14: ... tool is used to tighten the Nuts Bolts at a specified torque This instrument is used to check clear ance gaps between parts SPECIAL SERVICE MATERIAL The following Service material are necessary to use at the time of assembly of various parts 1 YAMAHA Bond TG 1215 This adhesive is used on mating surfaces while assembling Crankcase 1 and 2 This adhesive is used for Torx Screw tightening 2 LOCTITE T...

Page 15: ...TIONS 2 1 MAINTENANCE SPECIFICATIONS ENGINE 2 4 CHASSIS 2 10 ELECTRICAL 2 13 GENERAL TORQUE SPECIFICATIONS 2 15 LUBRICATION POINTS AND LUBRICANT TYPE ENGINE 2 16 CHASSIS 2 17 ENGINE LUBRICATION ROUTE 2 18 ENGINE BEARINGS 2 20 CABLE ROUTING 2 21 ...

Page 16: ...inclined single cylinder Displacement 105 6 cm Bore X Stroke 49 X 56 mm Compression ratio 9 1 Starting system Kick starter Lubrication system Wet sump Max power 7 6 BHP 7500 RPM Torque 8 Nm 6000 rpm Oil type or grade Engine oil Yamalube 4 stroke Oil 20W50 Type SF Oil capacity Engine oil Periodic oil replacement 1 0 L Total amount 1 2 L Air filter Washable dual Foam Wet type Oil soaked FUEL Fuel Ta...

Page 17: ...ype Double cradle Caster angle 26 4º Trail 83 mm Tyre Type With tube Size Front 2 50 18 4 PR Rear 2 75 18 6 PR Manufacturer Front LOCAL MADE Rear LOCAL MADE Type Front RIB TYPE Rear RIB LUG TYPE Tyre pressure cold tyre Loading condition A 0 90 kg 0 198 lbs Front 24 PSI 1 70 kgf cm Rear 28 PSI 2 00 kgf cm Loading condition B 90 162 kg 198 408 lbs Front 24 PSI 1 70 kgf cm Rear 32 PSI 2 30 kgf cm Loa...

Page 18: ...pring Oil damper Wheel travel Front wheel travel 110 mm Rear wheel travel 70 mm Electrical Ignition system CDI Digital Generator system Flywheel magneto Battery type LOCAL MADE Battery capacity 12V 2 5 AH Headlight type Bulb type Headlight bulb type Krypton bulb Bulb voltage wattage x quantity Headlight 12V 35W 35W x 1 Tail Brake light 12V 5W 21W x 1 Flasher light 12V 10W x 4 Meter light 12V 2W x ...

Page 19: ...op ring Type Barrel Dimensions B x T 1 0 x 1 95 mm End gap installed 0 10 0 25 mm Limit 0 35mm Side clearance installed 0 030 0 065 mm Limit 0 115m 2nd ring Type Taper Dimensions B x T 1 0 x 1 9 mm End gap installed 0 25 0 40 mm Limit 0 50mm Side clearance 0 020 0 065 mm Limit 0 115mm Oil ring Dimensions B x T 2 0 x 2 15 mm End gap installed 0 2 0 7 mm Side Clearance 0 040 For Rail Upper and Rail ...

Page 20: ...ft Inside diameter Rocker Arm 10 000 10 015 mm Limit 10 03 mm Outside diameter Rocker Armshaft 9 981 9 991 mm Limit 9 95 mm Cam chain Cam chain type No of links BUSH CHAIN 90 Cam chain adjustment method Automatic Valve Valve Seat Valve Guide Valve clearance cold IN 0 08 0 12 mm EX 0 10 0 14 mm Valve dimensions Head Dia Face Width Seat Width Margin Thickness A head diameter IN 22 90 23 10 mm EX 19 ...

Page 21: ...m Valve spring Free length IN 39 62 mm EX 39 62 mm Limit IN 38 17 mm EX 38 17 mm Set length valve closed IN 25 6 mm EX 25 6 mm Tilt limit IN 2 5 1 7 mm EX 2 5 1 7 mm Compression pressure installed IN 142 221 Nm 14 5 22 5 kgf EX 142 221 Nm 14 5 22 5 kgf Direction of winding top view Clockwise Crankshaft Crank width A 46 95 47 00 mm Runout limit C 0 03 mm Big end side clearance D 0 15 0 45 mm Small ...

Page 22: ...4DP19 2 Needle jet N J E OM 860 Cut away C A 3 0 Pilot outlet P O 1 1 Pilot jet P J 12 5 Valve seat size V S 1 5 Starter jet G S 1 30 Fuel level with special tool F L 2 5 0 5 mm Above the Joint Line of MCB Main Chamber Body and FCB Float Chamber Body Float height 9 3 1 mm Engine idle speed 1 300 1 500 r min Intake vaccum New Vehicle 24 0 29 4 kPa Market Run Vehicle 29 3 34 7 kPa Lubrication system...

Page 23: ...4 3 6 Intake Manifold Bolt M6 2 10 1 0 7 2 Carburetor Joint Manifold Bolt M6 2 10 7 2 7 2 Carburetor Joint Air filter Screw M4 1 2 0 2 1 5 Air filter Case Bolt M6 2 7 0 7 5 1 Muffler Cylinder Head Bolt M6 1 7 0 7 5 1 Muffler Assembly Bolt M8 1 15 1 5 11 Crankcase 1 and 2 Bolt M6 2 10 1 0 7 2 Bolt M6 6 10 1 0 7 2 Bolt M6 2 10 1 0 7 2 Crankcase Cover 1 Bolt M6 5 10 1 0 7 2 Bolt M6 2 10 1 0 7 2 Cover...

Page 24: ... hand t TIGHTENING TORQUE ENGINE Part to be tightened Parts name Thread size Q ty Tightening torque Remark Nm m kg ft lb Shift Pedal Bolt M6 1 10 1 0 7 2 Segment Screw M6 1 12 1 2 9 Torx Bolt Stopper lever Bolt M6 1 10 1 0 7 2 Sensor Assembly Bolt M6 2 10 1 0 7 2 Neutral Switch Assembly M10 1 4 0 4 3 ...

Page 25: ... grade Special YAMAHA oil Rear suspension Shock Absorber travel 70 mm Spring free length 205 4 mm Fitting length 197 4 mm Spring rate K1 18 6 N mm K2 27 8 N mm Stroke K1 0 40 mm K2 40 70 mm Swingarm Free play limit End 1 0 mm Side 1 0 mm Front wheel Type Spoke wheel Rim size 1 6 x 18 Rim material Steel Rim run out limit Radial 0 5 mm Lateral 0 8 mm Rear wheel Type Spoke wheel Rim size 1 6 x 18 Rim...

Page 26: ...ing free length 36 5mm Rear drum brake Type Leading Trailing Brake Drum inside diameter 130mm Wear limit 131 Lining Thickness 4 0 mm Wear limit 2 mm Shoe spring free length 36 5 mm Free Plays Brake Lever free play At lever end 10 15 mm Brake Pedal free play 20 30 mm Clutch Lever free play at lever end 10 15 mm Throttle Grip free play 3 7mm MAINTENANCE SPECIFICATIONS 2 11 ...

Page 27: ...RQUE CHASSIS MAINTENANCE SPECIFICATIONS Note 1 First tighten the Ring Nut approximately 45 5 Nm 4 55 m kg 32 3 ft lb by using the torque wrench then loosen the Ring Nut one turn 2 Retighten the Ring Nut to specifications 2 12 ...

Page 28: ...eto Model Manufacturer 5KA DENSO Charging Voltage 14 15V 5000 RPM Charging Coil Resistance 0 82 Ω 20 68ºF Lighting Lighting Voltage Min 12V 3 000 r min Max 15V 8 000 r min Lighting Coil Resistance 0 62Ω 20 68ºF Rectifier Regulator Type Semi conductor Short Circuit Type Model Manufacturer 36L Local Made CKD No load regulated voltage 13 14V Capacity 8A Withstand voltage 400 V Battery Specific Gravit...

Page 29: ...SPEC L 28 MAINTENANCE SPECIFICATIONS Circuit Breaker Type Fuse Amperage for individual circuit X quantity Main 10A X 1pc Reserve 10A X 1pc 2 14 ...

Page 30: ...ssemblied in a criss cross fashion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Components should be at room temperature 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 GENERAL TORQUE SPECIFICATION A Nut B Bolt General Torque specific...

Page 31: ...l Valve Stem End Rocker Arm Shaft and Rocker Arm Cam and Bearing Camshaft Push Rod Primary Driven Gear and Main Axle Push Lever Axle Rotary Filter and Oil Pump Sliding Gear Transmission Kick Axle Shaft Axle Drive Shift Fork and Guide Bar Shift Cam and Bearing shift cam Crankcase Mating Surfaces Yamaha bond No 1215 Crankcase Cover 1 and Grommet Yamaha bond No 1215 LUBRICATION POINTS AND LUBRICANT T...

Page 32: ...il Seal Lips all Pivot Shaft Swingarm Pivoting Points Brake Pedal Shaft and Frame Ball and Ball Race Steering Head Tube Guide Right Grip Pivoting points Brake Lever and Clutch Lever Pivoting Point Brake Shoe Plate Cable End Front Brake and Clutch Pivoting Points Sidestand Mainstand and Rear Footrest Brake Camshaft Cam and Shaft 2 17 ...

Page 33: ...SPEC L 32 ENGINE LUBRICATION ROUTE Engine Lubrication route 2 18 WARNING CAUTION DO NOT DAMAGE CRANK CASE SURFACES OTHERWISE OIL LEAKAGE WILL START ...

Page 34: ...SPEC R 33 ENGINE LUBRICATION ROUTE Engine Lubrication route 2 19 WARNING CAUTION FOR IMPROVED PERFORMANCE ALWAYS USE YAMALUBE OIL ...

Page 35: ...SPEC L 34 ENGINE BEARINGS ENGINE BEARINGS 2 20 ...

Page 36: ...ight lead left Ê Horn Ë Flasher light lead right A Pass the Clutch Cable À and the Handle bar Switch Lead Á through the cable guide of the left side B Pass the Throttle Cable Å and the Brake Cable Ä and the Front Brake switch lead Æ through the Cable Guide of the right side C Pass the Meter Cable Ç and the Brake Cable through the cable guide D Pass the Main Harness È through the wire Guide À Á Â Ã...

Page 37: ...hole of the flap C Align the white marking of wireharness with the frame clamp D Tighten the battery negative lead and th ground lead of the wireharness together E Pass the battery breather hose through the hole of the upper left side of the en gine bracket F Pass the battery breather hose the crankcase breather hose and the carburetor overflow pipe through footrest clamps G Pass the battery breat...

Page 38: ... cable Ç Breather hose A Pass the high tension cord À through the cable guide to the inside of throttle cable and the clutch cable Æ B Tighten the ground lead and ignition coil to gether C Pass the throttle cable through the head light stay D Pass breather hose through upper right side hole of frame bracket engine À Á Â Ã Ä Å Æ D C B A Ç Â 2 23 ...

Page 39: ...tifier regulator Á Flasher relay  Flasher light lead A Clamp the battery positive lead to the batterybox B Insert hose Air Bent to holder of frame À Á Â Ã Ä Å Æ B A Á à Stop tail light lead Ä Wireharness Å Battery Æ CDI unit assy  2 24 ...

Page 40: ...T 3 13 ENGINE OIL LEVEL INSPECTION 3 14 ENGINE OIL REPLACEMENT 3 14 AIR FILTER CLEANING 3 16 CLUTCH CABLE ADJUSTMENT 3 17 CHASSIS FRONT BRAKE ADJUSTMENT 3 18 REAR BRAKE ADJUSTMENT 3 18 BRAKE SHOE INSPECTION 3 19 BRAKE LIGHT SWITCH ADJUSTMENT 3 19 DRIVE CHAIN SLACK ADJUSTMENT 3 20 STEERING HEAD INSPECTION 3 22 FRONT FORK INSPECTION 3 24 REAR SHOCK ABSORBER ADJUSTMENT 3 24 TYRE INSPECTION 3 25 SPOKE...

Page 41: ...ed Choke Lever operation Tune if necessary Clean inspect lubricate replace if necessary Check Fuel Hose for cracks or damage Replace if necessary FRONT FORKS STEERING RACE BALL WHEEL BEARING WHEELS REAR ARM PIVOT CLUTCH BRAKE SHOES FRONT REAR BRAKE FRONT REAR OIL STRAINER ENGINE OIL FUEL FILTER Repack grease Repack grease Replace Oil Check operation oil leakage Repair if necessary Check Race Ball ...

Page 42: ...t if necessary Clean and lubricate Check all Chassis fittings and fasteners for looseness Tighten as per specification Check operation and lubricate if necessary Check electrolyte level and top it up with distilled water if necessary Check specific gravity Check Breather Pipe for blockage and routing Check operation free play Cable damage Readjust or replace as required EVERY MONTH CLUTCH FRONT BR...

Page 43: ...orcycle for removing the Lug Á from the Chassis ææææææææææææææææææææææææææææææææææ SIDE COVERS SEAT AND FUEL TANK SIDE COVERS SEAT AND FUEL TANK 3 3 1 2 3 1 2 3 REMOVAL SIDE COVER RH 1 Remove Side Cover RH ææææææææææææææææææææææææææææææææææ Removal steps Remove the Screw Pull the lug À towards you to remove it from the Fuel Tank Slide the Side Cover towards the rear end of the Motorcycle for remov...

Page 44: ...ock to the OFF dis connect the Fuel Hose Place a rag under the Fuel Line to absorb any spilt fuel REMOVAL SEAT 1 Remove Side Cover LH and RH Bolts 2 Nos Seat ææææææææææææææææææææææææææææææææææ Removal steps Open bolts and À inside the side covers Lift the front of the Seat and slide it forward WARNING Gasoline is highly flammable Avoid spilling of fuel on the hot Engine 1 2 ...

Page 45: ...TE Keep the projection on plate Á downward 2 Install Seat Bolts and À NOTE Insert the projection ç on the rear of the seat into the receptacles è on the Chassis then push down front of the seat and tighten the bolts 3 Install Side Cover LH and lock with Key 4 Install Side Cover RH À 5 Tighten Screw Á b a 1 2 2 Bolt fuel tank 20 Nm 2 0 mkg 14 4 ft lb Bolt Seat 3 8 Nm 0 38 mkg 3 0 ft lb ...

Page 46: ...Cam Sprocket should be aligned with the marking on Cylinder Head ENGINE 3 6 1 Remove Side Covers Seat Fuel Tank Refer to SIDE COVERS SEAT AND FUEL TANK section Page no 3 3 2 Remove Spark Plug Bolts Cylinder Head Side Cover 2 Nos Cylinder Head Side Cover À Valve Cover intake side Á Valve Cover exhaust side  3 Remove Timing Check Plug with O ring Center Plug with O ring À 4 Measure Valve clearance ...

Page 47: ...æææ 5 Adjust Valve clearance ææææææææææææææææææææææææææææææææææ Adjustment steps Loosen the Locknut Turn the Adjuster À in or out with the Valve adjusting tool Á until specified clearance is obtained Hold the Adjuster to prevent it from moving and tighten the Locknut Measure the Valve clearance If the clearance is incorrect repeat above steps until specified clearance is obtained æææææææææææææææææ...

Page 48: ...Engine idle RPM always check throttle cable free movement and free play 4 Insert Sampling probe CO tester to the exhaust pipe À Out of specification Adjust 3 8 Turning IN Increasing in rpm Turning OUT Decrease in rpm 7 Install Valve Covers with O ring Spark Plug Cylinder Head Side Cover À 8 Install Seat Side Covers Fuel Tank Refer to the SIDE COVERS SEAT AND FUEL TANK section Page no 3 3 1 Valve c...

Page 49: ...ntration as specified remove the CO tester make sure that the Engine idling speed has not changed ææææææææææææææææææææææææææææææææææ THROTTLE CABLE ADJUSTMENT NOTE Prior to adjusting the Throttle Cable free play the Engine idling speed should be adjusted 1 Check Throttle cable free play ç Out of specification Ÿ Adjust 2 Adjust Throttle Cable free play ææææææææææææææææææææææææææææææææææ Adjustment ...

Page 50: ...rmal color is medium to light tan color 4 Clean Spark Plug with Spark Plug cleaner or wire brush 5 Measure Spark Plug gap with a wire gauge Out of specification Ÿ Adjust gap 3 10 Turning IN ç Ÿ Free play is increased Turning OUT è Ÿ Free play is decreased WARNING After adjusting turn the Handlebar to the right and to the left to ensure that this does not cause the Engine idling speed to change WAR...

Page 51: ...rque is to finger tighten the Spark Plug and then tighten it another 1 4 to 1 2 turn to À using Box Spanner IGNITION TIMING CHECKING PROCEDURE NOTE Prior to checking the ignition timing check all electrical connections related to the starting sys tem Make sure that all connections are intact 1 Remove Plug Straight Screw 2 Attach Timing light À Spark Plug 17 5 Nm 1 75 mkg 12 6 ftlb Timing light SKC...

Page 52: ...æææææææææææææææææææææææææææææææææ Checking steps Increase the Engine speed from 1400 r min to 2250 r min Check the stationery pointer ç should be within the ignition timing range è marked on the Rotor Assembly Further increase the Engine speed from 2250 r min onwards Observe that Rotor ignition timing mark moves in clockwise direction gradually and later not visible If above phenomenon is not obse...

Page 53: ...sits If it is below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again Follow the table ææææææææææææææææææææææææææææææææææ Measurement steps Crank the Engine with the Throttle wide open until the reading on the compression gauge stabilizes ææææææææææææææææææææææææææææææææææ 7 Install Spark plug 3 13 WARNING Before cranking the engine ground Spark Plug leads...

Page 54: ...Dip Stick Oil Level Gauge 5 Inspect Engine oil level Oil level should be between maximum and minumim À marks Oil level is below the minimum mark Ÿ Add oil up to the proper level RECOMMENDED ENGINE OIL NOTE Wait a few minutes until the oil settles before inspecting the oil level ENGINE OIL REPLACEMENT 1 Start the Engine and let it warm up for sev eral minutes or drive approx 4 Kms 2 Turn off the En...

Page 55: ...mage Ÿ Tighten replace Gasket Exhaust Pipe Exhaust gas leaks Ÿ Tighten replace 2 Inspect Bolt À Muffler Loose Damage Ÿ Tighten replace 3 Inspect Screw Á Muffler Protector Loose damage Ÿ Tighten replace AIR FILTER CLEANING NOTE On the bottom of the Air Filter Case there is a Check Hose If dust and or water collects in this hose clean the Air Filter Element and Air Filter Case 3 15 1 3 Drain plug 20...

Page 56: ... Element Guide 6 Install Air Filter Element Assy Spring Wire Air Filter Case Cap Side Cover R H 3 16 WARNING CAUTION Never operate the Engine without the Air Filter element installed Unfiltered air will cause rapid wear of Engine parts and may damage the Engine Operating the Engine without the Air Filter Element will also affect the Carburetor tuning leading to poor Engine performance and possible...

Page 57: ...h Lever end then adjust it by using Adjuster below the Fuel Tank Below the Fuel Tank Remove Side Covers Seat and Fuel Tank Detach Clutch Cable from Push Lever Loosen the Locknut Á Turn the adjuster  in or out to increase or decrease the length of the Clutch Cable outer Tighten the locknut Á Attach the Clutch Cable end to the Push Le ver Adjust the Clutch Cable free play at Lever end as before Ins...

Page 58: ...ter on the Wheel end of the Front Brake Cable Wheel side Loosen the Locknut Á Turn the Adjuster  in or out until the speci fied free play is obtained Tighten the Locknut ææææææææææææææææææææææææææææææææææ CHASSIS 3 18 Turning in ç Ÿ Free play is increased Turning out è Ÿ Free play is decreased Turning in ç Ÿ Free play is increased Turning out è Ÿ Free play is decreased WARNING CAUTION Make sure t...

Page 59: ...edal 2 Inspect Brake shoes Wear indicator reaches the wear limit line À Ÿ Replace the brake shoes as a set Refer to FRONT WHEEL and REAR WHEEL in CHAPTER 6 page no 6 6 BRAKE LIGHT SWITCH ADJUSTMENT NOTE The Brake Light Switch is operated by move ment of the Brake Pedal Adjustment is correct when the Brake Light comes on just before the braking effect actu ally starts 1 Check Brake light operation ...

Page 60: ...mal noise and will affect the life of chain sprock ets and low fuel efficiency 1 Stand the Motorcycle on its center stand 2 Check Drive chain slack a Out of specification Ÿ Adjust 3 Remove Cotter pin 4 Loosen Axle Nut À Sprocket Axle Nut Á 5 Adjust Drive Chain slack 3 20 WARNING CAUTION Too little chain slack will overload the engine and other vital parts keep the slack within the specified limits...

Page 61: ...e alignment there are marks on swing arm Ä and mark on chain adjuster Å Ensure that left hand and right hand chain alignment marks are equally matched Use them when adjusting the slack for proper alignment Before tightening the Axle Nut and Driven Sprocket Locknut to specifications make sure that there is no clearance at the Adjuster or the Swing Arm end on both sides by pushing the Wheel forward ...

Page 62: ...nd gently rock the Fork Assembly Looseness Ÿ Adjust the Steering Head 4 Remove Bands Bolts Handlebar Upper holders À Handlebar upper holders Á Handlebar lower holders  Handlebar à Handle crown bolts Ä Handle crown Å 5 Adjust Steering head ææææææææææææææææææææææææææææææææææ Adjustment steps Remove Spacer Remove the lock washer À Remove the Ring Nut Á upper and Dumper Rubber  then loosen the Ring ...

Page 63: ...ned Install the Lock Washer À NOTE Make sure the lock washer tab is placed in the slots 6 Install Handle crown with Spacer Handle Crown bolt À Handlebar Lower Holder Á Handlebar  Handlebar upper holder à Bolts handlebar upper holders Ä Bands Å 3 23 NOTE Set the Torque Wrench to the Ring Nut Wrench so that they form a right angle WARNING Avoid over torquing Ring nut lower final tightening 15 5 Nm ...

Page 64: ...n Repair Refer to FRONT FORK in Chapter 6 Page no 6 21 REAR SHOCK ABSORBER ADJUSTMENT 1 Adjust Spring preload Turn the adjuster ring to direction ç or è using Shocker Adjuster or a plain rod as applicable 3 24 WARNING Securely support the motocycle so that there is no danger of it falling over WARNING Always adjust each Rear Shock Absorber preload to the same setting Uneven ad justment can cause p...

Page 65: ... Absorber to the same setting WARNING Tyre inflation pressure should only be checked and adjusted when the Tyre tem perature equals the ambient air tempera ture Tyre inflation pressure and suspen sion must be adjusted according to the cargo rider pasenger and accessories fairing saddlebags etc if approved for this model and according to whether the Motorcycle will be operated at high speed or not ...

Page 66: ...o rider passenger and accessories WARNING It is dangerous to ride with a worn out tyre When the tyre tread begins to show signs of wear replace the tyre immediately Patching a punctured tube is not recom mended If it is absolutely neccessary to do so use great care and replace the tube as soon as possible with a good quality re placement tube Do not use tubeless tyres on a wheel de signed for tube...

Page 67: ... 1 Inspect Wheels Damage Bends Ÿ Replace NOTE Always balance the wheel when a tyre or wheel has been changed or replaced SPOKES INSPECTION AND TIGHTENING 1 Inspect Spokes Bending damage Ÿ Replace Loose spoke Ÿ Retighten 2 Tighten Spokes NOTE Be sure to tighten the Spokes before and after break in Nipple 2 Nm 0 2 m kg 0 3 ft lb ...

Page 68: ...d water only for top up Tap water con tains minerals which are harmful to a Battery BATTERY INSPECTION 1 Remove Side Cover L H Refer to SEAT SIDE COVERS AND FUEL TANK section Page no 3 3 Battery 2 Inspect Electrolyte level Electrotyte level should be between the Upper and Lower À level marks Electrolyte level is too low Ÿ add distilled water to proper level 3 Inspect Battery terminals Poor connect...

Page 69: ...letely before installing it to ensure maximum performance WARNING Battery electrolyte is dangerous It contains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures Avoid body contact with electrolyte as it can cause severe burns and permanent eye injury Wear protective eye gear when handling or working near batteries Antidote EXTERNAL SKIN Flush with water fo...

Page 70: ...tch Install a new fuse with the proper current rat ing Turn on switches to verify operation of related electrical deveces If the fuse blows again immediately check the electrical circuit ææææææææææææææææææææææææææææææææææ 4 Install Fuse holder Side cover left Refer to SEAT SIDE COVERS AND FUEL TANK section Page no 3 3 3 30 WARNING CAUTION Always turn off the Main Switch when checking or replacing ...

Page 71: ...e the new Bulb with the Bulb spring 3 31 Push down Ÿ Headlight beam moves lower Pull up Ÿ Headlight beam moves higher WARNING Keep flammable products and your hands away from the Bulb while it is on it will be hot Do not touch the bulb unit it cools down WARNING CAUTION Avoid touching glass part of bulb Also keep it away from oil otherwise transparency of glass bulb life and brightness will be ad ...

Page 72: ...T 4 9 C D I MAGNETO 4 10 GUIDE STOPPER AND TIMIMG CHAIN 4 10 CRANKCASE 4 11 TRANSMISSION AND SHIFTER 4 12 CRANKSHAFT 4 12 CYLINDER HEAD ROCKER ARMS CAMSHAFT VALVES 4 13 INSPECTION AND REPAIRS CYLINDER HEAD 4 15 VALVE SEATS 4 16 VALVE SPRINGS AND VALVES 4 18 CAMSHAFT 4 19 ROCKER ARMS AND ROCKER ARM SHAFTS 4 20 TIMING CHAIN SPROCKETS AND CHAIN GUIDES 4 21 TIMING CHAIN TENSIONER 4 21 CYLINDER AND PIS...

Page 73: ...ENT 4 32 CRANKSHAFT 4 35 TRANSMISSION 4 37 SHIFTER 4 38 CRANKCASE 4 40 CDI MAGNETO 4 42 SHIFT SHAFT AND KICK STARTER 4 44 CLUTCH PRIMARY DRIVE GEAR AND OIL PUMP 4 47 CYLINDER AND PISTON 4 52 CYLINDER HEAD 4 53 CAM SPROCKET AND TIMING CHAIN 4 54 ENGINE MOUNTING 4 60 MAINTENANCE SPECIFICATIONS ...

Page 74: ...to the ENGINE OIL REPLACEMENT section in Chapter 3 Page no 3 14 BATTERY 1 Remove Fuse Negative terminal Black À Battery Breather Hose Á Battery  CARBURETOR 1 Loosen Air cleaner case mounting bolts À Hose Clamp assy Á 2 Remove Carburetor Mounting Bolts  2 nos Air vent hose à Carburetor Ä Refer to the CARBURETOR section in Chap ter 5 Page no 5 2 NOTE Cover the Carburetor with a clean cloth to pre ...

Page 75: ...Remove Bolt Holder Sprocket Holder Sprocket À Sprocket Drive Á Remove with the Drive Chain EXHAUST MUFFLER 1 Remove Bolt exhaust pipe Bolt muffler Refer to EXHAUST SYSTEM section in Chapter 3 Page no 3 15 2 Remove Exhaust muffler CLUTCH CABLE 1 Remove Clutch cable ææææææææææææææææææææææææææææææææææ Removal steps Loosen the locknut of the Clutch Lever Turn in the Adjuster À to enough to free the in...

Page 76: ... Remove Spark Plug Cap ENGINE REMOVAL 1 Remove Engine Mount Bolt front upper Bolt Engine Mount stay front upper À Bolt Engine Mount stay front lower Á Engine Mount Bolt front upper  Engine Mount Bolt front lower à Engine Mount Bolt rear Ä Engine Mount Bolt upper Å Bolts Engine mount stay upper Æ Engine Mount Stay upper Ç 3 Remove Engine Assembly From the left side of the Motorcycle 4 Mount Engine...

Page 77: ...ng À 3 Align Piston to TDC position NOTE Turn the Crankshaft anticlockwise with a Socket Spanner 17 mm ææææææææææææææææææææææææææææææææææ TDC alignment steps Turn the Crankshaft anticlockwise until the slit cut mark on magneto ç matches the station ary pointer è Align the I mark é on the Cam Sprocket with the stationary pointer ê on the Cylinder Head the Piston is at the Top Dead Center TDC of com...

Page 78: ...he Crankcase 8 Remove Guide Stopper 1 Dowel Pins À Gasket Cylinder Head Á Cylinder  5 Remove Tensioner Cap Bolt Retract completely the Tensioner Rod by Screw in clockwise direction Bolts timing chain tensioner À 2 Nos Timing Chain Tensioner Assembly Á Gasket 7 Remove Bolts Cylinder Head as per sequence 6 nos Cylinder Head NOTE Loosen the Bolts 1 4 turn each and remove then after all are loosened ...

Page 79: ... the Crankcase cavity 9 Remove Dowel Pins Gasket Cylinder À 1 Remove Bolts Crankcase Cover 1 L H 7 nos Crankcase Cover 1 L H Neutral Light wire from Neutral Switch NOTE Loosen the Bolts in criss cross pattern 2 Attach Magneto holder C D I MAGNETO NOTE The CDI Magneto can be removed while the Engine is mounted on the Motorcycle by remov ing the following parts Shift Pedal Cover Chain Case L H Pisto...

Page 80: ... the Motorcycle by remov ing the following parts and draining the Engine oil Kick Crank Assy 1 Remove Nut kick Crank assy Kick Crank Assy Bolts Crankcase Cover 2 R H 9 nos Crankcase Cover RH NOTE Hold Kick Crank Assy at extreme down posi tion for opening the Nut Kick Crank Assy Loosen the Bolts of Crankcase Cover 2 RH in a crisscross pattern 2 Remove Gasket 5 Loosen Straighten the Lock Washer tab ...

Page 81: ...ump assembly Á Gasket oil pump Oil strainer 8 Remove Nut Plate Washer Primary Drive Gear Key À Rotary Filter À OIL PUMP NOTE The oil pump can be removed while the engine is mounted by removing the following parts Clutch Primary drive gear Rotary filter 7 Loosen Nut Primary Drive Gear NOTE Open the Nut Primary Drive Gear by holding the Magneto with Magneto Holder Magneto Holder YSST 601 A ...

Page 82: ...lowing parts Shift Pedal Kick Crank Assy Crankcase Cover 2 RH Clutch 1 Remove Shift Shaft Torsion Spring À Bolt stopper lever Á Stopper Lever  2 Remove Torsion spring Kick axle assembly À KICK STARTER NOTE The kick starter can be removed while the en gine is mounted by removing the following part Kick Crank Assy Crankcase Cover 2 RH Clutch Drum Assy 1 Remove Circlip Plate washer À Gear Kick idle ...

Page 83: ... Bush NOTE Place the Bush on the Crankshaft threaded end before using the Magneto Puller to avoid thread damage 3 Remove CDI magneto using magneto puller À Key wood ruff 4 Remove Bolt Guide Stopper 2 À Bush Timing chain Á 5 Remove Torx Screw Segment using Torx Bit WARNING Never use Phillips screw driver Magneto Holder YSST 601 A Magneto Puller YSST 602 Torx Bit YSST 611 ...

Page 84: ...rew driver ex cept at the separating slot Separate the Crankcase after first check ing that the shift cam segments and the Drive Axle Circlip can be removed Do not damage the Crankcase mating sur faces 2 Remove Dowel pins CRANKCASE 1 Remove Bolts Crankcase RH 2 nos 1 Remove Right crankcase half NOTE Open the Engine stand mounting Nuts 2 nos Then separate the Crankcase by using the flat head screw ...

Page 85: ...bly Push Rod 2 Washer Push Lever Assembly Á Lock Oil Seal 3 Remove Neutral switch Gasket CRANKSHAFT 1 Attach Crankshaft Removal Tool À 2 Remove Crankshaft using Crankshaft removal tool À NOTE Fully tighten the Crankshaft removal tool hold ing Bolts but make sure that the tool body is parallel with the Crankcase If necessary one holding bolt may be turned out slightly to adjust the Crankshaft Remov...

Page 86: ...cer À NOTE Before the Valves Valve Springs Valve Stem Seals etc are removed from the Cylinder Head the Valve sealing should be checked 6 Check Valve sealing Leakage at the valve seat Ÿ Inspect the valve face valve seat and seat width Refer to INSPECTION AND REPAIR VALVE SEAT on Chapter 4 Page no 4 16 ææææææææææææææææææææææææææææææææææ Checking Steps Pour clean petrol into the intake and ex haust p...

Page 87: ...s to be attached between the Valve Spring retainer and the Valve face Inlet and Exhaust one at a time 9 Remove Valve Spring Retainer Valve Spring À Valve Á Valve Stem Seal  Valve Spring Seat à NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place Valve Spring Compressor YSST 603 ...

Page 88: ...ecification Ÿ resurface replace ææææææææææææææææææææææææææææææææææ Warpage measurement and resurfacement steps Place a straightedge and a feeler gauge À across the Cylinder Head Measure the warpage If the warpage is out of specification resur face the Cylinder Head replace if necessary Place a 400 600 grit wet abrasive paper on the surface plate and resurface the Head using a figure eight sanding ...

Page 89: ... onto the valve seat to make a clear pattern Measure the Valve Seat width Where the Valve Seat and Valve Face made contact blueing will have been removed If the Valve Seat is too wide too narrow or the seat is not centered the valve seat must be refaced ææææææææææææææææææææææææææææææææææ VALVE SEATS 1 Remove Carbon deposits from the Valve Face and Valve Seat 2 Inspect Valve Seats Pitting wear Ÿ re...

Page 90: ...t while rotating the Valve Apply a fine lapping compound è to the Valve face and repeat the above steps NOTE Make sure to clean off all compound from the Valve face and Valve seat after every lapping operation Apply Mechanic s blueing dye Dykem è to the Valve face Install the Valve in the Cylinder Head Press the Valve through the Valve Guide and onto the Valves Seat to make a clear pattern Measure...

Page 91: ...e Spring free length ç Out of specification Ÿ Replace 3 Check Spring contact face Wear pitting scratches Ÿ Replace 5 Measure Valve stem diameter 4 Measure Valve guide inside diameter Valve spring free length 39 62 mm Limit 38 17 mm Spring Tilt Limit 1 7 mm Valve guide inside diameter Intake 5 000 5 012 mm Limit 5 042mm Exhaust 5 000 5 012 mm Limit 5 042mm ...

Page 92: ...o guide clearance Valve guide inside diameter Valve stem diameter 3 Inspect Camshaft oil passage Chocked Ÿ Blow out oil passage with compressed air CAMSHAFT INSPECTION 1 Inspect Cam lobes Pitting scratches blue discoloration Ÿ Replace 2 Measure Cam lobes dimension ç and è Out of specification Ÿ Replace Runout Limit 0 01 mm Cam lobes dimension Intake ç 25 356 25 456 mm limit 25 326 mm è 20 989 21 0...

Page 93: ...er Arm Shaft hole Cam lobe contact surface Excessive wear Ÿ Replace Inspect the surface condition of the Rocker Arm Shafts Pitting scratches blue discoloration Ÿ Re place and check lubrication route Measure the inside diameter ç of the Rocker Arm holes Out of specification Ÿ Replace Measure the outside diameter è of the Rocker Arm Shafts Out of specification Ÿ Replace æææææææææææææææææææææææææææææ...

Page 94: ... 3 Inspect Guide Stopper 1 Guide Stopper 2 À and Bush Wear damage Ÿ Replace TIMING CHAIN TENSIONER 1 Check One way Cam operation If Unsmooth operation Ÿ Replace ææææææææææææææææææææææææææææææææææ Checking steps While pressing the Tensioner Rod lightly with fingers use a flat screwdriver and retract the Tensioner Rod up fully clockwise When releasing the screwdriver by pressing lightly with fingers...

Page 95: ...sure the Piston Skirt diameter P with a Micrometer ç 4 5 mm from the Piston bottom edge If out of specification replace the Piston and the Piston Rings as a set 3rd step Calculate the Piston to Cylinder clearance us ing the following formula If out of specification rebore or replace the Cylinder and replace the Piston and Piston Rings as a set ææææææææææææææææææææææææææææææææææ Piston size p Stand...

Page 96: ...ore NOTE Push the Ring with the Piston Crown so that the Ring will be at right angles to the Cylinder Bore 5 mm from the bottom side 3 Measure End gap using a feeler gauge Out of specification Ÿ Replace NOTE You cannot measure the end gap on the ex pander spacer of the Oil Ring If the Oil Ring Rails show excessive gap replace all three Rings Side clearance Top Ring Limit 0 030 0 065 mm 2nd Ring Li...

Page 97: ...f specification re place the Piston Pin Measure the Piston Pin hole inside diameter è using a Internal Micrometer Calculate the Piston Pin to Piston clearance using the following formula Out of specification Ÿ replace the Piston ææææææææææææææææææææææææææææææææææ ENGINE INSPECTION AND REPAIR 4 24 Piston Pin to Piston clearance Bore size Piston Pin è Outside diam eter Piston Pin ç Outside diameter ...

Page 98: ...re Crank width ç Out of specification Ÿ Replace Crankshaft 2 Measure Big end side clearance ç using a Feeler Gauge Out of specification Ÿ Replace big end Bearing Crank Pin and Connecting Rod CRANKSHAFT 1 Measure Crankshaft runout using a Surface plate and Dial gauge Keep the Crankshaft on V blocks and rotate slowly while measuring Out of spescification Ÿ Replace Runout 0 01 mm limit 0 03 mm Big en...

Page 99: ...2 Measure Friction Plate thickness ç using a Vernier Calliper at four points Out of specification Ÿ Replace the Friction Plates as a set 3 Inspect Clutch Plates for damage Clutch Plate Warpage Using a Surface Plate and a Feeler Gauge Out of specification Ÿ Replace the Clutch Plates as a set 4 Inspect Clutch Springs Damage Ÿ Replace the Clutch springs as a set 5 Measure Free length Clutch Spring ç ...

Page 100: ...end Ÿ Replace 2 Inspect Push Rod 2 Wear damage Bend Ÿ Replace 6 Inspect Dogs on the Primary Driven Gear Scoring wear damage Ÿ Deburr or replace Clutch Boss Splines À Scoring wear damage Ÿ Replace NOTE Scoring on the Clutch Housing Dogs and the Clutch Boss Splines will cause erratic operation of the clutch ...

Page 101: ...hift Cam Segment À Wear damage Ÿ Replace 3 Check Shift Fork movement on the Guide Bar Unsmooth operation Ÿ Replace the Shift Fork and the Guide Bar 4 Inspect The assembly for proper working Shift Fork C center Shift Fork R right À Shift Fork L left Á Guide bars small and big  Shift Cam à Shift fork cam follower Ä Roll the Guide Bar on a flat surface Bent Ÿ Replace WARNING Do not attempt to straig...

Page 102: ...ted Dogs Rounded edges cracks missing portions Ÿ Replace 7 Inspect Shift Shaft Damage bent wear Ÿ Replace Return spring shift shaft À Return Spring stopper lever Á Wear damage Ÿ Replace KICK STARTER INSPECTION 1 Inspect Gear teeth kick Gear Gear teeth Idle Gear À Wear damage Ÿ Replace 2 Measure Torsion spring force Using a Spring Gauge Out of specification Ÿ Replace Kick Clip friction force 0 8 1 ...

Page 103: ...ing and Rotor clearance é between the Pump Housing Á and the Rotors and À Out of specification Ÿ Replace the Oil Pump Assembly Damage Ÿ Replace Contamination Ÿ Clean with flushing oil 3 Inspect Oil strainer Damage Ÿ Replace Contamination Ÿ Clean with flushing oil 2 Inspect Rotary Filter Cracks damage chocked Ÿ Replace Contamination Ÿ Clean with flushing oil Tip clearance ç 0 15 mm Limit 0 20 mm Si...

Page 104: ...ghness noise Ÿ Replace 2 Inspect Oil Seals À Damage wear Ÿ Replace CRANKCASE 1 Thoroughly wash the crankcase L H R H in mild solvent 2 Thoroughly clean all the Gasket Mating surfaces and Crankcase Mating surfaces using solvent 3 Inspect Crankcase Cracks damage Ÿ Replace Oil delivery passages Blockage Ÿ Blow the passages with compressed air DELIVERY PASSAGE INSPECTION CRANK CASE RH 1 Check Oil deli...

Page 105: ...LYANDADJUSTMENTS 4 32 VALVES ROCKER ARM AND CAMSHAFT Valve Cotters À Valve Spring Retainer Á Valve Springs  Valve Stem Seal à Valve Spring seat Ä Valve intake Å Valve exhaust Æ Lock Nut Ç Adjuster È Valve Rocker Arm É Rocker Arm Shaft Ê Camshaft Ë Plate ...

Page 106: ...g 2 Apply Molybdenum disulfide oil on the Valve Stem and Oil Seal 4 Install Valve Cotters NOTE Install the Valve Cotters while compressing the valve spring with Valve Spring compressor À 3 Install Valve Spring Seat Valve Stem Seal À New Valve Á in the valve guide Cylinder Head Valve Spring  Spring retainer à NOTE Install the Valve Spring with the small pitch è facing downward ç facing upwards è f...

Page 107: ...lfide oil on the rocker arm and Rocker Arm Shaft CAMSHAFT AND ROCKER ARM INSTALLATION 1 Lubricate Camshaft 5 Secure the Valve Cotters onto the Valve Stem by tapping lightly with a mallet WARNING CAUTION Do not hit so much as to damage the Valve Camshaft and Camshaft bearing Multrigrade engine oil Molybdenum disulfide oil Bolt Plate 7 Nm 0 7 m kg 5 1 ft lb ...

Page 108: ...ENG R 107 ENGINEASSEMBLYANDADJUSTMENTS 4 35 CRANKSHAFT Crank Pin À Crank Shaft Á Connecting Rod  Big end Bearing à Crankshaft Bearing Ä Wood ruff Key Å Bearing Æ Spacer ...

Page 109: ...d to ease the Installation procedure apply Engine Oil onto each Bearing and crankcase LH 4 Install Neutral Switch 3 Install Crankshaft by tightening the Nut NOTE Hold the Connecting Rod at Top End with one hand while turning the Nut of the Installing Tool with the other Operate the Installing Tool until the Crankshaft is seated against the Bearing Crankshaft Installing Tool YSST 266 Spacer YSST 26...

Page 110: ...TS 4 37 TRANSMISSION Drive Sprocket À Oil Seal Á Bearing  4th Wheel Gear à Drive Axle à 2nd Wheel gear Å 3rd Wheel Gear Æ Clutch Dog È Bearing É Bearing Ê 4th Pinion Gear Ë 3rd Pinion Gear Ì 2nd Pinion Gear Í Main axle Î Plate Ï Bearing ...

Page 111: ...ENG L 110 ENGINEASSEMBLYANDADJUSTMENTS 4 38 SHIFTER Shift Fork Guide Bar long À Shift Fork R Á Shift Fork L  Shift Cam à Segment Ä Shift Fork Guide Bar short Å Shift fork C Æ Torx Screw Ç Pin Shaft Cam ...

Page 112: ...ft Forks for smooth operation by turning the Shift cam with your hand 3 Install The following parts in Crankcase LH in following sequence Shift Fork L left face the L side for the Clutch side Shift Fork R right À face the R side for the Clutch side Shift Fork C center Á face the C side for the Clutch side Shift Fork Guide Bar 1 Â Short Shift Fork Guide Bar 2 Ã Long NOTE Install the Shift Forks wit...

Page 113: ...ENG L 112 ENGINEASSEMBLYANDADJUSTMENTS 4 40 CRANKCASE Crankcase 1 LH À Dowel Pins Á Crankcase Breather Hose  Crankcase 2 RH à Holder Clutch Cable Tightening Sequence ...

Page 114: ...tall Crankcase RH with the Crankcasse LH Tap lightly on the Case with mallet NOTE Tighten the Engine Mounting Nuts 2 nos for holding the Engine on the engine stand 4 Tighten Bolts 2 nos Crankcase RH Bolts 8 nos Crankcase LH as per sequence 5 Apply 4 Stroke Engine Oil on the Crank Pin Bearings and Oil Delivery Hole 6 Check Crankshaft and transmission operation for smooth rotation shifting by hand U...

Page 115: ...ENG L 114 ENGINEASSEMBLYANDADJUSTMENTS 4 42 CDI MAGNETO Timing Chain À Guide Stopper 1 and 2 Á CDI Rotor Assy  Wood Ruff Key à Stator Assy Ä Gasket Å Dowel Pin Æ Cover Crankcase 1 ...

Page 116: ...all Guide stopper 2 À with spacer Tighten the bolt Á C D I MAGNETO INSTALLATION 1 Install Woodruff Key 2 Install C D I Magneto À Washer Nut NOTE When installing the Magneto Rotor make sure that the Woodruff Key is properly seated in the Keyway of the Crankshaft 3 Tighten Nut CDI Magneto using the Magneto Holder À Nut CDI Magneto 70 Nm 7 0 m kg 51 ft lb Drive sprocket Holder YSST 605 Bolt Sprocket ...

Page 117: ...MBLYANDADJUSTMENTS 4 44 SHIFT SHAFT AND KICK STARTER Shift Shaft À Torsion Spring Á Stopper Lever  Return Spring à Segment Ä Kick Starter Assembly Å Circlip Æ Washer Ç Kick Idle Gear È Kick Shaft Assy É Cover Crankcase 2 ...

Page 118: ...er lever Á NOTE Hook the Spring ends on the Stopper Lever and the Crankcase Pin Mesh the Stopper Lever with the Cam Shifter Stopper 2 Install Segment using Torx Bit Tool NOTE Fit the Dowel Pins on the Cam Shifter to the lo cating hole ç on the Cam Shifter and install the Segment SEGMENT AND SHIFT SHAFT 1 Install Dowel Pins on the Cam Shifter À Bolt Stopper Lever 10 Nm 1 0 m kg 7 2 ft lb Torx Bit T...

Page 119: ...ck Gear Clip À Torsion Spring Á NOTE Turn the Torsion Spring clockwise and hook into the proper hole ç in the Crankcase 2 Install Following parts on the Axle Drive Ä Circlip Washer À Kick Idle gear Á Washer  Circlip à NOTE Install Circlips radius side towards the compo nent refer Chapter 1 Page no 1 3 ...

Page 120: ...ate  Push Rod 1 à Friction Plate Ä Clutch Plate Å Clutch Boss Æ Thrust Washer Ç Primary Driven Gear È Ball É Push Rod 2 Ê Push lever Axle Ë Primary Drive Gear Ì Rotary Filter CLUTCH PRIMARY DRIVE GEAR AND OIL PUMP Í Key Î Oil Pump Drive Gear Ï Oil Pump Driven Gear Ð Oil Pump Ñ Gasket ...

Page 121: ...4 Install Rotary Filter NOTE Align the Rotary Filter Dog ç with groove of the Crankshaft è and make sure to keep TOP marking facing upside 2 Install Drive gear Oil Pump Gasket Oil Pump Assy Á 3 Tighten Screw 2 nos À OIL PUMP INSTALLATION 1 Lubricate Oil delivery passage Crankcase RH Oil Pump Assembly Recommended Lubricant 4 Stroke Engine Oil Nut Primary Drive Gear 70 Nm 7 0 m kg 51 ft lb Magneto H...

Page 122: ...ate with Projec tion Mark offset approximately 90 º from pre vious plates projection continue this procedure in clockwise direction until all Clutch Plates are installed 3 Tighten Nut Clutch Boss while holding the Clutch Boss with Clutch Hub Holder À 2 Install Washer Spacer À Primary Driven Gear Á Thrust Washer  Clutch Boss à Lock Washer Ä New Clutch Boss Nut Å CLUTCH INSTALLATION 1 Install Oil S...

Page 123: ...s è while in stalling the Pressure Plate Tighten the Clutch Spring Bolts in stage using a crisscross pattern 9 Check Push Lever position Push the Push Lever Assembly in the arrow direction and make sure that the mach mark are aligned adjust ç Match mark on the Push Lever Assembly è Match mark on the Crankcase 10 Adjust Push Lever position ææææææææææææææææææææææææææææææææææ Adjustment steps Loosen ...

Page 124: ...æææ NOTE Tighten the Bolts in decreasing numerical order see number on the illustration 13 Install Kick Crank Nut Kick Crank À 14 Install Dowel Pins Gasket Crankcase Cover 1 New Crankcase Cover 1 L H NOTE Tighten the Bolts in decreasing numerical order 11 Install Strainer NOTE Always keep its wider side outside of Crankcase 12 Install Dowel Pins Gasket Crankcase 2 New Crankcase Cover 2 RH Bolts Cr...

Page 125: ...ENG L 124 ENGINEASSEMBLYANDADJUSTMENTS 4 52 Cylinder À Gasket Cylinder Á Dowel Pins  Piston Rings à Piston Pin Circlips Ä Piston Å Pin Piston CYLINDER AND PISTON ...

Page 126: ...EMBLYANDADJUSTMENTS 4 53 Bolt Flange À Washer Á Bolt  Valve Cover intake à O Ring Ä Valve Cover exhaust Å Cylinder Head Æ Dowel Pin Ç Gasket Cylinder Head È O Ring É Cover Cylinder Head Side 3 Ê Spark Plug CYLINDER HEAD ...

Page 127: ...ENG L 126 ENGINEASSEMBLYANDADJUSTMENTS 4 54 CAM SPROCKET AND TIMING CHAIN Gasket À Timing Chain Tensioner Assembly Á Guide Stopper 2  Cam Sprocket à Timing Chain Ä Guide Stopper 1 ...

Page 128: ... so that the GTP TOP1 GTP TOP 2 marks are lo cated on the upper side of the 2nd Ring Top Ring Lubricate the Piston and Piston Rings with En gine Oil 2 Install Piston Piston Pin À using Piston Pin Replacer Tool Piston Pin Circlip Á New NOTE Apply Engine Oil on the Piston Pin The Ÿ mark ç on the Piston must be kept towards the exhaust side of the Cylinder Before installing the Piston Pin Circlip Cov...

Page 129: ...own ç Top Ring End è Oil Ring end lower é Oil Ring End upper ê 2nd Ring End 5 Lubricate Piston outer surface Piston Rings Cylinder Inner Surface 6 Install Cylinder NOTE Install the Cylinder with one hand while com pressing the Piston Rings with the other hand Pass the Timing Chain and Guide stopper 2 through the Timing Chain Cavity Press the Piston down to rest on Piston Base YSST 604 Piston Base ...

Page 130: ...mark é on the Cam Sprocket with the stationary pointer ê on the Cylinder Head Fit the Timing Chain on Cam Sprocket À and install the Cam Sprocket on the Camshaft NOTE When installing the Cam Sprocket keep instal lation of the Camshaft Damage or improper Valve timing will result NOTE Remove the safety wire from the Timing Chain before installation of Sprocket Cam ææææææææææææææææææææææææææææææææææ ...

Page 131: ... Tensioner ææææææææææææææææææææææææææææææææææ Installation steps Remove the Tensioner Cap Bolt While Pressing the Tensioner Rod lightly with fingers use a Flat Head Screwdriver and retract the Tensioner Rod up fully clockwise With the Rod fully retracted install the Gas ket  and the Chain Tensioner à and tighten the Bolt Ä with Copper Washer to the speci fied torque Release the Chain Tensioner Ro...

Page 132: ...s with O Ring Cylinder Head Side Cover with O Ring À Bolts Á 8 Check Valve clearance specifications Out of specification Ÿ Adjust Refer to the VALVE CLEARANCE ADJUST MENT section in Chapter 3 Page no 3 8 9 Lubricate 4 Stroke Engine Oil Recommended Lubricant Engine Oil YAMALUBE Valve Cover 17 5 Nm 1 75 m kg 13 ft lb Bolts Cylinder Head Side Cover 10 Nm 1 0 m kg 7 2 ft lb Bolts intake Manifold 10 Nm...

Page 133: ... 3 Install Engine Mount Bolt Rear Lower Engine Mount stay upper À Engine Mount bolt Front upper Ç Mounting Bolt Engine mount stay upper Á Mounting Bolt upper  Engine Mount Stay front à Bolt Engine Mount Stay Front upper Ä Bolt Engine Mount stay Front lower Å Engine Mount Bolt Front lower Æ Engine Mount Bolt Front upper Ç 4 Tighten Bolts Foot Rest Assembly Spark Plug 17 5 Nm 1 75 m kg 12 6 ft lb P...

Page 134: ...ENT section in Chapter 3 Page no 3 20 Bolt Engine Mount stay front lower 38 Nm 3 8 m kg 27 5 ft lb Engine Mount Bolt Front lower 38 Nm 3 8 m kg 27 5 ft lb Engine Mount bolt from upper 38 Nm 3 8 m kg 27 5 ft lb Engine Mount Bolt Rear 38 Nm 3 8 m Kg 27 5 ft lb Bolt Engine mount Stay 38 Nm 3 8 m kg 27 5 ft lt Engine mount bolt upper 38 Nm 3 8 m kg 27 5 ft lt Bolt Engine Mount Stay front upper 38 Nm 3...

Page 135: ... Page no 3 14 17 Adjust Idle Speed Refer to IDLING CO MEASUREMENT AND ADJUSTMENT in Chapter 3 Page no 3 8 18 Adjust Throttle cable Free play Refer to THROTTLE CABLE ADJUSTMENT in Chapter 3 Page no 3 9 13 Install Battery Box Battery Battery Flap 14 Connect Battery Leads Sensor Coil Lead Coupler Bolts Air Filter Case 7 Nm 0 7 m kg 5 1 ft lb Bolts Battery Box 3 8 Nm 0 38 mkg 3 ft lb WARNING CAUTION C...

Page 136: ...CARB R 135 CHAPTER 5 CARBURETION CARBURETOR VIEW 5 1 REMOVAL 5 2 DISASSEMBLY 5 3 INSPECTION 5 4 ASSEMBLY 5 6 INSTALLATION 5 7 TUNING 5 8 CARBURETION ...

Page 137: ... Plug Drain à Float Chamber Body Ä O Ring Å Main Chamber Body Æ Float Pin Ç Float È Needle Valve Assembly É Jet Main Ê Throttle valve Ë Nozzle Main Ì Screw Pilot Assembly Í Jet Pilot Î Starter Lever Ï Plunger Starter Assy Ð Throttle stop Screw Ñ Pipe Drain Ò Cable Adjust Screw Set Ó Seal F C B Ô Gasket CARBURETOR CARBURETOR 5 1 ...

Page 138: ... CARBURETOR 5 2 7 Remove Throttle Cable Remove with Carburetor Chamber Top and Throttle Valve 5 Remove Bolts Intake Manifold 2 nos Joint À with O ring 6 Remove Carburetor Assembly with O ring 3 Disconnect Air Vent Hose Fuel Hose À Over Flow Hose Á 4 Loosen Screw Clamp Air Filter Hose  Bolts Air Filter Case à 2 nos Open Bolt Air filter case Ä WARNING Petrol is highly flammable Avoid spilling fuel ...

Page 139: ...d inspected without Carburetor Disassembly Throttle Valve Assembly Starter lever Starter Plunger Assembly Before disassembly of Carburetor clean the outer surface of Carburtor and Check the Starter Lever Opeartion 3 Remove Float Pin Float À 4 Remove Needle Valve 5 Remove Screw stopper plate À Stopper Plate Á Valve Seat  6 Remove Main Jet Main Nozzle À 5 3 ...

Page 140: ...pening Cap Plunger à Starter Plunger Assembly Á 9 Remove Throttle Stop Screw Set  Spring Washer and O ring INSPECTION Carburetor Float Chamber Body 1 Inspect Cracks damage Ÿ Replace Fuel Starter Passage Blockage Ÿ Clean with petrol and compressed air Contamination Ÿ Clean ææææææææææææææææææææææææææææææææææ Cleaning Steps ó Wash the Carburetor in petroleum based sol vent Do not use any caustic cle...

Page 141: ...ring Plunger à Starter Plunger Ä for seat and free movement Throttle Valve 1 Check Free movement Insert the Throttle Valve in the Carburetor body and check for free movement Hinderance Ÿ Clean Replace Float 1 Inspect Damage Ÿ Replace Jets and Screws 1 Inspect Jet Needle Needle Jet À Main Nozle Main Jet Á Pilot screw  Pilot jet à Throttle Stop Screw Ä Bends wear damage Replace Blockage Ÿ Blow the ...

Page 142: ...ot jet Pilot screw assembly À ASSEMBLY 7 Install Seal Float Chamber New Float Chamber À Screw Á with Spring Washer 4 nos 6 Measure Float Height ç Incorrect Ÿ Adjust 5 Install Float Float Pin À 3 Install Needle Jet Main Nozzle Main Jet À 4 Install Valve Seat Valve seat stopper À Valve seat Stopper screw Á Needle Valve  Float Height 9 3 1mm 5 6 ...

Page 143: ... è on the Carburetor Body 3 Install Carburetor Assembly and Joint together on the intake manifold NOTE While installing Joint A keep its lug side downword and L H S of Engine 4 Tighten Bolts Intake manifold 2 nos 5 Install Air Filter hose on the Carburetor 6 Tighten Clamp Screw Bolts À Air Filter Case 2 nos 7 Connect Over Flow Hose Á Air Vent Hose  Fuel Hose 8 Install Throttle Stop Screw set 9 In...

Page 144: ...ation Ÿ adjust Engine Idling Speed 1300 1500 R P M ææææææææææææææææææææææææææææææææææ Adjustment Steps Turn the Throttle Stop Screw in or out until specified idling speed is obtained CO density 2 5 1 5 v v ææææææææææææææææææææææææææææææææææ 4 Insert Sampling probe À of CO tester calibrated to the exhaust pipe Á using suitable adapter  If out of specification Ÿ adjust 5 Adjust CO density through p...

Page 145: ...r Body Fuel Level Gauge 6 Adjust Idling speed by Throttle Stop Screw ææææææææææææææææææææææææææææææææææ FUEL LEVEL ADJUSTMENT 1 Measure Fuel Level ç Out of specification Ÿ Adjust ææææææææææææææææææææææææææææææææææ Measurement and adjustment steps Place the motorcycle on a level surface on cen tre stand Connect the Fuel Level Gauge to the Drain Pipe À Loosen the Drain Screw Á Hold the Gauge vertica...

Page 146: ...crease By Lifting Up Ÿ Float Height Decrease Otherwise adjust Float level by bending the Float Tang  on the Float slightly up or down as required Install the Carburetor Recheck the fuel level Adjust Float height through Float Tang  ææææææææææææææææææææææææææææææææææ ...

Page 147: ...LATION 6 15 DRIVE CHAIN AND SPROCKETS 6 16 REMOVAL 6 17 DRIVE CHAIN INSPECTION 6 18 CLUTCH HUB INSPECTION 6 19 DRIVEN SPROCKET ASSEMBLY 6 19 DRIVEN SPROCKET AND DRIVE CHAIN INSTALLATION 6 19 FRONT FORK 6 20 FRONT FORK REMOVAL 6 21 FRONT FORK DISASSEMBLY 6 21 FRONT FORK INSPECTION 6 23 FRONT FORK ASSEMBLY 6 24 FRONT FORK INSTALLATION 6 26 STEERING HEAD AND HANDLEBAR 6 27 REMOVAL 6 28 HANDLEBAR REMO...

Page 148: ...CHAS R 147 FRONT WHEEL Cotter Pin À Axle Nut Á Speedometer Cable Assy  Wheel Axle à Spacer Ä Brake Shoe Plate Assy Å Dust Seal Collar Æ Front Wheel FRONT WHEEL AND FRONT BRAKES 6 1 ...

Page 149: ...L 148 FRONT BRAKE Brake Shoe Assy À Oil Seal Á Clutch Meter  Gear Drive à Lever Camshaft Ä Indicator Plate FRONT WHEEL AND FRONT BRAKES 6 2 Å Camshaft Æ Bush Ç Plate Washer È Gear Meter É O Ring Ê Oil Seal ...

Page 150: ...ble by removing the clip À 4 Remove Cotter Pin Nut À 5 Lift Front Wheel NOTE Place a suitable stand under the Engine 5 Remove Front Wheel Axle Brake Shoe Plate Assembly À Dust Seal Collar Á Front Wheel  1 Loosen Lock nut and screw in the adjuster À fully to loosen the Brake Cable 2 Remove Front Brake Cable Á by slacking and removing it first from the Handlebar end and then from the Front Wheel en...

Page 151: ...PECTION in Chapter 3 Page no 3 27 3 Check Spokes Bends damage Ÿ Replace Loose Spokes Ÿ Tighten Turn the Wheel and tap the Spokes with a Screwdriver NOTE A tight Spoke will emit a clear ringing tone a loose Spoke will sound flat 4 Tighten Loose Spokes Nipple NOTE Check the Front Wheel runout after tighteneing the Spokes FRONT WHEEL AND FRONT BRAKES WARNING Do not attempt to straighten a bent Axle 6...

Page 152: ... Seals Wear damage Ÿ Replace 7 Inspect Collar Grooved Wear Ÿ Replace the Collar and the Oil Seal as a set BRAKE SHOE PLATE DIASSEMBLY 1 Remove Bush Meter Gear À Remove the bush using a Meter Gear Bush Tool Á FRONT WHEEL AND FRONT BRAKES SPEEDOMETER GEAR INSPECTION 1 Inspect Meter Clutch 6 5 2 Inspect Meter Drive Gear Meter Gear À Front Wheel runout limits Radial ç 0 5 mm Lateral è 0 8 mm Spanner S...

Page 153: ...ake Shoes as a set if either is worn to the limit 3 Measure Brake Drum inside diameter ç Out of specification Ÿ Replace the Wheel Drum 4 Inspect Brake Drum inner surface Oil Scratches Ÿ Repair Oil Use a Rag soaked in solvent Scratches Use an emery cloth and polish lightly and evenly 5 Inspect Camshaft Face Wear Ÿ Replace WARNING When inspecting the Brake Lining do not spill oil or grease on the Br...

Page 154: ...the Spanner Speedom eter Gear Nut 2 Install Cam Lever Bolt Cam Lever À BRAKE SHOE PLATE ASSEMBLY 1 Install Camshaft Indicator Plate À ææææææææææææææææææææææææææææææææææ Installation steps Align the projection ç on the Indicator Plate À with the Camshaft notch è ææææææææææææææææææææææææææææææææææ 3 Install Brake Shoes Tension Springs À New NOTE When installing the Springs and Brake Shoes take care ...

Page 155: ...tion WARNING Always use a new Cotter Pin 4 Install Cotter Pin New and bend its ends 3 Tighten Front Wheel Axle Axle Nut Front Wheel NOTE Do not loosen the Axle Nut after Torque tight ening If Axle Nut groove is not aligned with the Wheel axle Cotter Pin hole align groove to hole by tightening up on the Axle Nut 2 Install Front Wheel NOTE Make sure that the slot ç in the Shoe Plate fits over the St...

Page 156: ...ake for proper operation Improper operation Ÿ Recheck or disassemble 7 Adjust Brake Lever free play Refer to FRONT BRAKE ADJUSTMENT section in Chapter 3 Page no 3 18 FRONT WHEEL AND FRONT BRAKES 6 9 WARNING Make sure that the Brake Cable and Meter Cable is routed properly ...

Page 157: ...er À Pin Á CompressionSpring  Cotter Pin à Tension Bar Ä Axle Nut Å Chain Puller Æ Driven Sprocket Axle Ç Rear Wheel Assembly È Brake Shoe Plate Assembly É Damper Ê Bearing Ë Spacer Collar Ì Bearing REAR WHEEL AND REAR BRAKE 6 10 ...

Page 158: ...CHAS R 157 REAR BRAKE Brake Shoe Kit À Cam Lever Á Indicator Plate  Camshaft REAR WHEEL AND REAR BRAKE 6 11 ...

Page 159: ... 1 Remove Chain Cover upper and lower À 2 Loosen Chain Adjuster Á 3 Remove Adjuster Rear Brake Pin À Nut Á with Bolt Tension Rod  Compression Spring à Brake Rod Ä 4 Remove Cotter Pin Nut Wheel Axle À Wheel Axle Á Collar  NOTE When removing the Wheel Axle the Collar will fall off Take care not to lose it 5 Remove Axle Wheel Rear Wheel À Rear Brake Shoe Plate Á Remove from the Rear Wheel Hub ...

Page 160: ...to FRONT WHEEL INSPECTION Page no 6 4 3 Inspect Clutch Hub Damper Wear damage Ÿ Replace REAR BRAKE INSPECTION 1 Inspect Brake Lining surface 2 Measure Brake Lining thickness 3 Inspect Brake Drum inner surface for Oiliness and Scratches Refer to FRONT WHEEL BRAKE INSPECTION page no 6 6 4 Measure Brake Drum inside diameter ç Out of specification Ÿ Replace Brake Drum inside diameter Standard 130 mm L...

Page 161: ... Hub as sembly 2 Adjust Drive Chain Slack Refer to DRIVE CHAIN ADJUSTMENT section in Chapter 3 Page no 3 20 3 Tighten Nut Rear Wheel Axle NOTE Do not loosen the Axle Nut after torque tighten ing If Axle Nut Groove is not aligned with the Wheel Axle Cotter Pin Hole align Groove to hole by tightening up on the Axle Nut 4 Install Cotter Pin New NOTE Bend the ends of the Cottor Pin 5 Check Rear Brake ...

Page 162: ...ETS Chain Case À Crankcase Cover 3 Á Drive Sprocket  Clip Chain Joint à Link Plate Ä Chain Joint Å Drive Chain Æ Nut Driven Sprocket Axle Ç Driven Sprocket Assembly È Chain Tensioner É Circlip Ê Oil Seal DRIVE CHAIN AND SPROCKETS 6 15 ...

Page 163: ...Chain Joint Á Drive Chain  WARNING Securely support the Motorcycle on Centre stand so that there is no danger of it falling over REMOVAL 1 Stand the Motorcycle on a level surface 2 Remove Chain Case upper and lower Shift pedal À Crankcase Cover 3 Á Drive Sprocket Refer to ENGINE REMOVAL Section in Chapter 4 Page No 4 1 3 Remove Rear Wheel Refer to REAR WHEEL Section Page no 6 12 ...

Page 164: ...re 10 link length è Drive Chain Out of specification Ÿ Replace the Drive Chain NOTE Tighten the Drive Chain with a fingers before measuring 10 link length is the distance è between the inside edge of Roller and É as shown 10 link length measurement should be done at two or three different places 2 Inspect Drive Chain Driven Sprocket À More than 1 2 tooth wear ç Ÿ Replace the Drive Chain and both t...

Page 165: ...e Sprocket Assembly NOTE Align the slot on the Swingarm with the flat face of the Driven Sprocket Axle 2 Tighten Nut Driven Sprocket Axle DRIVEN SPROCKET ASSEMBLY 1 Install Driven Sprocket on Clutch Hub Lock Washer À New Nut Á NOTE Tighten the Nuts in a crisscross pattern 2 Bend Lock Washer Tab along a flat side of the end Nut Driven Sprocket 26 Nm 2 6 m kg 19 ft lb Nut Driven Sprocket Axle 91 Nm ...

Page 166: ...19 3 Install Drive Sprocket Drive Chain Chain Joint À Plate Á 4 Install Clip New 5 Install Chain Case upper Chain Case lower Shift Pedal Refer to ENGINE REMOVAL section in Chapter 4 Page no 4 1 6 Adjust Drive Chain Slack Refer to DRIVE CHAIN SLACK ADJUST MENT section in Chapter 3 Page no 3 20 7 Tighten Driven Sprocket Axle ...

Page 167: ...T FORK Front Fender À Cap Bolt Á Holder Cable  O Ring à Collar Ä Spring Seat Å Fork Spring Æ Seal Dust Ç Ring Snap È Washer É Bolt Ê Gasket Ë Spindle Taper Ì Cylinder Comp Front Fork Í Inner Tube Î Sub Spring Ï Oil seal Ð Outer Tube ...

Page 168: ...t Upper À Spring Front Fork Á 3 Remove Front Wheel Front Fender Refer to FRONT WHEEL REMOVAL Section Page no 6 3 Handlebar Refer to HANDLEBAR REMOVAL Section Page no 6 30 4 Remove Cap Bolts Inner Tube 2 Nos Cap Bolt Under Bracket 1No À FRONT FORK REMOVAL 1 Stand the Motorcycle on a level surface 2 Elevate the Front Wheel by placing a suit able stand under the Engine ...

Page 169: ...g snap Washer Oil Seal using Oil Seal Remover À 4 Remove Bolt Damper Rod Washer À Cylinder complete Fornt Fork Spindle Taper Spring Sub 3 Loosen Bolt Allen Damper Rod Loosen the Bolt Damper Rod while holding the Damper Rod with T Handle À T Handle YSST 213 Oil Seal Remover YSST 275 ...

Page 170: ...s damage Ÿ Replace Spring Sub Á Spindle Taper  Bends damage Ÿ Replace Contamination Ÿ Blow out all Oil Passages with Compressed Air 6 23 WARNING Do not attempt to straighten a bent Inner Tube as this may dangerously weaken the Tube WARNING CAUTION When disassembling and assembling the Front Fork do not allow any foreign mate rial to enter the Oil Inner Tube bending limit 0 2 mm Front Fork Spring ...

Page 171: ...ube Á Outer Tube  FRONT FORK ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points NOTE When assembling the Front Fork be sure to replace the following parts Oil Seal Seal Dust Snap Ring Before assembling the Fork make sure that all the components are clean 1 Install Spring Sub Cylinder Complete À 2 Lubricate Inner Tube outer surface 4 Install Washer New Bolt Damper Rod À Recommend...

Page 172: ... a T Handle À 6 Install Oil Seal New Using TFF Oil Seal Installation Tool NOTE Before installing the Oil Seal apply lithium soap base grease onto the Oil Seal lips Adjust the Ring Snap so that it fits into the Outer Tube Groove TFF Oil Seal Installation Tool YSST 275 T Handle YSST 213 Bolt Cylinder Complete 23 Nm 2 3 m kg 17 ft lb 8 Inspect Inner Tube operation Unsmooth operation Ÿ Disassembly and...

Page 173: ...bracket Cap Bolts À Pinch Bolt Underbracket 28Nm 2 8 m kg 20 ft lb Bolt Cap Bolt 23Nm 2 3 m kg 17 ft lb FRONT FORK 6 26 9 Fill Fork Oil 10 After filling up slowly Pump the Fork up and down to distribute the Fork Oil 11 Install Front Fork Spring Seat Upper Spacer 12 Install Cap Bolt Temporarily to avoid oil drain NOTE Install the Fork Spring with its smaller Pitch upward Before installing the Cap B...

Page 174: ...ight à Handle Crown Ä Lock Washer Å Ring Nut upper Æ Damper Rubber Ç Ring Nut lower È Ball Race Cover É Under Bracket Ê Ball Race upper Ë Ball upper Ì Ball lower Í Ball Race center Î Ball Race lower Ï Bush Tightening Steps Tighten the ring nut Lower 45 5 Nm 4 55 m kg 32 3 ft lb Loosen One turn Retighten The ring nut Lower 15 5 Nm 1 55 m kg 11 2 ft lb ...

Page 175: ...tch Cable Á Speedometer Cable  2 Remove Switch Handle 3 Remove Bolts 4 Nos Handlebar Upper Holder À Handlebar Á Throttle Grip Lever Holder Front Brake 4 Remove Front Wheel Refer to FRONT WHEEL Section Page No 6 4 Front Fender Front Fork Refer to FRONT FORK Section Page no 6 21 5 Remove Fuel Tank Refer to SIDE COVERS SEAT FUEL TANK section in Chapter 3 page no 3 3 6 Remove Headlight Assembly Stay ...

Page 176: ...ANDLEBAR INSPECTION 1 Inspect Handlebar Bends Cracks damage Ÿ Replace HANDLEBAR REMOVAL 1 Remove Grip left ææææææææææææææææææææææææææææææææææ Removal Steps Blow with compressed air between the Handle bar and Adhesive side of the Grip to remove ææææææææææææææææææææææææææææææææææ 9 Remove Bearing Cover Bearing Race À Balls upper Á Lower Bracket  Balls lower à 8 Remove Ring Nut lower Use a Ring Nut ...

Page 177: ...shown Install the new Dust Seal and Races ææææææææææææææææææææææææææææææææææ NOTE Always replace Bearing races as a set STEERING INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Lubricate Balls upper and lower Ball Races 2 Install Ring Nut lower Damper Rubber À Ring Nut upper Á Lock Washer  Refer to STEERING HEAD INSPECTION section in Chapter 3 Page no 3 22 3 Install Bush Me...

Page 178: ...olders should be in stalled with the longer side ç to the forward then tighten the Front Bolt as shown 2 Install Front Brake Lever Assembly Handlebar Switch left Grip Assembly Throttle Cable Housing Throttle Grip NOTE Align the projection ç on the Handlebar Switch with the Hole è in the Handlebar 3 Adjust Throttle Cable free play Brake operation Refer to THROTTLE CABLE ADJUSTMENT BRAKE LEVER ADJUS...

Page 179: ...CHAS L 178 REAR SHOCK ABSORBER AND SWING ARM REAR SHOCK ABSORBER AND SWINGARM Rear Shock Absorber À Axle Nut Á Swing arm  Tension Bar à Seal Guard 6 32 ...

Page 180: ...ERS SEAT AND FUEL TANK section in Chapter 3 Page no 3 3 3 Remove Rear Wheel Driven Sprocket Assembly Refer to DRIVE CHAIN AND SPROCKETS section Page no 6 16 4 Remove Nut Rear Shocker upper and lower Rear Shock Absorber left and right 5 Remove Nut Footrest L H R H Axle Nut Swing Arm Washer À Axle Shaft Á Foot Rest LH RH Swing Arm  WARNING Securely support the Motorcycle on a level sur face 6 33 ...

Page 181: ...ct Swingarm looseness Looseness exists Ÿ Tighten the Pivot Shaft nut or replace Bushes Swingarm up and down movement Unsmooth movement bending rough spots Ÿ Replace Bushes 2 Inspect Rear Shock Absorber Oil leaks damage Ÿ Replace the Rear Shock Absorber Element 6 34 ...

Page 182: ...G OF CONNECTIONS 7 3 IGNITION SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 7 4 TROUBLESHOOTING 7 4 CHARGING SYSTEM TROUBLESHOOTING 7 9 LIGHTING SYSTEM CIRCUIT DIAGRAM 7 10 TROUBLESHOOTING 7 10 LIGHTING SYSTEM CHECK 7 12 SIGNAL SYSTEM CIRCUIT DIAGRAM 7 14 TROUBLESHOOTING 7 14 SIGNAL SYSTEM CHECK 7 16 ...

Page 183: ...ELEC L 182 CIRCUIT DIAGRAM CIRCUIT DIAGRAM 7 1 ...

Page 184: ...r Relay Assy Á C D I Unit Assy  Battery à Fuse Ä Stop Switch Rear Å Neutral Switch Assy Æ Rectifier Regulator Assy Ç Ignition Coil Assy È Spark Plug Cap É Horn Ê Spark Plug LOCATION OF ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 7 2 ...

Page 185: ...r two or three times 4 Pull the lead to check that it will not come off CHECKING OF CONNECTIONS 5 If the terminal comes off bend up the pin and reinsert the terminal in to the con nector 6 Check for continuity with a tester NOTE If there is no Continuity Check Clean the ter minals Be sure to check the steps 1 to 6 listed above when checking the wire harness Use the tester on the connector as shown...

Page 186: ...lug Cap resistance 3 Ignition coil 4 Main switch 5 Sensor coil resistance 6 Charging Coil resistance 7 Rectifier cum Regulator Unit 8 Wiring connections entire ignition system 9 CDI Note Remove the required parts before trouble shooting 1 Side covers LH and RH 2 Seat 3 Fuel Tank Use Service Instrument as specified NOTE For Checking Coil resistance set Multimeter a step higher than specified range ...

Page 187: ...RESISTANCE Remove the Spark Plug Cap Connect the Multimeter ΩX1k to the Spark Plug Cap NOTE When removing the Spark Plug Cap turn out the Spark Plug Cap from high tension Cord Remove Ÿ Turn anticlockwise Connect Ÿ Turn clockwise When connecting the Spark Plug Cap cut the High Tension Cord about 5 mm Multimeter lead Ÿ Spark Plug side Multimeter lead Ÿ High tension Cord side À Replace the Spark Plug...

Page 188: ... Multimeter to the Ignition Coil Check the secondary coil resistance Multimeter lead Ÿ High Tension lead Multimeter lead Ÿ Orange Terminal À Replace the Ignition Coil OUT OF SPECIFICATION Ignition Coil OK BOTH MEET SPECIFICATIONS 4 MAIN SWITCH Check for Continuity of Switch ON position Check for ignition ON OFF position NO CONTINUITY Replace the Main Switch CONTINUITY 7 6 æ Primary coil resistance...

Page 189: ...CIFICATION MEETS SPECIFICATION Sensor coil is OK 6 CHARGING COIL RESISTANCE Remove the Charging Coil coupler from the Wire Harness Connect the Multimeter to the charging coil Measure the charging coil resistance MEETS SPECIFICATIONS Charging coil is OK Multimeter lead Ÿ White Terminal Multimeter lead Ÿ Black Terminal À Replace the Charging CoiL OUT OF SPECIFICATION IGNITION SYSTEM CHARGING SYSTEM ...

Page 190: ...Charging voltage 14 15 V at 5000RPM Multimeter lead Ÿ Battery terminal Multimeter lead Ÿ Battery terminal À MEETS SPECIFICATIONS Charging Circuit and Rectifier cum Regula tor are OK Rectifier cum Regulator unit is faulty Replace RR unit OUT OF SPECIFICATION 8 WIRING CONNECTIONS Check the connection for entire Ignition and Charging System REFER TO CIRCUIT DIAGRAM Page 7 4 POOR CONNECTIONS Repair Re...

Page 191: ...illed water Clean the Battery terminals Recharge or Replace the Battery INCORRECT 3 CHARGING VOLTAGE Refer to Rectifier cum Regulator unit in spection method in the Ignition System section in this Chapter Page no 7 8 4 CHARGING COIL RESISTANCE Refer to Charging coil resistance checking method in the Ignition System section in this Chapter Page no 7 7 MEETS SPECIFICATIONS The Charging circuit is OK...

Page 192: ...oil resistance 2 Light Switch 3 Dimmer Switch 4 Lighting Voltage 5 Wiring connections entire lighting system 6 Check individual lighting circuits Note Remove the following parts before trouble shooting 1 Side covers LH and RH 2 Seat 3 Headlight Assembly 4 Battery 5 Battery Box LIGHTING SYSTEM CIRCUIT DIAGRAM AC 7 10 Engine Tachometer Digital Multimeter ...

Page 193: ...Coupler from Wireharness Connect the Multimeter Ω X 1 to Handle bar Switch LH Terminals Check the switch connections for continu ity between Blue and Yellow Red NO CONTINUITY CONTINUITY Repair or Replace the Handlebar Switch LH 3 DIMMER SWITCH Disconnect the Handlebar Switch LH Coupler from wireharness Connect the Multimeter Ω X 1 to Handle bar Switch LH Terminals Check the Switch connections for ...

Page 194: ...ividual Lighting System Circuits 4 LIGHTING VOLTAGE Connect the Tachometer to Spark Plug lead Disconnect the Taillight coupler from wire harness Connect the Multimeter AC 20 V to tail light wire Start the Engine and accelerate the engine up to 3000 RPM and then to 8000 RPM Measure the lighting Voltage with full load by switching on the Headlight Multimeter lead Ÿ Blue terminal Multimeter lead Ÿ Bl...

Page 195: ... Bulb and Bulb socket for conti nuity 6 INDIVIDUAL LIGHTING CIRCUITS A If the Headlight and Highbeam Indicator Light do not work Replace Bulb and or Bulb Socket NO CONTINUITY 2 LIGHTING VOLTAGE Refer the lighting Voltage section Page no 7 12 CONTINUITY 1 BULB AND BULB SOCKET Check the Bulb and Bulb Socket for continuity B If the meter light does not work Replace Bulb and or Bulb socket NO CONTINUI...

Page 196: ...INDICATOR LIGHTS DO NOT WORK IF THE HORN DOES NOT WORK PROCEDURE CHECK 1 Fuse 2 Battery 3 Main Switch 4 Wiring connections entire lighting system 5 Check individual lighting circuits Note Remove the following parts before trouble shooting 1 Side covers LH RH 2 Seat 3 Fuel Tank 4 Headlight 7 14 Digital Multimeter ...

Page 197: ... coupler from wireharness Check the continuity between Brown and Red wires Top up the Battery fluid Clean Battery terminal Recharge or replace the Battery INCORRECT CORRECT NO CONTINUITY CONTINUITY Repair Replace the Main Switch 4 WIRE HARNESS Check the entire signal system for poor connections Refer to SIGNAL SYSTEM CIRCUIT DIA GRAM Page 7 14 Repair Replace the Wireharness POOR CONNECTIONS CORREC...

Page 198: ...UITY 5 INDIVIDUAL SIGNAL SYSTEMS The wiring circuit from the Main Switch to the Horn is faulty Repair Replace wireharness OUT OF SPECIFICATION MEETS SPECIFICATION 3 HORN Disconnect the Pink terminal from the horn Connect the multimeter 5 A to the open terminal at Horn Turn the main switch ON Check current Amperage drawn by Horn by connecting to body earth Specified current 1 5 A MEETS SPECIFICATIO...

Page 199: ...ck The voltage 12V between the Yel low and Black terminal NO CONTINUITY CONTINUITY MEETS SPECIFICATIONS Brake Light circuit is OK 7 17 4 WIRING CONNECTION Wiring circuit from Main Switch to the Bulb Sockets connector is faulty Repair Refer to SIGNAL SYSTEM wiring diagram Page no 7 14 2 BRAKE SWITCH FRONT REAR Disconnect the Brake switch Coupler from wire Harness Check the switch front and rear for...

Page 200: ...te and Darkgreen and Brown White and Chocolate Replace the left Handlebar Switch CONTINUITY CONTINUITY MEETS SPECIFICATION NO CONTINUITY NO CONTINUITY OUT OF SPECIFICATION The wiring circuit from Main Switch to Flasher Relay connector is faulty Repair Replace 7 18 3 VOLTAGE Connect the Multimeter DC20 V to the Flasher Relay coupler Turn the Main Switch to ON Check or voltage 12V of the Brown lead ...

Page 201: ...k Green Terminal À Multimeter lead Ÿ Body earth Á MEETS SPECIFICATIONS Wiring connection Wiring circuit from the Turn Switch to Bulb Socket connector is faulty Repair Replace Refer to CIRCUIT DIAGRAM OUT OF SPECIFICATION This circuit is O K 4 FLASHER RELAY Connect the Multimeter DC20V to the flasher relay coupler Turn Main switch to ON Check for voltage 12V on Brown White lead at Flasher Relay and...

Page 202: ...indicator lights fails to operate Replace the Bulb and or Bulb Socket NO CONTINUITY CONTINUITY Replace the Neutral switch NO CONTINUITY 3 VOLTAGE Connect the Multimeter DC20 V to the neutral switch lead Turn the main switch to on position Select the gear position in neutral Check for voltage 12 V on the Brown ter minal on the Neutral Bulb and body earth Sky Blue wire Multimeter lead Ÿ Sky Blue Ter...

Page 203: ... SPEED PERFORMANCE 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 POOR SPEED PERFORMANCE 8 3 CLUTCH SLIPPING DRAGGING 8 3 FAULTY GEAR SHIFTING 8 4 OVER HEATING 8 4 FAULTY BRAKE 8 4 FRONT FORK MALFUNCTION 8 5 UNSTABLE HANDLING 8 5 FAULTY SIGNAL AND LIGHTING SYSTEM 8 6 L 202 ...

Page 204: ...roperly adjusted Valve clearance Improperly sealed Valve Improperly contacted Valve and Valve seat Improper Valve timing Broken Valve Spring Seized Valve FUEL SYSTEM Fuel Tank Empty Clogged Fuel Tank Cap Breather Hole Deteriorated fuel or fuel containing water or foreign material Fuel Cock Clogged Fuel Hose Clogged Fuel Cock Carburetor Deteriorated fuel or fuel containing water or foreign material...

Page 205: ...rned Starter Plunger Loose or clogged Pilot jet Damaged Carburetor Joint Improperly tightened Carburetor Joint Clamp hose Improperly adjusted idle speed Pilot Screw Throttle stop Screw Improperly adjusted Throttle Cable Flooded Carburetor Air Filter Clogged air filter element Ignition system Faulty Spark Plug Faulty High tension Cord Faulty C D I Unit Faulty Sensor up Coil Faulty Ignition Coil Val...

Page 206: ...GGING section Page no 8 3 Engine Oil Improper oil level low or over oil level Improper quality low oil viscosity Deterioration Clogged oil passage Brakes Dragging brake POOR SPEED PERFORMANCE CLUTCH SLIPPING DRAGGING CLUTCH DRAGGING Clutch Warped pressure plate Unevenly tensioned clutch spring Bent push rod Broken clutch boss Burnt primary driven gear bushing Bent clutch plate Swollen friction pla...

Page 207: ...r dog OVER HEATING Ignition system Improper Spark Plug gap Improper Spark Plug heat range Faulty C D I unit Fuel system Improper Carburetor setting Improper fuel level adjustment Clogged air Filter element Compression System Heavy carbon deposit built up Improperly adjusted Valve timing Improperly adjusted Valve clearance Engine oil Incorrect Engine oil level Improper Engine oil quality high visco...

Page 208: ...ned Steering Nut Loose or overtightened Steering Nut Bent Under Bracket Improperly installed Steering Shaft improp erly tightened Ring Nut Damaged Bearing or Ball Race Front forks Uneven oil levels on both sides Uneven spring tension Broken Front Fork Spring Fatigued Front Fork Spring Twisted Front Forks Wheels Incorrect Wheel balance Loose Spokes Deformed Wheel Rim Unevenly worn Tyres Incorrect T...

Page 209: ...BLINK Improperly grounded Insufficient battery capacity Faulty Fuse Faulty Turn Switch Faulty Flasher Relay Broken wireharness incorrect coupler con nection Bulb burnt out FLASHER KEEPS ON Faulty Flasher Relay Insufficient Battery capacity nearly dis charged Bulb burnt out front or rear FLASHER BLINKS SLOWER Faulty Flasher Relay Insufficient Battery capacity nearly dis charged Improper Bulb Faulty...

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