Yamaha DT200L 1984-1988 Service Manual Download Page 200

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Summary of Contents for DT200L 1984-1988

Page 2: ...VICE MANUAL 1984 by Yamaha Motor Co Ltd 1st Edition April 1984 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 3: ...u 1 d maan factu red by Yamaha Modifications are ica t c g s p cm a ron o7proceduresw llbeforw d d o d Zslaanldw ill whe e applicable appear in future editions of this manual OVERSEAS SERVICE OVERSEAS OPERATIONS YAMAHA MOTOR CO LTD HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation NOTE WARNING A NOTE provideskeyinformationtomake proc...

Page 4: ...prehensive explanations of all disassembly repair assembly and inspectionoperations In this revised format the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol e g Bearings Pitting Damage Replace EXPLODED DIAGRAM Each chapterprovidesexploded diagrams beforeeachdisassemblysectionforease in identifying correct disassembly and assem...

Page 5: ... number and 7 ELEC PPX c Q 3 Q t E Symbol marks 9 to Q4 indicate specific data as the following items Recommended liquid Recommended grease Tightening torque Wear limit Engine speed n v A Symbol marks Q to l in the exploded diagram indicategrade of lubricantand locationof lubrica tion point Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight ...

Page 6: ...INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL APPENDICES 0 GEN JlMFO INSP ADJ ENG 3 COOL 4 CARS 5 CHAS Q ELEC 7 s APPX 3 ...

Page 7: ...AL NUMBER IMPORTANT INFORMATION ALL REPLACEMENT PARTS GASKET OIL SEALS AND 0 RINGS LOCK WASHER PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS 1 1 1 1 1 1 1 2 1 2 1 2 1 2 1 3 1 3 SPECIAL TOOLS 1 4 FOR TUNE UP 1 4 FOR ENGINE SERVICE 1 5 FOR CHASSIS SERVICE 1 6 FOR ELECTRICAL COMPONENTS 1 7 1 ...

Page 8: ...ering head pipe ENGINE SERIAL NUMBER The engine serial number D is stamped into the elevated part of the left rear section of the engine NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting Serial Number 39L 000101 NOTE Designs and specifications are subject to change without notice 1 1 ...

Page 9: ...SEALS AND 0 RINGS 1 All gaskets seals and 0 rings should be replaced when an engine is overhauled All gasket surfaces oil seal lips and 0 rings must be cleaned 2 Properly oilall mating parts and bearings dur ing reassembly Apply grease to the oil seal lips OR ou ODER LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers Plates D and cotter pins must be replaced when they are removed Lock tab s sh...

Page 10: ...weight lithium base grease to the seal lip s Oil the bearings liberally when installing D Do not use compressed air to spin the bear ings dry This causes damage to the bearing surfaces D S D Bearing CIRCLIPS 1 All circlips should be inspected carefully before reassembly Always replace piston pin clipsafter one use Replace distorted circlips When installing a circlip D make sure that the sharp edge...

Page 11: ...lp prevent damage caused by the use of improper tools or improvis ed techniques FOR TUNE UP 1 Inductive Tachometer P N 90890 03082 This tool is needed for detecting engine rpm 2 Inductive Timing Light P N 90890 03109 This tool is necessary for adjusting timing 3 Fuel Level Gauge P N 90890 01312 This gauge is used to measure the fuel level in the float chamber 1 4 ...

Page 12: ...ol is used to hold the clutch when removing or installing the clutch boss locknut 2 Rotor Holding Tool P N 90890 01235 0 This tool is used to hold the rotor when removing or installing the flywheel magneto securing nut 3 Rotor Fuller P N 90890 01189 This tool is needed to remove the flywheel magneto 4 Crank Installer Pot P N 90890 01274 This tool is used to install the crankshaft 1 5 ...

Page 13: ... is needed to separate the crankcases 7 Piston Pin Fuller P N YU 01304 CD 5 This tool is used to remove the piston pin FOR CHASSIS SERVICE 1 T Handle P N 90890 01326 Damper Rod Holder P N 90890 01294 This tool is used to loosen and tighten the front fork cylinder holding bolt 2 Front Fork Seal Driver Weight P N 90890 01367 Adapter P N 90890 01370 These tools are used when installing the fork seal ...

Page 14: ...to loosen and tighten the steering ring nut FOR ELECTRICAL COMPONENTS 1 Electro Tester P N 90890 03021 2D BA es This instrument isnecessaryfor checkingthe ignition system components 2 Pocket Tester P N 90890 03104 Thisinstrumentisinvaluableforcheckingthe electrical system 1 7 ...

Page 15: ...ENT 2 12 FRONT BRAKE PAD INSPECTION 2 13 BRAKE FLUID LEVEL INSPECTION 2 13 REAR BRAKE ADJUSTMENT 2 14 REAR BRAKE LINING INSPECTION 2 14 CLUTCH ADJUSTMENT 2 15 DRIVE CHAIN TENSION CHECK 2 17 DRIVE CHAIN TENSION ADJUSTMENT 2 17 DRIVE CHAIN LUBRICATION 2 18 FRONT FORK OIL CHANGE 2 19 STEERING HEAD INSPECTION 2 21 STEERING HEAD ADJUSTMENT REAR SHOCK ABSORBER ADJUSTMENT WHEEL BEARINGS CHECK CABLE INSPE...

Page 16: ...ion fluid leakage See NOTE Adjust if necessary Check operation Adjust if necessary Check rear arm assembly for looseness Moderately repack Check operation Moderatery repack Check balance damage runout spoketightnes Check bearings assembly for looseness damage Replace if damaged Check bearingsassembly for looseness Moderately repackevery24 000 16 000 or 24 months Check operation oil leakage Check o...

Page 17: ...2 Throttle stop screw Standard Turned Out 1 and 1 2 4 Start the engine and let itwarm up 5 Adjust Idling speed Turn the throttle stop screw 2 to adjust Idling speed 1 350 r min 6 Install Rear shock absorber gas chamber NOTE Insert the projectionon the gas chamber into the hole on the gas chamber bracket Throttle Cable Adjustment NOTE Before adjusting the throttle cable free play the engine idling ...

Page 18: ...filter element D The engineshould never be run without the airdeaner element excessive piston and or cylinder wear may result 3 Clean Air filter element Clean it with solvent NOTE Aftercleaning remove theremainingsolventby squeezing the element 4 Inspect Element Damage Replace 5 Apply SAE 10W30 motor oil 6 Squeeze out the excess oil NOTE The element should be wet but not dripping 2 3 ...

Page 19: ...ust plate moves out to its limit 3 Measure Gap Between the raised boss on the pump adjust pulley and adjust plate Minimum Pump Stroke 0 35 0 40 mm 0 014 0 016 in NOTE When inserting the thickness gauge between the adjust plate and the adjust pulley be careful so that neitherthe plate nor the pulley is moved In other words do not force the thickness gauge into the gap 1 Thicknessgauge 4 Repeat step...

Page 20: ...nd delivery linemust be bl ed on the following occasions Setting up a new motorcycle out of the crate Whenever the Autolube tank has run dry Whenever any portion of the Autolube system is disconnected 1 Bleeding the pump case and or oil pipe a Remove Pump cover Bleed screw b Keep the oil running out until air bubbles disappear c Inspect Bleed screw gasket Damage Replace d Install Components in abo...

Page 21: ...troke should be set to a maximum c Keep the engine running at about 2 000 r min for two minutes or so and both distributor and delivery pipe can be com pletely bled Engine Oil Level Inspection 1 Place the motorcycle on a level place NOTE Be sure the motorcycle is positioned straight up and on both wheels when inspecting the oil level Y 2 Start the engine and let it warm up 3 Inspect Engine oil lev...

Page 22: ...itch ON Oil warning indicator light does not come on Oil warning indicator light comes on Wait a few second Oil warning indicator light does not come on Oil warning indicator light comes on Inspect electrical circuit Engine oil level and elec trical circuit are OK Go ahead with riding Supply engine oil NOTE If the main switch isturned on immediate the oillevelwarninglightwent off the lig not come ...

Page 23: ...ine for several minutes NOTE Be sure the motorcycle is positioned straight up and on both wheels When inspectingthe oillevel a slighttilttoward the side can produce false readings Stop the engine and visually inspect the oil level through the level window Recommended Oil SAE 10W30 Type SE Motor Oil Oil Capacity Total Amount 0 63L 0 55 Imp qt 0 67 US qt Do not add any chemical additives Trans missi...

Page 24: ...smission oil 3 Tighten Drain plug o 20 Nm 2 0 m kg 14 ft lb 4 Fill Transmission oil Recommended Oil SAE 10W30 Type SE Motor Oil Oil Capacity Periodic Oil Change 0 55 L 0 48 Imp qt 0 58 US qt Do not add any chemical additives Transmission oil also lubricates the clutch and additives could cause clutch slippage Be sure no foreign material enters the crankcase 5 Inspect Oil leaks 2 9 ...

Page 25: ... water if you can t get soft water WARNING When coolant splashes to your eye Thoroughly wash your eye with water and see your doctor When coolant splashes to your clothes Quickly wash it away with water and then with soap When coolant is swallowed Quickly make him vomit and take him to a doctor Coolant Level Inspection 1 Inspect Coolant level Coolant level low Add tap water Soft water 4J Coolant r...

Page 26: ...er or salt water is harmful to the engine You may use distilled water if you can t get soft water WARNING Do not remove the radiator cap when the engine is hot SIN CHASSIS Fuel Cock Cleaning 1 Turn the fuel cock lever to the OFF 2 Remove Filter cup 3 Clean Filter cup Clean it with solvent 4 Install Filter cup NOTE Be careful not to clamp the filter cup too tightly as this may unseat the 0 ring and...

Page 27: ...day Be sure the brake is working properly WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system This air must be removed by bleeding the brake system before the motor cycle is operated Air in the system will cause greatly diminished braking capability and can result in loss of control and an acci dent Inspect and bleed the system if necessary 3 Ti...

Page 28: ...nspection 1 Inspect Brake fluid level Brake fluid level low Replenish fluid Q Lower level 0 DOT 3 NOTE Be sure that Spilled fluid iscleaned up immediately to pre vent painted surfaces or plastic parts from eroding WARNING 1 2 Use only the designated quality brake fluid otherwise poor brake perform ance will result Water does not enter the master cylinder when refilling otherwise poor brake perform...

Page 29: ... 4 in Below the Top of the Footrest WARNING After adjusting the pedal height adjust brake pedal free play 2 Free play a Adjust Free play 1 Turn the adjuster 2 until the free play is within the specified limits 20 30 mm 0 8 1 2 in WARNING Check the operation of the brake light after adjusting the rear brake r Rear Brake Lining Inspection 1 Depress the brake pedal 2 Inspect Wear indicator 1 Indicato...

Page 30: ...ighten Locknuts NOTE The above procedure provides for maximum cable free play to allow for proper clutch ac tuating mechanism adjustment 2 Mechanism adjustment a Loosen Cable length adjuster locknuts Fully b Tighten Cable length adjusters Until tight c Remove Oil pump cover Oil pump cable d Drain Transmission oil Coolant e Remove Pipe joint Engine guard Rear brake f Disconnect Radiator hose 2 15 ...

Page 31: ...r finger until it stops D Adjuster D j Adjust Free play With the push lever in this position turn the adjuster either in or out until the push lever mark 1 and crankcase match mark 5 are aligned 3 Push k Tighten Locknut 8 Nm 0 8 m kg 5 8 ft lb I Install Connect Fill Components in above list Steps g f e d c m Adjust Clutch cable free play 2 16 ...

Page 32: ...n this tight chain posi tion 1 Place the motorcycle on a level place and hold it in an upright position NOTE The both wheels on the ground without rider on it 2 Check Drive chain deflection Out of specification Adjust Drive Chain Deflection 35 45mm 1 4 1 8 in Drive Chain Tension Adjustment Excessive chain tension will overload the engine and other vital parts keep the ten sion within the specified...

Page 33: ...tion The chain consists of many parts which work againsteach other Ifthe chain isnot maintained properly itwillwear out rapidly therefore form the habit of periodicallyservicing the chain This service is especially necessary when riding in dusty conditions This motorcycle has a drive chain with small rub ber 0 rings between the chain plates Steam cleaning high pressure washes and certain sol vent ...

Page 34: ...afe handling Have any problem corrected before operatingthe motorcycle 2 Securely support the motorcycle so there is no danger of it falling over 1 Elevate the front wheel by placing a suitale stand under the engine 2 Remove Handlebars Rubber cap 3 Loosen Pinch bolts Q D 0 4 4 Depress the cap bolt to remove the stopper ring 5 Remove Stopper ring Use a small screwdriver Cap bolt 2 together with 0 r...

Page 35: ...il will cause diminished braking capacity and will damage the rubber components of the brake assembly 8 Inspect Cap bolt 0 ring Drain bolt gasket Damage Replace 9 Install Drain bolt 10 Fill Fork oil 1 0 Fork Oil Capacity Each Fork 366 cm3 12 9 Imp oz 12 4 US oz Recommended Oil SAE 10W30 Type SE Motor Oil After filling pump the forks slowly up and down to distribute the oil 11 Install Components in...

Page 36: ...unched mark 2 1st D 2nd Gap Firsttightentheboltsonthefrontsideofthe handlebar holder and then tighten the bolts on the rear side Steering Head Inspection WARNING Securely support the motorcycle so there is no danger of it falling over 1 Elevatethefrontwheel by placinga suitable stand under the engine 2 Check Steering assembly bearings Grasp the bottom ofthe forks and gently rock the fork assembly ...

Page 37: ...oosen Fork pinch bolt Steering fitting bolt 5 3 Tighten Ring nut Use the Ring Nut Wrench 90890 01268 38 Nm 3 8m kg 27ft lb WARNING Avoid over tightening 4 Tighten Steering fitting bolt Fork pinch bolt Steering Fitting Bolt 58 Nm 5 8 m kg 42 ft Ib Fork Pinch Bolt 23 Nm 2 3m kg 17 ft lb Headlight stay securing bolts 5 Check Steering assembly bearings Looseness Adjust steering head 2 22 ...

Page 38: ...t to open the cylinder assembly 2 Do not subject shock absorber to an open flame or other high heat source This may cause the unitto explode due to excessive gas pressure m A 3 Do not deform or damage the cylinder inany way Cylinder damage will result in poor damping performance 1 Spring NOTE The spring preload ofthe rearshock absorber can be adjusted to suitrider spreference weight and the course...

Page 39: ...ments of 2 mm 0 08 in at a time Never attempt to turn the adjuster beyond the maximum or minimum setting c Tighten Locknut 55 Nm 5 5 m kg 40 ft lb Always tighten the locknut against the spring adjuster and torque the locknut to specification 2 Damping NOTE The damping of the rear shock absorber can be adjusted to suit rider s pre ference weight and course conditions a Adjust Damping Turn the adjus...

Page 40: ...le spining the wheel Excessive vibration Replace bearings 2 Rear wheel a Remove Rear wheel b Check Bearing movement Roughness Replace bearings Cable Inspection and Lubrication Cable Inspection and Lubrication Steps Remove the two screws that secure throt tie housing to handlebar Hold cable end high and apply several drops of lubricant to cable Coat metal surface of disassembled throt tie twist gri...

Page 41: ...18psi 22psi 90kg 198lb Maximum load High Speed Riding 147 k Pa 177RPa 1 5kg cm2 1 8kg cm2 22psi 147k Pa 1 5kg cm2 22psi 26psi 177kPa d Skg cm2 26psi Load isthe total weightof cargo rider passenger and accessories WARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Tire inflation pressure must be adjusted ac cording to t...

Page 42: ...ide Properly adjust the suspension for your load and check the con dition and pressure of your tires NEVER OVERLOAD YOUR MOTORCYCLE Make sure the total weight of the cargo rider passenger and accessories fairing sad dlebags etc if approved for this model does not exceed the maximum load of the motorcycle Operation of an overloaded motorcycle could cause tire damage an ac cident or even injury 2 In...

Page 43: ...is not recommended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement Wheels Check 1 Inspect Wheel Crack bend warpage Replace Spoke Tight Damage Adjust Repalce WARNING Never attempt even small repairs to the wheel NOTE Always balance the wheel when a tire or wheel has been changed or replaced 2 28 ...

Page 44: ...INSP ADJ WHEELS CHECK 2 Tighten Valve stem tocknut 1 5 Nm 0 15 m kg 1 1 ft lb WARNING Ride conservatively after installing a tire to allow it to seat itself properly on the rim 2 29 ...

Page 45: ...on the rotor should move to the advance posi tion Incorrect Check ignition system NOTE Refer to CHAPTER 7 ELECTRICAL for further information 1 BTDC8 at 1 350 r min 2 BTDC 30 at 4 000 r min Battery Inspection 1 Inspect Battery fluid level Battery fluid level low Fill Fluid level should be between upper and lower level marks Upper level Lower level Normal tap water contains minerals which are harmfu...

Page 46: ... with milk of magnesia beaten egg orvegetable oil Call a physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries pro duce explosive gases Keep sparks flame cigarettesetc away Ventilate when charg ing or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 2 Remove Battery 3 Inspect Battery fluid s...

Page 47: ... correctly If the breather pipe touches the frame or exits in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmetic damage to the motorcycle can oc cur 6 Inspect Battery breather pipe Obstruction Remove Damage Replace 4 Spark Plug Inspection 1 Inspect Electrode Wear Damage Replace Insulator color 2 Normal condition is a medium to light tan color Distinctl...

Page 48: ...on Regap Use a wire gauge Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in 5 Tighten Spark plug NOTE Before installing a spark plug clean the gasket surface and plug surface 20 Nm 2 0m kg Uft lb NOTE Ifa torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turns part finger tight Havethesparkplugtorqued tothecorrect value as soon as possib...

Page 49: ...move Headlight cowling 2 Remove Headlight unit assembly 3 Disconnect Headlight leads t 1 4 Remove Defective bulb Turn the bulb holder Q counter clockwise to release bulb WARNUNG Keep flammable products or your hands away from the bulb while it is on it will be hot Do not touch the bulb until it cools down 5 Install Bulb New Secure the new bulb with the bulb holder Avoid touching the glass part of ...

Page 50: ...tment Turn the adjusting screw D counterclockwise Turn the adjusting screw 1 clockwise 2 Adjust Headlight beam Vertically Higher Lower Vertical Adjustment Turn the adjusting screw 1 clockwise Turn the adjusting screw counterclockwise Fuse Inspection 1 Inspect Fused Defective Replace Blow fuse New Inspect circuit 2 Spare fuse Do not use fuses of higher amperage rating than those recommended Substit...

Page 51: ...STON RINGS PISTON PIN AND BEARING AUTOLUBE PUMP CLUTCH 3 2 3 2 3 3 3 3 3 4 3 5 3 6 3 6 3 7 3 7 3 8 3 8 3 9 3 9 3 10 3 10 3 11 DISASSEMBLY CYLINDER HEAD CYLINDER POWER VALVE REED VALVE PISTON PIN AND PISTON KICK CRANK CRANKCASE COVER RIGHT 3 CLUTCH AND PRIMARY DRIVE GEAR TACHOMETER GEAR KICK AXLE CHANGE SHAFT BEARING STOPPER PLATE CRANKCASE SHIFTER AND TRANSMISSION CRANKSHAFT 3 11 3 13 3 13 3 13 3 ...

Page 52: ...ANSMISSION CRANKCASE BEARING STOPPER PLATE CHANGE SHAFT KICK AXLE TACHOMETER GEAR CLUTCH AND PRIMARY DRIVE GEAR CRANKCASE COVER RIGHT KICK CRANK PISTON PIN AND PISTON REED VALVE POWER VALVE CYLINDER CYLINDER HEAD CDI MAGNETO REMOUNTING ENGINE 3 24 3 25 3 25 3 25 3 26 3 27 3 27 3 27 3 28 3 28 3 30 3 33 3 34 3 34 3 34 3 35 3 37 3 40 3 40 3 40 3 41 3 41 3 42 3 43 3 45 3 47 ...

Page 53: ...ENG 3 1 ...

Page 54: ... cleaning equipment Refer to CHAPTER 1 GENERAL INFOR MATION SPECIAL TOOLS section NOTE When disassemblingthe engine keep mated parts together This includes gears cylinder piston and other parts that have been mated through nor mal wear Mated parts must be reused as an assembly or replaced v 3 During engine disassembly clean all parts and place them in trays in the order of disassembly This will sp...

Page 55: ...DIC INSPECTIONS AND ADJUSTMENTS Transmission Oil Replacement section 3 7 Drain the coolant completely Refer to CHAPTER 4 COOLING SYSTEM Coolant Replacement section It R rts nd Fuel Tank 1 Remove Side covers Left and Right Seat 2 Turn the fuel cock to the OFF position 3 Disconnect Fuel pipe or an 4 Remove Holding bolt Q Holding plate 2 Fuel tank irts of bly or Exhaust Pipe 1 Remove MufflerCD 3 3 ...

Page 56: ...1 3 Disconnect Oil pipe D NOTE Plug the oilpipeso the oilwill not run out of the oil tank Oil delivery pipe 5 4 Remove Wire clip D Oil pump cable Rotate the pump pulley to the full throt tie position 5 Disconnect Clutch cable D Firstdisconnectthe handlebar leverside and then crankcase side Tachometer cable 2 3 4 ...

Page 57: ... 8 Remove Pulley 9 Disconnect Pulley cables 5 10 Remove power valve cover 11 Disconnect Thermo unit lead ill throt Carburetor 1 Remove Y E I S air chamber Rear shock absorber gas chamber ver side 2 Loosen Carburetor joint holding screws Q 3 Remove Carburetor top 2 together with throttle valve 3 3 5 ...

Page 58: ...g to prevent dirt or foreign matter into the carburetor Change Pedal 1 Remove Change pedal CDI Magneto 1 Remove Crankcase cover Left 1 fed 2 Remove Magneto securing nut Q Use Rotor Holding Tool 2 90890 01235 to lock the magneto Remove CDI magneto CD Use Rotor Puller D 90890 01189 3 6 ...

Page 59: ...lead 5 Remove Starter assembly Woodruff key Drive Chain 1 Remove Securing bolts Apply the rear brake Holding plate Drive sprocket Drive chain Engine Removal 1 Disconnect Radiator hoses D 5 2 Remove Brake pedal assembly 3 Remove Engine mouting bolts D Pivot shaft 3 7 ...

Page 60: ...orber gas chamber JS DISASSEMBLY Cylinder Head 1 Remove Thermo unit D Thermostatic valve cover Gasket Thermostatic valve 4 0 ring WARNING Handle the thermo unit with special care Never subject it to strong or allow it to be dropped Should it be dropped it must be replaced CD 2 Remove Cylinder head Cylinder head gasket NOTE 1 Before looseningthe cylinder head loosen the spark plug 5 2 The cylinder ...

Page 61: ...ce the cylinder in an inverted position and drain the coolant Power Valve 1 Remove Power valve holder Left 0 2 Remove Hexagon socket head bolt T Hold the right end of the power valve with ptiers NOTE If stiff use a wooden piece D through the exhaust port to steady the valve 3 9 ...

Page 62: ...e Piston pin clip Q NOTE Before removing the piston pin clip cover the crankcase with a clean rag so you will not acciden tally drop the clip into the crankcase 2 Remove Piston pin D Piston NOTE Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficult to remove use Piston Pin Fuller YU 01304 3 10 ...

Page 63: ...e Crankcase cover Right NOTE The crankcase cover can be removed without removing the Autolube pump and water pump ip je Clutch and Primary Drive Gear 1 Remove Clutch spring holding screws Clutch springs 2 Pressure plate Friction plates Clutch plates 5 Push rod 1 6 to 2 Remove Ball D Push rod 2 5 3 Straighten Lock washer tab 3 11 ...

Page 64: ...ear 2 Spacer 3 Knock pin 4 Shim 6 Straighten Lock washer tab Balancer gear Loosen Primary drive gear nut D Balancer gear nut Place a folded rag 3 between the teeth of the drive gear 4 and balancer to lock them w sl 8 Remove Primary drive gear nut 1 Spring washer Primary drive gear 3 Drive gear Key 9 Remove Balancer gear nut Lock washer 2 Balancer gear Key A 3 12 ...

Page 65: ...ve Stopper plate Tachometer driven gear Tachometer drive gear ith Kick Axle 1 Unhook the kick spring from its position 2 Remove Kick axle assembly Rotate the shaft counterclockwise A 3 Remove Circlip Plain washer Kick idle gear Plain washer Circlip Change Shaft 1 Remove Change lever Spring 3 13 ...

Page 66: ...rankcase holding screws NOTE Loosen each screw 1 4 turn and remove them after all are loosened NOTE Turn the shift cam to the position shown in the figure so that it does not contact the crankcase when separating the crankcase 2 Attach Crankcase Separating Tool 90890 01135 D 3 Remove Crankcase Right NOTE Fully tightenthe tool holding bolts but make sure the tool body is parallel with the case If 3...

Page 67: ...o not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw realign and start over If the cases do not separate check for a remaining case screw or fitting Do not force r Shifter and Transmission 1 Remove Guide bars Shift forks Shift cam D NOTE Note the position of each part Pay particular at tention to...

Page 68: ...oil seal lip A recommended practiceisto fitthe 0 ring and to apply grease over the fitted area 3 Remove Transmission assembly Tap lightly on the transmission drive shaft with a soft hammer Remove Balancer weight D Crankshaft 1 Attach Crankcase SeparatingTool 90890 01135 D 2 Remove Crankshaft 3 16 ...

Page 69: ...ylinder head warpage out of specifica tion Re surface Warpage Measurement and Re surface ment Steps Attach a straight edge and a thickness gauge on the cylinder head Measure the warpage limit Warpage Limit 0 03 mm 0 0012 in If the warpage is out of specification re surface the cylinder head Place a 400 600 grit wet sandpaper on the surface plate and re surface the head using a figure eight sanding...

Page 70: ...ly cleaning groove D 3 Inspect 0 ring Bush Oil seal Wear Damage Replace Piston 1 Remove Carbon deposits From the piston crown and ring grooves 0 2 Remove Score markes and lacquer deposits From the sides of piston Use a 600 800 grit wet sandpaper NOTE Sand in a crisscross pattern Do not sand excessively 3 Inspect Piston wall Wear Scratches Damage Replace 3 18 ...

Page 71: ... specification Rebore Use a Cylinder Bore Gauge Cylinder Bore c Standard 66 00 mm 2 598 in Taper T Out of Round R C Maximum D T Maximum Di or 02 Minimum Ds or D R Maximum Di Da or Ds Minimum Di D4 or De Wear Limit 66 10 mm 2 602 in 0 08 mm 0 003 in 0 05 mm 0 002 in e 0 10 mm 0 4 in 4 Measure Piston outside diameter P Out of specification Replace Use a Micrometer 1 NOTE Measurement should be made a...

Page 72: ...ce piston Rebore cylinder or Piston Clearance 0 060 0 065 mm 0 0024 0 0026 in A C P A Piston clearance C Cylinder bore P Piston outside diameter 0 D a CD Radiator Pipe and Joint Pipe 1 Inspect Radiator pipe and joint pipe Crack Replace 0 ringCD Damage Replace Piston Rings 1 Measure Side clearance Out of specification Replace piston and or rings Use a Feeler Gauge V 3 20 ...

Page 73: ...as a set Use a Feeler Gauge CD Standard Limit TopRin9 2 O Smn 70mm t0 028 2nd Ring 0 80mm 0 032in Oversize Piston Ring Oversize 1 66 25 mm 2 608 in Oversize 2 66 50 mm 2 618 in Piston Pin and Bearing 1 Lubricate Piston Pin lightly 2 Install Piston pin Into the small end of connecting rod d 3 Check Free play There should be no noticeable for the play Free play exists inspect the connecting rod for ...

Page 74: ...ns of heat discoloration Replace Autolube Pump Wear or an internal malfunction may cause pump output to vary from the factory setting This situa tion is however extremely rare If improper out put is suspected inspect the following 1 Inspect Delivery line Obstructions Blow out Pump body seal Crankcase cover seal Wear Damage Replace Check ball Spring Miss lmproper Repair 2 Inspect Allowing air Air e...

Page 75: ...tion plate thickness Out of specification Replace friction plate as a set Measure at all four point Wear Limit 2 7 mm 0 11 in 3 Inspect Clutch plate Damage Replace clutch plate as a set 4 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate and feelergauge D Warp Limit 0 05 mm 0 002 in __Li_ 5 Measure Clutch spring free length Out of specification Rep...

Page 76: ...g bearing Chafing Wear Damage Replace 8 Inspect Clutch boss splines Scoring Wear Damage boss Replace clutch NOTE Scoring on the clutch boss splines will cause er ratic operation Primary Drive 1 Inspect Drive gear and driven gear Pitting Wear Damage Replace D 6 c 0 2 It is always advisable to pay strict attention to the lash numbers mark during replace ment Marks are scribed on the side of each gea...

Page 77: ...ge Wear Replace 2 Measure Kick spring tension Out of specification Replace Use a spring balance d lace clutd Standard Tension 1 0 kg 2 2 Ib II cause Do not try to bend the clip ace Shifter 1 Inspect Shift return spring Damage Replace Change shaft Damage Bends Wear Replace t attentioi ng replace iide of eactl 0 Transmission 1 Inspect Shift forks Gear and shift cam contact surfaces Wear Chafing Bend...

Page 78: ...ut Out of specification Replace Use centering device and Dial Gauge 90890 03097 Runout Limit 0 08 mm 0 0031 in 5 Inspect Gears Damage Wear Replace 6 Check Gear movement Unsmooth operation Replace 7 Inspect Mating dogs Cracks Wear Damage Replace c c Crankshaft 1 Measure Runout limit C Connecting rod big end side clearance D Small end free play limit F Out of specification Replace Use V Blocks Dial ...

Page 79: ... Damage Wear Replace 2 Check Gear movement Unsmooth operation Replace 0 0 Bearings and Oil Seals 1 Inspect Bearings Pitting Damage Replace Oil seal lips Damage Wear Replace Crankcase 1 Thoroughly wash the case halves in mild solvent 2 Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly 3 Inspect Crankcase Cracks Damage Replace Oil delivery passages Clog Blow out with comp...

Page 80: ... the grease to the oil seal lips and app ly the engine oil to each hearing 1 Attach Crankshaft Installing Tool 90890 01274 1 90890 01275 90890 01278 3 2 and 2 Install Crankshaft NOTE Hold the connecting rod at top dead center with one hand while turning the nut of the Installing Tool with the other Operate the Installing Tool untilthe crankshaft bottoms againstthe bearing 3 28 ...

Page 81: ...pin clip Cylindrical bearing Straight key Crank Right Washer Connecting rod Crank pin Cylindrical bearing Crank Left Woodruff key Bearing Oil seal PISTON TO CYLINDER CLEARANCE 0 060 0 065 mm 0 0024 0 0026 in END GAP INSTALLED 0 30 0 45 mm 0 012 0 018 in C CRANKSHAFT A 58 00 g mm 2 283 o in C 0 03 mm 0 0012 in D 0 4 0 7 mm 0 016 0 028 in F 2 mm 0 08 in c c D 55 Mm 5 5 m kg 40 ft lb 0 B6205C4 3 29 ...

Page 82: ...attention to the oil seal Iip A recommended practice is to fit the 0 ring and apply grease over the fitted area 2 Check Transmission operation Unsmooth operation Repair 3 Install Shift cam D Shift forks Guide bars v NOTE Each shiftforks isidentifiedby a number cast on itsside All the numbers should face the left side 4 Check Shifter operation Unsmooth operaion Repair 3 30 ...

Page 83: ...5T 5th wheel gear 22T Special washer 3rd wheel gear 24T 4th wheel gear 24T 6th wheel gear 1ST 2nd wheel gear 30T Bearing Main axle 11T 5th pinion gear 23T 3rd pinion gear 17T 21T 6th pinion gear 22T 2nd pinion gear 16T Cylindrical bearing Q st on side RUNOUT LIMIT 0 08 mm 0 0031 in B6204CS CD 0 0 10 Nm 1 0 m kg 7 2 ft lb 0 B6303Z RUIMOUT LIMIT 0 08 mm 0 0031 in 0 5 7 Cl 3 31 ...

Page 84: ...ENG SHIFTER Circlip Guide bar 1 Shift fork 3 Shift fork 1 Shift cam assembly D Shift fork 2 Guide bar 2 ENGINE ASSEMBLY AND ADJUSTMENT CD 0 0 D 0 4 0 S D D 3 32 ...

Page 85: ...ot contact the crankcase when installing the crankcase Before installing and torquing the crankcase holding screws be sure to check whether the transmission is functioning properly by manually rotating the shift cam either way 4 Tighten Crankcase holding screws NOTE Tighten the crankcase holding screws in stage using a cnsscross pattern 8 Nm 0 8 m kg 5 8 ft Ib 5 Apply 2 stroke oil To the crank pin...

Page 86: ... kg 11 ft lb Change Shaft 1 Install Spring Stopper lever Securing bolt 3 2 Set the stopper lever and torsion spring as properly position 3 Tighten Securing bolt Apply LOCKTITE 14 Nm 1 4 m kg 10 ft Ib 4 Install Change lever Spring 5 Check Change operation Unsmooth operation Repair y A Kick Axle 1 Install Circlip Plain washer Kick idle gear Plain washer Circlip 3 34 ...

Page 87: ...stopper is stopped at the projection of the crankcase 2 Make sure that the spring is engaged with the crankcase hole 3 Set the kick spring D to the spring hook 4 Check Kick axle operation Unsmooth operation Repair Tachometer Gear 1 Install Tachometer drive gear Tachometer driven gear Stopper plate 5 Nm 0 5 m kg 3 6 ft Ib 3 35 ...

Page 88: ...er Conical spring washer Knock pin Push rod 1 Ball Push rod 2 Push lever axle Primary driye gear 6 Nm 0 6 m kg 4 3 ft lb d CLUTCH SPRING FREE LENGTH A LIMIT 30 0 mm 1 18 in FRICTION PLATE WEAR LIMIT 2 7mm 0 11 in CLUTCH PLATE WARP LIMIT 0 05 mm 0 002 in D CLUTCH PLATE THICKNESS E 1 1 6mm 0 068 in F OTHER 1 2 mm 0 047 in 0 55 Nm 5 5 rn kg 40 ft lb g Q 0 80 Nm 8 0 m kg 58 ft lb 0 4 3 36 ...

Page 89: ...punched mark 3 on the balancer gear which must be aligned to install the balancer gear CD 4 Install Key Balancer gear Lock washer New lock washer Balancer gear nut Key Drive gear Primary drive gear Spring washer Primary drive gear nut 5 Tighten Primary drive gear nut Balancer gear nut Place a folded rag 3 between the teeth of the drive gear 4 and balancer gear 5 to lock them Primary Drive Gear Nut...

Page 90: ... Crankcase side 8 Install Primary driven gear Holding plate 2 NOTE Install the primary driven gear while turning the kick idle gear primary drive gear and balancer gear 9 Install Clutch boss Lock washer New lock washer Locknut 10 Attach Universal Clutch Holder D 90890 04086 To hold the clutch boss 11 Tighten Clutch boss lock nut 55 Nm 5 5 m kg 40 ft Ib 12 Bend the lock washer tab along the nut fla...

Page 91: ...alled closest to the pressure plate 5 00000 0 the icer CD 36 ts d r r Clutch plate 1 Clutch plate Other Thickness 1 6mm 0 063 in 1 2 mm 0 047 in Quantity 1 5 Clutch plate other 3 Friction plate 04 Clutch boss 14 Install Clutch pressure plate NOTE Align the punched mark on the clutch boss with the arrow mark on the clutch pressure plate 15 Install Clutch springs Clutch spring holding screws 6 Nm 0 ...

Page 92: ... Ib Piston Pin and Piston 1 Apply 2 stroke oil To the piston pin bearing piston ring grooves and piston skirt areas 2 Install Small end bearing Piston D Piston pin Piston pin clip 3 NOTE 1 The arrow on the piston must point to the front of the engine 2 Before installing the piston pin clip cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material int...

Page 93: ...s on the valve holders Left and right 2 Install Half power valve Left Half power valve Right 2 Insert the half valve with pliers 3 Install Hexagon socket head bolt Hold the right end of the power valve with pliers Power valve holder Left Socket Head Bolt 6 Nm 0 6 m kg 4 3 ft Ib Valve Holder Left 5 Nm 0 5 m kg 3 6 ft Ib D Cylinder 1 Install Dowel pins Cylinder gasket New gasket 2 Offset the piston ...

Page 94: ...r with one hand while compress ing the piston rings with the other hand 4Lx p 4 Apply Molybdenum disulfide grease To the 0 ring New 0 ring of the joint pipe 5 Install Joint pipe Cabie holder 2 6 Tighten Cylinder holding nuts Joint pipe holding screws Cylinder Holding Nuts 25 Nm 2 5 m kg 18 ft lb Joint Pipe Holding Screws 10 Nm 1 0 m kg 7 2 ft Ib fi Cylinder Head 1 Install Cylinder head gasket 1 Ne...

Page 95: ...ve cover 03 Locknut QjS Adjuster d Pulley 1 Power valve cap The HEAD mark on the gasket must point to the front of the engine 5 Nm 0 5 m kg 3 6 ft lb D 22 Nm 2 2 m kg 16 ft lb 0 ec D D 0 o Q 5 Nm 0 5 m kg 3 6 ft lb BR8ES NGK SPARK PLUG GAP 0 7 0 8 mm 0 028 0 031 in 20 Nm 2 0 m kg 14 ft lb 10 Nm 1 0 m kg 7 2 ft lb CYLINDER HEAD B WARP LIMIT 0 03 mm 0 0012 in 25 Nm 2 5 m kg 18 ft lb iW a e 0 0 0 6 I...

Page 96: ...linder Head Holding Nuts 22 Nm 2 2 m kg 16 ft Ib Spark Plug 20 Nm 2 0 m kg 14 ft Ib D 0 0 3 Install 0 ring Thermostatic valve Gasket Thermostatic valve cover Thermo unit NOTE The thermostatic valve breather hole installed in backward direction must be 2 F W D 4 Tighten Thermostatic valve cover holding screws Thermo unit WARNING Avoid overtightening 3 44 ...

Page 97: ...Neutral switch lead 3 Install CDI magneto Plain washer CDI magneto securing nut NOTE When installingthe CDI magneto make sure the woodruff key is properly seated in the key way of the crankshaft Apply a light coating of lithium soap base grease to the tapered portion of the crankshaft end 4 Tighten Magneto securing nut Q Use Rotor Holding Tool 2 90890 01235 to lock the magneto 83 Nm 8 3 m kg 60 ft...

Page 98: ...ENG ENGINE ASSEMBLY AND ADJUSTMENT Remounting Engine K e f 80 Nm 8 0 m kg 58 ft Ib K c I 38 Nm 3 8 m kg 27 ft lb 64 Nm 6 4 m kg 46 ft lb 3 46 ...

Page 99: ... Nm 6 4 m kg 46 ft lb Rear 38 Nm 3 8 m kg 27 ft Ib Pivot Shaft 80 Nm 8 0 m kg 58 ft lb 2 Install Brake pedal assembly NOTE After installing the brake pedal assembly adjust the brake free play 3 Install Drive chain Drive sprocket Holding plate Securing bolts 10 Nm 1 0 m kg 7 2 ft Ib NOTE After installing the drive chain adjust the drive chain tension 4 Install Crankcase cover Left 8 Nm 0 8 m kg 5 8...

Page 100: ...lve cover Pulley cables Pulley Q Power Valve Cover 5 Nm 0 5 m kg 3 6 ft Ib Pulley 10 Nm 1 0 m kg 7 2 ft lb NOTE Check to see that pulley moves freelypriorto on necting the pulley cables 7 Adjust Pulley cable free play vf Cable Free Play Adjustment Steps Align the ident portion on the pulley with the hole into the valve cover Insert the 4mm 0 16 in pin D into the hole in order to steady as well as ...

Page 101: ... are aligned If not aligned repeat above steps 8 Install Power valve seal cap 5 Nm 0 5 m kg 3 6 ft lb 9 Connect Clutch cable NOTE After connecting the clutch cable adjust the clutch cable free play 10 Connect Oil delivery pipe Oil pipe NOTE After connecting the pipes bleed the air 11 Install Oil pump cover 10 Nm 1 0 m kg 7 2 ft lb Exhaust pipe 18 Nm 1 8m kg 13 ft Ib 3 49 ...

Page 102: ...NT 12 Apply Transmission oil Coolant p Transmission Oil Total 0 63 L 0 55 Imp qt 0 67 US qt Coolant Radiator 0 64 L 0 56 Imp qt 0 68 US qt V t Reservoir Tank 0 13 L 0 114 Imp qt 0 137 US qt 13 Inspect Oil leakage Coolant leakage 3 50 ...

Page 103: ...ANT COOLANT REPLACEMENT 4 1 4 1 WATER PUMP 4 4 DISASSEMBLY 4 4 INSPECTION 4 5 OIL SEAL REPLACEMENT 4 5 ASSEMBLY 4 6 THERMOSTATIC VALVE 4 3 REMOVAL 4 8 INSPECTION 4 9 ASSEMBLY 4 10 RADIATOR REMOVAL INSPECTION ASSEMBLY 4 10 4 10 4 10 4 11 ...

Page 104: ... the radiator cap by the following procedure Remove the radiator cover by removing the screw Place a thick rag like a towel over the radiator cap slowly rotate the cap counterclockwise to the detent This pro cedure allows any residual pressure to escape When the hissing sound has stop ped press down on the cap while turning counterclockwise and remove it D III 1 Place an open container under the e...

Page 105: ...er ap ro to 0 p ng 6 Drain Coolant Completely NOTE Thoroughly flush the cooling system with clean tap water 7 Inspect Drain bolt gaskets Damage Replace 8 Tighten Drain bolts Cylinder and water pump cover Drain Bolt Cylinder and Water Pump Cover 10Nm 1 0m kg 7 2ft lb 9 Fill Coolant 4 2 ...

Page 106: ...Total Amount 0 64L 0 56 Imp qt 0 68 US qt Reservoir Tank Capacity 0 13L 0 114 Imp qt 0 137 US qt From LOW to FULL Level 0 11L 0 10 Imp qt 0 12 US qt 1 Hard water or salt water is harmful to the engine You may use distilled water if you can t get soft water 2 Do not mix more than one type of ethlen glycol antifreeze containing cor rosion for aluminum engine inhabitors 10 Install Radiator cap 11 Run...

Page 107: ... reser voir tank 14 Install Radiator cover 15 Inspect Cooling system Coolant leaks Repair Always check coolant level and check for coolant leakage before starting engine WATER PUMP Disassembly NOTE It is necessary to disassemble the water pump unless there is no abnormality such as excessive change in coolant temperature and or level discoloration of coolant or milky transmission oil 1 Drain Coola...

Page 108: ...lant out of the water pump while taking care so that itdoes not splashes to the Autolube pump 4 Remove Water pump housing cover Q Circlip Plain wahser 5 Remove Impeller shaft gear Plain washer Knock 6 Pull out the impeller shaft assemt 7 Eliminate deposits from the impeller and water pump housing Inspection 1 Inspect Impeller Cracks Wear Damage Repalace Oil seal Wear Damage Replace 4 5 ...

Page 109: ...TE Install the oil seal with the WATER SIDE mark is on the inside 0 0 NOTE Press fit the oil seal until they contact the bot torn 0 0 3 Q o0 o 0 Assembly 1 Apply Lightweight lithium base grease Apply a grease to oil seal and impeller shaft 2 Install Impeller shaft Install the shaft while turning it NOTE Take care so that the oil seal lip is not damaged or the spring does not slip off its position ...

Page 110: ...e a new gasket 5 Install Joint pipe NOTE When intalling the joint grease the 0 rings on the joint o 10 Nm 1 0m kg 7 2ft lb Always use the new 0 ring 6 Install Fill Components in above list Disassembly steps 2 and 1 After warming up the engine proceed as follows 1 Retighten the pump cover screws to specification 2 Check for coolant leakage particularly leakage into the transmission case 4 7 ...

Page 111: ...r shaft gear C6 Plain washer Circlip g Housing cover 9 0 ring Joint pipe THERMOSTATIC VALVE J WATER SIDE mark COOL D 0 A A B B 10 Nm 1 0 m kg 7 2 ft lb 0 8 Nm 0 8 m kg 5 8 ft lbl 4 0 THERMOSTATIC VALVE Removal 1 Remove Thermostatic valve covert Thermostatic valve 2 D 0 ring 4 8 ...

Page 112: ...Heat water slowly Observe thermometer while stirring water continually LD Thermometer Full open 3 Opening sequence begins S S A A 3 mm 0 12 in 82 1 5 C 180 35 F 95 C 203 F 4 Water Thermostatic valve Vessel Open Close NOTE Thermostatic valve is sealed and its setting is specialized work If its accuracy is in doubt always it A faulty unit could cause serious overheating or overcooling 2 Inspect 0 ri...

Page 113: ...stall Thermostatic valve cover 8Nm 0 8m kg 5 8ft lb CD RADIATOR Removal 1 Remove Radiator cover D 2 Drain off the coolant 3 Remove Radiator mounting bolts 4 Disconnect Coolant 5 Remove Radiatord CD Inspection 1 Inspect Radiator core Obstruction Blow out with com pressed airthrough rear of the radiator Flattend fin Repair replace T Compressed air 4 10 ...

Page 114: ...g System Tester 90890 01325 to the radiator cap Apply the specified pressure for 10 seconds and make sure there is no pressure drop Assembly 1 Install Radiator Coolant hoses 2 Fill Coolant Refer to Coolant Replacement 3 Inspect Cooling system Decrease of pressure leaks Repair as required Inspection Steps Attach the Cooling System Tester 90890 01325 to the radiator Apply 98 1 kPa 1 0 kg cm2 14 Ib i...

Page 115: ...AL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION ADJUSTMENT REED VALVE REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION YAMAHA ENERGY INDUCTION SYSTEM HANDLING NOTES INSPECTION 5 1 5 2 5 2 5 2 5 4 5 5 5 5 5 6 5 6 5 6 5 7 5 8 5 8 5 9 5 9 5 9 5 ...

Page 116: ...eedle valve assembly Float Main jet Main nozzle Pilot jet Float chamber cover Drain screw SPECIFICATIONS Main Jet M J Main Air Jet M A J Jet Needle J N Needle Jet N J Pilot Jet P J Pilot Air Screw P A S Float Height F H Fuel Level F L Engine Idling Speed 146 00 5 4J6 4 P 4 22 5 1 and 1 2 22 0 1 0 mm 0 87 0 04 in 0 5 1 0 mm 0 02 0 04 in 1 300 50 r min A FUEL LEVEL 0 0 D 3 5 1 ...

Page 117: ...w Starter plunger Throttle stop screw Disassembly 1 Remove Pilot air screw Throttle stop screw Starter plunger 3 2 Remove Float chamber cover Float pin Float Needle valve 5 3 Remove Valve seat CD Main jet D Main nozzleCD Pilot jet 4 Inspection 1 Inspect Carburetor body Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with compressed air 5 2 ...

Page 118: ...ct Pilot airscrew D Throttle stop screw Starter plunger Wear Contamination Replace D 4 Inspect Throttle valve Wear Damage Replace 5 Check Free movement Stick Replace Insert the throttle valve into the car buretor body and check for free movement 6 Inspect Jet needle Bends Wear Replace 7 Inspect Float Damage Replace Gasket 0 ring Damage Replace 5 3 ...

Page 119: ... and top of the float using a gauge D Float height NOTE The floatarm should be testingon the needle valve but not compressing the needle valve If the float height is not within specifica tion inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by bending the float tangCDon the float Recheck the float height Assembly 1 Install Compone...

Page 120: ...ace the motorcycle on a level place Use a garuge jack under the engineto en sure that the carburetor is positioned vertically Disconnect the overflow pipe Attach the Fuel Level Gauge 90890 01312 to the overflow pipe nozzle Loosen the drain screw and start the engine Measure the fuel level 2 with gauge b Adjust Fuel level If necessary Adjustment Steps Remove the carburetor Inspect the valve seat an...

Page 121: ...air fuel mixture characteris ties of the motorcycle Poor condition Jet needle position change Jet Needle Type 4J6 Standard Clip Position No 4 Groove Up Leaner condition Down Richer condition D 1st 2nd 3rd C4 4th Standard position 5 5th REED VALVE Removal 1 Remove Reed valve assembly Refer to engine removal section Disassembly 1 Remove Read valve stopper Reed valve 5 6 ...

Page 122: ... seats If in doubt as to sealing ability apply suc tion to carburetor side of assembly Leakage should be slight to moderate ft 2 Measure Valve stopper clearance Out of specification Adjust stop per Replace valve stopper Valve Stopper Clearance 10 3 mm 0 41 in NOTE If it is 0 4 mm 0 016 in more or less than specified replace the valve stopper Measure Reed valve bending limit Out of specification Re...

Page 123: ...er of the reed and stopper plate 2 Tighten Reed valve securing screws Use LOCTITE 1 Nm 0 1 m kg 0 7 ft lb NOTE Tighten each screw gradually to avoid warping Installation When installing the reed valve reverse the removal procedure Note the following points 1 Install Gasket New 2 Tighten Reed valve securing bolts 0 8 Nm 0 8 m kg 5 8 ft lb NOTE Tighten each bolt gradually to avoid warping 5 8 ...

Page 124: ...em The air chamber and hose should be handled with special care Any imperfect connectionor installation of these parts or damaged parts wil have an adverse ef feet on the performance of the system Check parts and be sure to replace any defective one Inspection 1 Inspect Air chamber Crack Damage Replace Looseness Replace 5 9 ...

Page 125: ...BLY 6 14 MASTER CYLINDER DISASSEMBLY 6 15 BRAKE INSPECTION AND REPAIR 6 17 BRAKE REASSEMBLY 6 18 AIR BLEEDING 6 20 BRAKE DISC INSTALLATION 6 21 FRONT FORK 6 22 REMOVAL 6 23 DISASSEMBLY 6 23 INSPECTION 6 26 ASSEMBLY 6 27 INSTALLATION 6 29 STEERING HEAD 6 31 REMOVAL 6 32 INSPECTION 6 33 ASSEMBLY 6 33 REAR SHOCK ABSORBER 6 36 HANDLING NOTES 6 36 NOTES ON DISPOSAL 6 36 REMOVAL 6 38 INSPECTION 6 38 ASS...

Page 126: ...CHAS TQ f SWINGARM INSPECTION REMOVAL ADJUSTMENT INSPECTION AND LUBRICATION ASSEMBLY 6 40 6 41 6 41 6 42 6 43 6 44 DRIVE CHAIN AND SPROCKETS REMOVAL INSPECTION ASSEMBLY 6 45 6 45 6 46 6 46 6 ...

Page 127: ...CHAS 6 1 ...

Page 128: ...ont Rear 127 kPa 147 kPa 1 3kg cm2 1 5kg cm2 18psi 22psi 147kPa 177kPa 1 5kg cm2 1 8kg cm2 22psi 26psi 147 kPa 177 kPa 1 5kg cm2 1 8kg cm2 22psi 26psi Load isthe total weight of cargo rider and accessories Up to 90 kg 198lb load 90kg 198lb Maximum load High speed riding SE C3 4 B6202 0 0 B TIRE SIZE 3 00 21 4PR WHEEL SIZE 1 60x21 C WHEEL RUNOUT LIMIT D VERTICAL 2 mm 0 08 in E LATERAL 2 mm 0 08 in ...

Page 129: ...cle on a level place 6 Elevate the front wheel by placing a suitable stand under the engine 7 Remove Axle nut Front axle Front wheel NOTE Do not depress the brake lever when the wheel is off the motorcycle as the brake pads will be forc ed shut Inspection 1 Inspect Front axle Roll the axle on a flat surface Bends Replace WARNING Do not attempt to straighten a dent axle 6 3 ...

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Page 132: ... meshed with the flats in the wheel hub 3 Install Front wheel assembly NOTE Be sure the boss on the outer fork tube correctly engages with the locating slot on the gear unit assembly 4 Tighten Axle nut o 85 Nm 8 5 m kg 61 ft lb 5 Install Cotter pin WARNING Always use a new cotter pin on the axle nut 6 6 ...

Page 133: ...et Bearing Oil seal Collar Drive chain FRONT WHEEL CHAS 85 Nm 8 5m kg 61ft Ib 8 Nm 0 8m kg 5 8ft Ib D WHEEL RUNOUT LIMIT E VERTICAL 2 mm 0 08 in F LATERAL 2 mm 0 08 in 3 r B TIRE SIZE 4 10 18 4PR WHEEL SIZE 2 15x18 LINING WEAR LIMIT 2mm 0 08 in B6202RS 39 Nm 3 9m kg 28 ft lb L i 3 CD 62 Nm 6 2m kg 45ft Ib DRIVE CHAIN FREE PLAY 35 45mmd 4 1 8in 6 7 ...

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Page 136: ...asy assembly Installation When installing the rear wheel reverse the removal procedure Note the following points 1 Apply Lithium base grease Lightly grease to the oil seal lips 2 Install Rear wheel assembly NOTE 1 Be sure the swingarm boss correctly engages the locating slot on the brake shoe plate 2 Make sure the rear wheel axle is inserted on the left hand side and that the chain pullers are ins...

Page 137: ... WHEEL 4 Install Cotter pin WARNING Always use a new cotter pin on the axle nut 5 Adjust Drive chain tension Rear brake free play WARNING Check the operation of the brake light after adjusting the rear brake 6 11 ...

Page 138: ...ake pads Pad spring FRONT BRAKE Be sure to position the pad so that its round side is backward 2 BRAKE DISC PAD A WEAR LIMIT 0 8mm 0 031 in BRAKE DISC B WEAR LIMIT 3 0mm 0 12in 0 0 6 Nm 0 6m kg 4 3 ft Ib CD 18 Nm 1 8m kg 13ft Ib D t R 0 0 0000 OOCO 0 BRAKE PAD cc 35 Nm 3 5m kg 25ft Ib 6 12 ...

Page 139: ...vents on brake internal components Solvents will cause seals to swell and distort Use only clean brake fluid for clean ing Use care with brake fluid Brake fluid is injurious to eyes and will damage painted surfaces and plastic parts D Caliper Pad Replacement It is not necessary to disassemble the brake caliperand brake hose to replacethe brake pads 1 Remove Retaining 2 Turn the caliper body counte...

Page 140: ...NOTE Be sure to positionthe pad so that its round side is backward C2 5 Apply Lithium base grease Apply a light coating of grease to the re taining bolt 6 Set the caliperbody at the originalposition 7 Install Retaining bolt 18Nm 1 8m kg 13ft lb Caliper Disassembly 1 Remove Retaining bolt Pads Pad springs Refer to Caliper Pad Replacement section 6 14 ...

Page 141: ...n Removal Steps Blow compressed air l into the tube joint opening to force out the caliper piston from the caliper body WARNING Never try to pry out the caliper piston WARNING Cover the piston with a rag Use care so that piston does not cause injury as it is expelled from the cylinder Master Cylinder Disassembly NOTE Drain the brake fluid before remainingthe master cylinder 6 15 ...

Page 142: ...CHAS JQ Union bolt Copper washer 3 Master cylinder 4 Brake hose Master cylinder kit FRONT BRAKE 27 Nm 2 7m kg 19ft Ib I D 23 Nm 2 3m kg 17ft lb S VCQ BRAKE FLUID DOT 3 C4 27 Nm 2 7m kg 19 ft Ib J 6 16 ...

Page 143: ...linder Master cylinder 3 Remove Dust boot Circlip Master cylinder cup assembly Brake Inspection and Repair Recommended Brake Component Replacement Schedule Brake Pads Piston Seal Dust Seal Brake Hoses Brake Fluid As required Every two years Every four years Replace only when brakes are disassembled 6 17 ...

Page 144: ...iston and dust seals whenever a caliper is disassembled 3 Inspect Master cylinder body Scratches Wear Replace NOTE Clean all passages with new brake fluid 4 Inspect Brake hose Cracks Wear Damage Replace Brake Reassembly 1 Caliper When assembling the caliper reserve the disassembly procedure Note the following points WARNING 1 All internal parts should be cleaned in new brake fluid any 6 18 ...

Page 145: ... assembling the master cylinder reserve the disassembly procedure Note the following points a Install Master cylinder cup NOTE The cylinder cups are installed with the larger diameter lips inserted first b Install Master cylinder o 23 Nm 2 3 m kg 17 ft lb NOTE The master cylinder bracket should be installed with the UP mark unit on top c Install Brake hose 27 Nm 2 7 m kg 19 ft lb d Fill Brake flui...

Page 146: ...ot bled Air Bleeding Steps a Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill or overflow the reservoir c Connect the clear plastic tube tightly to the caliper bleed screw d Put the end of the tube into a container e Slowly apply the brake lever several times f Pull in lever Hold the lever in on position g Loosen the bleed screw Allow the lever to travel slow...

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Page 148: ...8 Damper rod ring FRONT FORK Je Oil lock piece Dust cover Retaining Oil seal t Ai bolt A FORK OIL CAPACITY EACH FORK 366cm3 12 9 Imp oz 12 4 USoz RECOMMENDED OIL B 14ft lb y 3 Ss 0 3 D S c 20 Nm 2 0m kg 14 ft Ib 6 22 9 Damper Rod Cylinder Complete 10 Rebound Spring 11 Inner tube Sorry oil stains on the original ...

Page 149: ...e hose holder 1 Speedometer cable holder 2 2 Remove Brake caliper assembly 1 NOTE Do not depress the brake lever when the wheel is off the motorcycte as brake pads will be forced shut CD 3 Loosen Front fork pinch boltsQ 4 Remove Front fork Rubber boot Disassembly 1 Remove Rubber ca 2 Depress the cap bolt to remove the stopper ring 6 23 ...

Page 150: ...ydraulically Fill the fork completely with the fork oil Reinstall the cap bolt with 0 ring and stopper ring D Take care so that no air remains in the in ner tube Place the socket on the top of the cap bolt and place the fork leg in a hand press as illustrated Turn slowly Socket Wrap with rag Ifthe inner tu isabruptly contracted or air enters the in er tube the oil may spurt out or o il Seal may sp...

Page 151: ... 6 Remove Cylinder securing bolt Use Damper Rod Holder 90890 01294 1 and T Handle 90890 01367 2 to lock the damper rod 7 Remove Damper rod cylinder complete Rebound spring 8 Remove Guide bush Slide bush Fork Bushes Removal Steps Hold fork leg in a vise horizontally Put in the inner fork tube just before it bottoms out and then pull it back quickly 6 25 ...

Page 152: ...ck piece will be damaged CD Remove Guide bush D Slide bush Oil lock piece Inspection 1 Inspect Inner fork tube Scratches Bends Replace WARNING Do not attempt to straighten a bent inner fork tube as this may dangerously weaken the tube 2 Inspect Outer fork tube Scratches Bends Damage Replace Fork springs Small and Large Over specified limit Replace Fork Spring Free Length Limit Large 570 6 mm 22 46...

Page 153: ...eplace Assembly Before assembling clean and inspect all parts and replace when necessary NOTE In front fork assembly be sure to use following new parts Guide bush Slide bush Oil seal Dust seal 3 1 Install Rebound springQ Damper ro Slide the damper rod into inner fork tube from its top Oil lock piece 3 Fit oil lock pieceover damper rod stick ing out of inner fork tube 6 27 ...

Page 154: ...294 and T Handle 90890 01367 to lock the damper rod B 3 1 20 Nm 2 0m kg Uft lb 5 Install Guide Into outer tube Use Fork Seal Driver Weight 90890 01367 Dand Adapter 90890 01370 3 1 2 3 4 1 2 3 6 Apply Oil To oil seal 7 Install Seal Oil seal Use Special Tools 90890 01367 90890 01370K2 D Outer tube Inner tube Guide bush 8 Install Retaining d Dust seal Use Special Tools 90890 01370 90890 01367 Q 6 28 ...

Page 155: ... SE MOTOR OIL NOTE After fillingslowly pump the forks up and down to distribute the oil 11 Install Cap bolt together with 0 ring Stopper ring Rubber boot Rubber cap Installation 1 Install Front fork NOTE Fit the front fork by pushing it up until its top is flush with the handle crown top end Holding the front fork in this position temporarily tighten the pinch bolts with fingers 6 29 ...

Page 156: ...h Bolts Handle Crown 23 Nm 2 3 m kg 17 ft lb Pinch Bolts Under Bracket 20 Nm 2 0 m kg 14 ft lb 3 Install Brake caliper assembly 0 35 Nm 3 5m kg 25ft lb 4 Install Speedometer cable holder Brake hose holder Front wheel Refer to FRONT WHEEL section 6 30 ...

Page 157: ...teering fitting bolt Ring nut C3 Ball race cover CO Ball race Upper D Balls C6 Ball race Lower C7 Taper roller bearing 70 Nm 7 0m kg 50 ft Ib 38 Nm 3 8m kg 27 ft lb 15Nm 1 5m kg 11 ft Ib D 0 7 Ss 0 0_ 0 0 0 23 Nm 2 3m kg 17ft Ib BSE 6 31 ...

Page 158: ...heel by placing a suitable stand under the engine 2 Remove Handlebars Front wheel Front forks Headlight stay Front fender 3 Remove Steering fitting bolt Handle crown D 4 Remove Ring nut Use Ring Nut Wrench 90890 01268 2 WARNING Support the under bracket so that it may not fall down 5 Remove Ball race covert Ball race Upper Q 6 32 ...

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Page 160: ...Arrange the balls around race and app ly more grease Ball Quantity Size 22 pcs 3 16 in 4 Install Under bracket Hold the under bracket until it is secured Ball race Upper Ball race cover 5 Tighten Ring nut 38 Nm 3 8m kg 27ft lb WARNING Do not overtighten 6 Install Handle crown Steering fitting bolt 70 Nm 7 0 m kg 50 ft lb 6 34 ...

Page 161: ...ERING HEAD CHAS VQ 8 Check Steering operation Turn the steering from lock to lock 9 Install Components in above list Removal Step 2 Refer to FRONT WHEEL FRONT FORK and Steering Head Adjustment section 6 35 ...

Page 162: ...NOCROSS SUSPENSION DE CARBN SYSTEM Rear shock absorber assembly 0 42 Nm 4 2m kg 30 ft Ib c t E A SPRING PRELOAD B STD LENGTH 198 mm 7 8 in C MIN LENGTH 188mm 7 4in D MAX LENGTH 208mm 8 2in c DAMPING FORCE G H HARD STD SOFT ADJUSTING POSITION 543 6 36 ...

Page 163: ...not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance 4 Take care not to scratch the contact surface of the piston rod with the cylidner or oil could leak out 5 When scrapping the shock absorber follow the instructions on disposal 25 30 mm 1 0 1 2 in j z z 0 Notes on Disposal Before disposingthe shock absorber be sure to extract the nitrogen gas To do...

Page 164: ...as chamber 3 Remove Shock absorber bottom holding nut Plain washer 5 Shock absorber bottom holding bolt a n 4 Remove Rear shock absorber D Rubber boot 2 Avoid damaging the rubber hose and shock absorber gas chamber 3 Inspection 1 Inspect Shock absorber rod Bends Damage Replace absorber assembly Shock absorber Oil leakes Replace absorber assembly 6 38 ...

Page 165: ...nts 1 Adjust Spring preload damping force Refer to Rear Shock Absorber Adjust ment section 2 Apply Lithium base grease To pivot points 3 Tighten Shock absorber holding nuts Top and Bottom Holding Nut Top 42 Nm 4 2 m kg 30 ft lb Holding Nut Bottom 42 Nm 4 2 m kg 30 ft lb 4 Install Rear shock absorber gas chamber NOTE Insert the projectionon the gas chamber into the hole on the gas chamber bracket 6...

Page 166: ...lay arm connecting rod A B SWINGARM SIDE PLAY 1 0mm 0 04 in SIDE CLEARANCE 0 4 0 7 mm 0 016 0 028 in JBE 0 I E_ D 1 SE_ 2 c s 59 Nm 5 9m kg 43 ft lb E 80 Nm 8 0m kg 58ft Ib WLESE 42 Nm 4 2m kg 30ft Ib 42 Nm 4 2m kg 30 ft Ib 42 Nm 4 2m kg 30 ft Ib 6 40 ...

Page 167: ...ushing or bearings Move swingarm from side to side Side Play At End of Swingarm 1 0 mm 0 04 in 3 Check Swingarm Vertical movement Tightness Binding Rough Spots Replace bearings Move swingarm up and down Removal 1 Remove Pivot shaft securing nut Re ay arm connecting rod securing nut 2 Remove Chain guided Swingarm assembly 6 41 ...

Page 168: ... A2 Bi Ai 1 Measure Bushing length Ai and Az Out of specification bushings Replace Specified Length A 68 75 69 05 mm 2 707 2 719 in AZ 68 75 69 05 mm 2 707 2 719 in 2 Measure Length B and Bz 3 Calculate swingarm side clearnace C by us ing formula given below C A A B 82 6 42 ...

Page 169: ...only one shim is used install iton the left side Two shims must be installed both sides Inspection and Lubrication 1 Inspect Thrust covers and oil seals Damage Replace Bushings Scratches Damage Replace 2 Install New bushings NOTE When pressing the new bushings note attention to the following points 1 Bushings should be exactly located as shown in the installation 4 mm 0 16 in from each side 6 43 ...

Page 170: ... mm 0 08 in Assembly When assembling the swingarm reverse the removal procedure Note the following points 1 Tighten Securing nuts o Relay Arm and Relay Arm Connec ting Rod 42 Nm 4 2 m kg 30 ft lb Swingarm and Relay Arm 59 Nm 5 9 m kg 43 ft lb Relay Arm Connecting Rod and Frame 42 Nm 4 2 m kg 30 ft lb 6 44 ...

Page 171: ...m movement DRIVE CHAIN AND SPROCKETS Removal 1 Drive sprocket a Flatten Lock washer tab Use a blunt chisel b Remove Sprocket securing bolts Lock washers Apply the rear brake c Remove Holding plate Drive sprocket 2 Driven sprocket a Remove Rear wheel b Flatten Lock washer tab Use a blunt chiset c Remove Sprocket securing huts Lock washers Driven sprocket 6 45 ...

Page 172: ... Inspect Drive and driven sprockets Wear Damage Replace D 1 4 tooth 2 Correct d Roller W Sorocket Assembly When assembling the sprockets reverse the removal procedure Note the following points 1 Tighten Sprockets Drive Sprocket 10Nm 1 0m kg 7 2ft lb o Driven sprocket 62 Nm 6 2 m kg 45 ft lb 2 Adjust Drive chain Rear brake 6 46 ...

Page 173: ...HARGING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING BATTERY INSPECTION 7 12 7 12 7 14 7 14 CHARGING OUTPUT TEST 7 15 CHARGING COIL RESISTANCE TEST LIGHTING SYSTEM 7 16 7 18 CIRCUIT DIAGRAM 7 3 TROUBLESHOOTING 7 20 A C LIGHTING CIRCUIT OUTPUT TEST 7 30 LIGHTING COIL RESISTANCE TEST 7 21 7 22 7 22 7 24 SIGNAL SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING SIGNAL SYSTEM TESTS AND CHECKS j_ SWITCHES INSPECTION 7 3...

Page 174: ...ELEC YAMAHA POWER VALVE SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING SERVOMOTOR UNIT TEST YPVS CONTROL UNIT TEST 7 36 7 36 7 38 7 39 7 40 7 ...

Page 175: ...ELEC 7 1 ...

Page 176: ...CIRCUIT DIAGRAM ELECTRICAL DT200L CIRCUIT DIAGRAM 1 Br Br G R G Y Br B R I Ch Dg L _ Br W Br Br OFF 0 ON T 1 HI r I OFF ION 0 Ill W Y R 1 RUN ISTOP ON IOFF o o o B W B W B R W R B W B R 4 Br R B W G 7 2 ...

Page 177: ...ch LIGHTS Dimmer switch HIGH BEAM indicator light Headlight LIGHTS switch Taillight Meter light Fuse Battery Rectifier with regulator CDI magneto ENGINE STOP switch CDI unit Ignition coil Spark plug Color Code B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue 0 Orange P Pink R Red Sb Sky blue W White Y Yellow B R BIack Red B W Black White B Y Black Yellow Br W Brown White G R Gree...

Page 178: ...TS ELECTRICAL COMPONENTS 1 1 Wire harness Oil level switch 3 Fuse 4 Battery 5 Rear brake switch C6 Neutral switch Ignition coil C8 Main switch SPECIFICATIONS IGNITION COIL PRIMARY SECONDARY RESISTANCE 0 60 10 6 6k0 20 r y 7 4 ...

Page 179: ...ELEC Y P V S Control unit CDI unit Flasher relay Thermo unit Servomotor Horn Rectifierwith regulator SPECIFICATIONS PICKUP COIL SOURCE COIL CHARGING COIL LIGHTING COIL POTENTIOMETER RESISTANCE 350 2 20 3550 20 0 430 20 0 350 20 7 5k0 30 Q 0 l f 7 5 ...

Page 180: ... SYSTEM IGNITION SYSTEM f Circuit Diagram 1 G Y Ch g L 6n Br W Br Br G R B Br B r Br OFF 0 B R rh 7 T Sb 4 I I B HI E o r i 7 I OFF ION 0 B Th W Y R D B B RUN ISTOP ON IOFF o o o B W B W B W B R B R Br R B W R W G 7 6 ...

Page 181: ...orementioned circuit diagram shows ignition circuit in wiring diagram NOTE For the encircled numbers and color codes see page 7 3 QSP Main switch CDI magneto ENGINE STOP switch CDI unit Ignition coil Spark plug 3 1 7 p y 7 7 ...

Page 182: ...ion OK Poor connection Ignition system circuit is good Correct OK Check spark plug condition Refer to Spark Plug Inspection section OK Check resistance of ignition coil Refer to Ignition Coil Resistance Test section Poor condition If other than specified Replace spark plug Replace ignition coil OK Check pick up and source coil resistance of CDI magneto Refer to Pick up Coil Resistance Test and Sou...

Page 183: ...rt the engine and in crease the spark gap until misfire occurs Test at various revolution between 1 300 8 000 r min 2 Spark plug lead 3 Spark plug Do not run the engine in neutral above 6 000 r min for more than 1 or 2 seconds D Minimum Spark Gap 6 mm 0 24 in Faulty ignition system operation at the minimum spark gap or smaller Follow the troubleshootingchart untilthe source of the pro blem is loca...

Page 184: ...ce check or Ohm x 100 For secondary win ding resistance check position 0x1 A 0 003 J 4 Measure Primary coil resistance A Secondary coil resistance B Out of specification Replace B 6 6KO 0 0x100 Primary Coil Resistance 1 6J2 10 at 20 C 68 F Secondary Coil Resistance 6 6kR 20 at 20 C 68 F CSCB 3 J Pick up Coil Resistance Test 1 Remove Fuel tank 2 Disconnect Pick up coil connector White Red White Gre...

Page 185: ...B Pick up Coil Resistance 350 2 20 at 20 C 68 F Source Coil Resistance 1 Remove Fuel tank 2 Disconnect n d 2 pin connector Brown and Black from CDI magneto One lead Black Red from CD magneto 3 Connect Pocket Tester 90890 03104 Set the tester selector to Ohm x 100 position 4 Measure Source coil resistance Out of specification Replace D Brown Black Red Source Coil Resistance 355 B 20 at 20 C 68 F 7 ...

Page 186: ... SYSTEM CHARGING SYSTEM Circuit Diagram J 1 pjl Br Br 0 R G Y Ch Dg I Br B R Br W 1 Br Br OFF i 0 ON B T T T 1 HI Lo l h i r 1 th OFF ION 0 W Y R D RUN 0 STOP ON OFF B W B w B _ W RJ B W B R Br R B W G T T 7 12 ...

Page 187: ...ARGING SYSTEM Aforementioned circuit diagt am shows charging NOTE For the encircled numbers and color codes see page 7 3 circuit in wiring diagram Fuse Battery Rectifier with regulator CDI magneto 3 7 13 ...

Page 188: ...n OK Check fuse and fuse connections OK Poor connection Low voltage and low specific gravity Weak connec tion or open circuit Correct Recharge battery Correct connection or replace fuse Check charging amperage and charging coil resistance of CDI magnate Refer to Charging Output Test and Charging Coil Resistance Test section If other than specified Replace charging coil OK Rectifier with regulator ...

Page 189: ...position 4 Start the engine 5 Accelerate the engine to specifications and check the charging amperage Never disconnect the leads from the battery before stopping the engine 6 Measure Charging output amperage Out of specification Perform the next test D Fuse positive lead Battery positive lead lo Sl Charging Output Amperage Day 0 7 A or more 2 000 r min 1 8 A or less 8 000 r min Night 0 3 A or more...

Page 190: ...ue White and Yellow Red from CDI magneto 2 pin connector Brown and Black from CDI magneto 3 Connect Pocket Tester 90890 03104 Set the tester setector to Ohm x 1 position 4 Measure Charging coil resistance Out of Specification Replace Q White Black lo 61 Charging Coil Resistance 0 43 2 20 at20 aC 68 F 7 16 ...

Page 191: ...CHARGING SYSTEM ELEC 7 17 ...

Page 192: ...IGHTING SYSTEM LIGHTING SYSTEM Circuit Diagram r 1 Jv Ch T 9 Br I t I R Br B r Br W Br Br OFF 0 ON B R G R T f I B HI 1 OFF ION 0 W Y R RUN 0 STOP ON lOFF S S B W B W B nfw R B W B R Br R B W G TtT 7 18 ...

Page 193: ...uit in wiring diagram LIGHTING SYSTEM ELEC NOTE For the encircled numbers and color codes see page 7 3 LIGHTS Dimmer switch HIGH BEAM indicator light Headlight LIGHTS switch Taillight Meter light Rectifier with regulator CDI magneto s 3 r f I 4 t 7 19 ...

Page 194: ...put Test section If other than specified Check lighting coil resistance of CDI magneto Refer to Lighting Coil Resistance Test section OK Rectifierwith regulator is faulty repalce it Poor condition Poor connection Replace bulb s Correct OK If other than specified Lighting system is good Replace lighting coil A C Lighting Circuit Output Test 1 Remove Headlight lens unit 2 Disconnect 3 pin connector ...

Page 195: ...ext test Lighting Voltage 12 V or more 2 000 r min 18 V or less 8 000 r min Lighting Coil Resistance Test 1 Remove Fuel tank 2 Disconnect 3 pin connector Sky blue Yellow Red and White from CDI magneto 2 pin connector Brown and Black from CDI magneto as 3 Connect Pocket Tester 90890 03104 Set the tester selector to Ohm x 1 position 4 Measure Lighting coilresistance Out of specification Replace Yell...

Page 196: ...SIGNAL SYSTEM SIGNAL SYSTEM Circuit Diagram 1 Br Br G R 0 G Y Ch Dg R Lv Br B R J Br W Br Br OFF ON T 1 c r B r B 1 OFF ION 0 R W Y R RUN 0 _B _ B_ ISTOP ON IOFF 0 B W B W B R W R B W B R Br R B W G Th 7 22 ...

Page 197: ... numbers and color codes see page 7 3 Horn HORN switch Oil level switch OIL warning indicator light Front brake switch Rear brake switch Brake light Neutral switch NEUTRAL indicator light Flasher relay TURN switch TURN indicator light Flasher light Left Flasher light Right 3 Main switch Fuse Battery 9 3 D Y 7 23 ...

Page 198: ...tion Poor connection Correct OK Check fuse and fuse connections Weak connec tion or open circuit Correct connection or replace fuse OK Check condition of each circuit for signal system Refer to Signal System Test and Checks and Switched Inspection section Poor condition Replace poor condition electrical component s Signal System Tests and Checks NOTE The battery provides power for operation of the...

Page 199: ...faulty replace 2 Brake light does not work Check for voltage 12V on Br lead at front brake switch connector OK Check for voltage 12V on B lead at rear brake switch connector OK No voltage Wiring circuit from fuse to front brake switch connector is faulty repair No voltage Wiring circuit from fuse to rear brake switch connector is faulty repair Check for voltage 12V on G Y lead at front brake switc...

Page 200: ...ulty replace it Wiring circuit from fuse to flasher relay terminal is faulty repair Flasher relay is faulty replace Wiring circuit from flasher relay to TURN switch is faulty repair TURN switch is faulty replace 4 NEUTRAL indicator light does not work Check for voltage 12V on Br lead at No voltage indicator light connector OK Check for voltage 12V on Sb lead at No voltage neutral switch connector ...

Page 201: ...voltage 12V on B R lead at oil level switch connector No voltage Indicator light bulb is faulty replace OK Check for condition of oil level switch Poor condition Oil level switch is faulty replace CD S ffijRNl HORN I Switches Inspection Switches may be checked for continuitywith a Pocket Tester 90890 03104 on the Ohm x 1 position LIGHTS Dimmer switch TURN switch 3 HORN switch C4 LIGHTS switch y EN...

Page 202: ...LOCK B W Lead Color B R Br 2 LIGHTS Dimmer switch Lead Color Y L HI LO Switch Position 3 HORN switch Switch Position OFF ON Lead Color P B 4 TURN switch Switch Position OFF ON Ch Lead Color Br W Dg 5 LIGHTS Switch Switch Position OFF ON Lead Color Y R L 7 28 ...

Page 203: ...Color B W B Oil Level Switch Test 1 Remove Oil level switch 2 Connect Pocket Tester 90890 03104 Set the tester selector to Ohm x 1 position t D rf Q 0 e 3 Measure Oil level switch resistance Out of specification Replace 5 S Oil Level Switch Resistance UP T o Down OK 7 29 ...

Page 204: ...COOLING SYSTEM COOLING SYSTEM Circuit Diagram 1 G Y Ch 0 L Dg 6R G R Br W Br OFF 0 ON Br Br Br M i i I 1 HI Y B r G B I LO Ill W Y R D RUN 0 D p STOP ON iOFF 0 B W B W B R W R B R B W T R B W G 3 WSP i rk 7 30 ...

Page 205: ...YSTEM ELEC Aforementioned circuit diagram shows cooling circuit in wiring diagram NOTE For the encircled numbers and color codes see page 7 3 g G3 Thermo unit 4 Temperature gauge Main switch Fuse Battery A 7 31 ...

Page 206: ...unit Resistance Test section OK Check temperature gauge condition Refer to Temperature Gauge Test section Poor connection Weak connec tion or open circuit If other than specified Poor condition Correct Correct connection or replace fuse Replace thermo unit Replace temperature gauge Thermo unit Resistance Test 1 Remove Thermo unit WARNING Handle the thermo unit with special care Never subject it to...

Page 207: ... 120 5 C 229 219 F Resistance 57912 127 n 47 9 Q 41 6 Q After measuring the thermo unit install the unit 14 Nm 1 4 m kg 10ft lb A4 SM Avoid overtightening Check the coolant level and leakage Temperature gauge Temperature Gauge Test 1 Turn the ignitionto ON position 2 Disconnect Thermo unit lead CD Green Red from thermo unit CD 3 Connect Test lead 2 To thermo unit lead 4 Check Temperature gauge ope...

Page 208: ...rature Gauge Operation Check Steps Ground the test lead Do not keep the ground more than few seconds on any one attempt The tempe ituregauge should H Red zone If it does not read H the temperature gauge is broken Red zone 7 34 ...

Page 209: ...COOLING SYSTEM ELEC 7 35 ...

Page 210: ...EM YAMAHA POWER VALVE SYSTEM Circuit Diagram r r f Qr f 0 1 G Y Ch 0 B A Br W S Br Br Br Br n B R a B t T i OFF 0 ON B rh I I HI FO y B r 8 r r 1 OFF ION 0 Ill W Y R D n RUN ISTOP ON 10FF 0 6 0 B W gjw B R W R B W B R R B 8r W G 7 36 ...

Page 211: ...ELEC Aforementioned circuit diagram shows Yamaha Power Valve System Cirsuit in wiring diagram NOTE For the encircled numbers and color codes see page 7 3 0 Servomotor YPVS Control unit Main switch Fuse Battery CDI unit D r 7 37 ...

Page 212: ...cuit is good Correct Check YPVS control unit condition Refer to YPVS Control Unit Test section OK CDI unit is faulty replace it Poor condition Replace YPVS control unit 2 Step B Check battery for voltage and specific gravity Refer to Battery Inspection section OK Check entire Yamaha Power Valve System for connections Refer to WIRING DIAGRAM section OK Check fuse and fuse connections OK Check servo...

Page 213: ...rvomotor unit Test leads Red Dand Black 4 Servomotor 5 Black Yellow 6 Black Red 4 Check Servomotor operation Malfunction Replace Good operation Perform the next test 5 Disconnect Components in above list Step 3 V L W R 7 5KQ 1 I Wr 6 Connect Pocket Tester 90890 03104 Set the tester selection to Ohm x 100 position 7 Measure Potentiometer resistance Out of specification Replace Yellow Blue White Bla...

Page 214: ...unit 6 YPVS control unit Servomotor B W B W L J3 B W II Br B 3 Connect One lead D Red Black from CDI unit One lead 3 Black White from YPVS control unit Use a jump 4 Start the engine and increaserevolution to 3 000 r min 5 Check Servomotor operation Mulfunction Replace control unit Mulfunction Replace YPVS control unit Good operation Replace CDI unit 7 40 ...

Page 215: ...APTER 8 APPENDICES SPECIFICATIONS I GENERAL SPECIFICATIONS II MAINTENANCE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS CABLE ROUTING DT200L WIRING DIAGRAM 8 1 8 1 8 4 8 14 8 14 8 15 8 21 8 ...

Page 216: ...EngineOil Transmission Oil Periodic Oil Change Total Amount Radiator Capacity Including All Routes Reservoir Tank Capacity Air Filter DT200L 39L 39L 000101 39L 000101 2 150 mm 84 6 in 820 mm 32 3 in 1 190mm 46 9 in 850 mm 33 5 in 1 365 mm 53 7 in 290mm 11 4 in 110 kg 243Ib 2 000 mm 78 7 in Liquid cooled 2 stroke gasoline torque induction Single cylinder Forward inclined 195 cm3 66 0x57 0 mm 2 598x...

Page 217: ... Ib load 156 kg 344 lb loacT F R High Speed Riding F R DT200L Regular gasoline 10L 2 2lmpgal 2 6USgal 1 5 L 0 3 Imp gal 0 4 US gal VM26SS MIKUNI BR8ES NGK 0 7 0 8 mm 0 028 0 031 in Wet multiple disc Gear 52 17 3 058 Chain drive 41 13 3 153 Constant mesh 6 speed Left foot operation 35 11 3 181 30 16 1 875 24 17 1 411 24 21 1 142 22 23 0 956 18 22 0 818 Steel tube Semi double cradle 28 114 mm 4 5 in...

Page 218: ... Battery Capacity Headlight Type Bulb Wattage Quantity Headlight Tail Brake Light Flasher Light Meter Light Indicator Light Wattage Quantity NEUTRAL HIGH BEAM OIL TURN DT200L Disc brake Single Right hand operation Drum brake Right foot operation Telescopic fork Swing arm Monocross suspension Coil spring Oil damper Gas Coil spring Oil damper 240mm 9 4 in 210mm 8 3 in C D I Magneto Flywheel magneto ...

Page 219: ...Ring 2nd Ring Crankshaft F 66 00 r mm 2 598 g0008 in 0 08 mm 0 003 in 0 05 mm 0 002 in 66 00 g oe mm 2 598 oo24 in 10 mm 0 4 in 0 060 0 065 mm 0 0024 0 0026 in 66 25 mm 2 608 in 66 50 mm 2 618 in Zero mm Zero in Keystone B 1 2 mm 0 047 in T 2 6 mm 0 102 in Plain with expander B 1 2 mm 0 047 in T 2 4 mm 0 094 in 0 30 0 45 mm 0 012 0 018 in 0 30 0 45 mm 0 012 0 018 in 0 03 0 05 mm 0 0012 0 0020 in 0...

Page 220: ...m 1 18 in Omm Oin 0 015 0 049 mm 0 0006 0 0020 in 166 1 B B C C D D Inner push cam push 0 15mm 0 006in Cam drum Guide bar Kick and mesh type P 1 Okg 2 2 Ib 0 8 1 2 kgd 8 2 6lb Air Filter Oil Grade Oiled Filter Carburetor Type Manufacturer Quantity I D Mark Main Jet M J Main Air Jet M A J Jet Needle clip Position J N Needle Jet N J Cutaway C A Pilot Jet P J Pilot Air Screw P A S Valve Seat Size V S...

Page 221: ...th Height Thickness Radiator Cap Opening Pressure Water Pump DT200L Separate lubrication Yamaha Autolube Pump Brown 0 35 0 40 mm 0 014 0 016 in 1 85 2 05 mm 0 073 0 018 in 0 88 1 01 cm3 0 031 0 036 Imp oz 0 030 0 034 US oz 4 65 5 15cm3 0 164 0 181 Imp oz 0 157 0 174 US oz Auto adjuster 122 5 mm 4 82 in 240 Omm 9 45 in 32 0mm 1 26 in 88 15 kPa 0 9 0 15 kg cm2 13 2 psi Single Suction Centrifugal Pum...

Page 222: ... name Crown nut Stud bolt Screw Nut Screw Screw Screw Screw Bolt Nut Stud bolt Screw Bolt Screw Screw Nut Stud bolt Nut Nut Bolt Nut Screw Tightening torque Q ty Remarks size Nm m kg ft lb M14 M 8 M 8 M 6 M10 M12 M 6 M 6 M 6 M 5 M 6 M 8 M 8 M 6 M12 M10 M 6 M 6 M 8 M 8 M12 M12 M 5 M12 M 8 1 5 5 3 1 1 2 3 1 2 4 2 2 10 1 1 13 4 4 4 1 1 4 1 1 20 22 10 8 14 83 10 8 10 5 8 18 10 8 20 4 10 25 10 80 55 6 ...

Page 223: ...Power valve cover Power valve seal cap Change pedal Part name Screw Nut Bolt Bolt Bolt Bolt Bolt Bolt Screw Bolt Bolt Thread _ Tightening torque Q ty slze Nm m kg ft lb M 6 2 10 1 0 7 2 M12 1 65 6 5 47 M 6 1 14 1 4 10 M 6 2 10 1 0 7 2 M 6 1 5 0 5 3 6 M 5 1 5 0 5 3 6 M 5 1 6 0 6 4 3 M 6 1 10 1 0 7 2 M 5 2 5 0 5 3 6 M 5 2 5 0 5 3 6 M 6 1 15 1 5 11 Remarks Apply LOCTITE Apply LOCTITE 8 8 ...

Page 224: ...e Drive Chain Type Manufacturer Number of Links Chain Free Play DT200L Ball and Taper Roller Bearing 22 pcs 3 16 in HI CAP 32006 JRRS 240mm 9 45 in t 576 4mm 22 69 in h 53 7mm 2 11 in jEi 570 6 mm 22 46 in tz 53 2 mm 2 09 in Ki 1 96N mm 0 2kg mm 11 2lb in 0 63mm 0 2 48in K 2 94 N mm 0 3 kg mm 16 8 Ib in 63 240 mm 2 48 9 45 in No 366 cm3 12 9 Imp oz 12 4 US oz 139 5 mm 5 Sin From top of inner tube ...

Page 225: ...Shoe Spring Free Length Brake Lever Brake Pedal Brake Lever Free Play Brake Pedal Free Play Brake Pedal Position Clutch Lever Free Play DT200L Single disc 220x3 5 mm 8 66x0 14 in 3 0mm 0 12in 6 Omm 0 24 in 0 8mm 0 03in 11 0mm 0 43 in 34 9mmd 37in DOT 3 Leading trailing 130mm 5 12in 131mm 5 16in 4mm 0 2in 2mm 0 08in 36 5mmd 44in 5 8 mm 0 2 0 3 in 20 30 mm 0 8 1 2 in 10 mm 0 4 in Vertical height bel...

Page 226: ... shock absorber and relay arm Connecting rod and relay arm Relay arm and swing arm Connectingrod and frame Brake caliperand front fork Master cylinder and brake hose Brake hose and brake caliper Thread size M14 M14 M10 M10 M 8 M12 M 8 M14 M 8 M25 M 8 M 8 M10 M10 M10 M12 M10 M10 M10 M10 Tightening torque Q ty Remarks Nm m kg ft lb 1 1 4 1 1 1 4 1 4 1 4 1 1 1 1 1 2 1 1 85 85 62 8 5 8 5 6 2 64 6 4 38...

Page 227: ...r Ignition Coil Model Manufacturer Minimum Spark Gap Primary Winding Resistance Secondary Winding Resistance Charging System Type Charging Current F34Y YAMAHA 350Q 20 at 20 C 68 F W R W G 355Q 20 at 20 C 68 F Br B R 37F MO HITACHI C2T4 YAMAHA 13 kV or more at 500 r min 23 kV or less at 8 000 r min 1 6 3 10 at200C 68 F 6 6 kQ 20 at 20 C 68 F Flywheel Magneto 15 10 u f CT Day Night Charging Coil Res...

Page 228: ...attage Oil Level Switch Model Manufacturer Circuit Breaker Type Amperagefor Individual Circuit Quantity Main Reserve Control Unite Model Manufacturer Servo Motor Unit Model Manufacturer Potentiometer Resistance Color DT200L Short Circuit Type EHU 01TR07 MATSUSHITA 14 5V 12V3AH 1 260 Plain type x 1 MF 12 NIKKO 1 5A Condenser 061300 7110 NIPPONDENSO No 60 120 cycle min 23WX4 3 4W AST1 TAIHEIYO Fuse ...

Page 229: ...y threads Com ponents should be at room temperature A Nut 10mm 12mm 14mm 17mm 19mm 22mm B Bolt 6mm 8mm 10mm 12mm 14mm 16mm General torque specifications Nm 6 15 30 55 85 130 m kg 0 6 1 5 3 0 5 5 8 5 13 0 ft lb 4 3 11 22 40 61 94 A Distance across flats B Outside thread diameter C3 DEFINITION OF UNITS Unit Read mm millimeter cm centimeter kg kitogram N Newton Nm Newton meter m kg Meter kilogram Pa ...

Page 230: ...nector cover Left White taping Band Flasher relay Wire harness Auxiliarylight lead Connector cover Right Front flasher light lead Right Tachometer cable Tachometer lead Clamp Brake hose Throttle cable Front brake switch lead Engine stop switch lead After connecting cover the connector cover Left After connecting cover the connector cover Right 0 0 0 5 6 11 10 8 15 ...

Page 231: ...Enginestop switch lead Front brake switch lead Handlebar band 4 Handlebar switch lead Clutch cable Throttle cable 7 Brake hose CABLE ROUTING Appx Pass throttle cable at the back of rear view mirror 1 2 7 6 0 0 3 4 8 16 ...

Page 232: ...DI magneto lead Clamp Clutch cable Cable holder Brake hose Speedometer cable d3 Cable guide Cable guide Cl Throttle cable Secure the ground lead together with the ignition coil Pass the speedometer cable and brake hose into the cable guide Pass the clutch cable and throttle cable into the cable guide 0 0 I y r 10 10 8 17 ...

Page 233: ...rflow pipe Reservoir tank breather pipe Battery breather pipe Rear brake switch Fuse Battery lead Clamp Fuel pipe Pass the high tension cord between the frame and radiator B Pass the serve motor lead between the tension pipe and servo motor ter connecting the coupler place the coupler between the seat rail and seat rail lug ter connecting the coupler place the coupler in the hollow of the oil tank...

Page 234: ...Right Clamp Taillight lead Rear flasher lightlead Left A Insert the oil tank breather pipe into the main pipe Align the band positionwith the hollow of the oil tank After connectingthe rear flasher light leads place the leads in the rear fener hole toso o o r II II II r II 00000 r t a 8 19 ...

Page 235: ...CABLE ROUTING APPX 8 20 ...

Page 236: ...S Dimmer switch LIGHTS switch Main switch Headlight Tachometer Meter light OIL NEUTRAL HIGH BEAM TURN Temperature gauge Speedometer Meter light ENGINE STOP switch Front brake switch Front flasher light R COLOR CODE B Black B R Br Brown B W Ch Chocolate B Y Dg Dark green Br W G Green G R Gy Gray G Y L Blue L R 0 Orange R B P Pink W B R Red W G Sb Skyblue W R W White Y L Y Yellow Y R Black Red Btack...

Page 237: ......

Page 238: ...MEMO 8 25 ...

Page 239: ... YAMAHA MOTOR LTD PRINTED IN JAPAN 84 2 0 76 x 1 B B ...

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Yamaha DT200L 1984-1988, Service Manual

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Summary of Contents for DT200L 1984-1988

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