Yamaha Fazer Service Manual Download Page 159

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CHAS

5 Install :

• Meter Cable ¿

• Clip À

• Brake Cable Á thru nozzle

• Bush Â

• Nut

6. Check :

• Front Brake 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.

Summary of Contents for Fazer

Page 1: ...SERVICE MANUAL ...

Page 2: ...L 1 FAZER SERVICE MANUAL YAMAHAMOTOR INDIAPVT LIMITED All rights reserved Any reprinting or unauthorised use without the written permission of YAMAHAMOTOR INDIAPVT LIMITED is expressly prohibited ...

Page 3: ...standing 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 Au...

Page 4: ...each Removal and Disassembly section 1 An easy to see Exploded Diagram 4 is provided for Disassembly and Assembly jobs 2 Numbers 5 are given in the order of jobs in the exploded diagram A number that is en closed by a circle indicates a part 3 An explanation of jobs and notes are presented in an easy to read way by the use of Symbol Marks 6 The meaning of the Symbol Marks are given on the next pag...

Page 5: ...iodic inspection and adjustment 4 Engine 9 Filling fluid 11 Special Tool 15 Resistance Voltage Current 12 Torque 13 Wear Limit Clearance 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 6: ...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 7: ...AL 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 8: ...nd 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 5YY 000001 X 5YY...

Page 9: ...includes 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 10: ...s 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 v...

Page 11: ... removing or installing the Magneto Securing Nut and Primary Drive Gear Nut 1 Magneto Holder YSST 627 This tool is used to adjust Valve clearance 5 Valve Clearance Adjusting Tool YSST 606 This tool is used to replace Piston Pin 6 Piston Pin Replacer YSST 607 This tool is needed to support the Piston while installing Cylinder 4 Piston Base YSST 604 This tool is used to hold the Clutch Hub when remo...

Page 12: ... Valve Clearance 15 Feeler Gauge YSST 615 ç è 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 hold the TFF plunger for loosening and tightening of Hex Socket Head Bolt 17 T Handle YSST 213 This tool is used to loosen or tighten the Cam Shifter Segment Screw 12 Torx Bit T 30 YSST 611 This tool i...

Page 13: ...e the Bearing 6201 of the Axle Main 24 Bearing Puller YSST 623 This tool is used to remove the Bearing 6202 of the Axle Drive 25 Bearing Puller YSST 624 To Tighten Loosen the Spoke 27 Spoke Tighting Tool YSST 629 This tool is used to install Oil Seal in Crank Case Cover 2 23 Oil Seal Installing Tool YSST 622 To install upper and lower Racer Bearing 19 Racer Installing Tool YSST 626 20 TFF Top Plug...

Page 14: ...icrometer 0 25 mm 50 75 mm This instrument is used for measuring Piston size Valve stem size etc 2 Timing light This instrument is used for checking ignition timing SKC S14 121 OR NATIONAL 3 Compression Gauge 7 CO Gas Analyser This instrument is used for checking the engine compression This instrument is used for measuring CO concentration in exhaust of motorcycle 4 Mutimeter This instrument is us...

Page 15: ...ts Bolts at a specified torque This instrument is used to check clearance 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 Three Bond 1322 13 Temperature Me...

Page 16: ...CATIONS 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 17: ...gle cylinder Displacement 123 7 cm Bore X Stroke 54 X 54 mm Compression ratio 10 1 Starting system Kick starter Lubrication system Wet sump Max power 11 BHP 8 0 KW 8500 RPM Torque 1 06 Kgm 10 4 NM 6500 rpm Oil type or grade Engine oil Yamalube 4 stroke Oil 20W40 Type SG 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 ...

Page 18: ...nd Caster angle 26 4º Trail 83 mm Tyre Type With tube Size Front 2 75 18 4 PR Rear 3 00 18 6 PR Manufacturer Front LOCAL MADE Rear LOCAL MADE Type Front RIB TYPE ZAPPER TYPE Rear UNIVERSAL ZAPPER TYPE Tyre pressure cold tyre Loading condition A 0 90 kg 0 198 lbs Front 25 PSI 1 75 kgf cm Rear 28 PSI 2 00 kgf cm Loading condition B 90 162 kg 198 408 lbs Front 25 PSI 1 75 kgf cm Rear 32 PSI 2 30 kgf ...

Page 19: ...per Wheel travel Front wheel travel 120 mm Rear wheel travel 90 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 S 1 Type Bulb Bulb voltage wattage x quantity Headlight 12V 25W 25W x 2 Tail Brake light 12V 5W 21W x 1 Flasher light 12V 10W x 4 Meter light 12V 3 4W x 2 NEUTRAL ...

Page 20: ...Type Barrel Dimensions B x T 1 0 x 2 1 mm End gap installed 0 15 0 30 mm Limit 0 40mm Side clearance installed 0 030 0 07 mm Limit 0 12 mm 2nd ring Type Taper Dimensions B x T 1 0 x 2 1 mm End gap installed 0 30 0 45 mm Limit 0 55mm Side clearance 0 020 0 060 mm Limit 0 12 mm Oil ring Dimensions B x T 2 0 x 2 2 mm End gap installed 0 2 0 7 mm Side Clearance 0 040 For Rail Upper and Rail Lower MAIN...

Page 21: ...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 Sprocket Cam chain type No of links SILENT CAM CHAIN 90 No of Teeth Sprocket 36 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 3...

Page 22: ... 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 104 119 7 Nm 10 60 12 21 kgf EX 104 119 7 Nm 10 60 12 21 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 end free play limit F 0 8 mm Balancer Balancer Drive Meth...

Page 23: ...e jet N J E 3M 906 Pilot Air Jet PAJ 1 1 4 Pilot outlet P O 0 8 Pilot jet P J 15 Valve seat size V S 1 8 Starter jet G S 1 25 G S 2 0 8 Fuel Level 6 5 0 5 above the joint line of MCB Main Body Chamber and F C B Float Chamber Body Float Height 29 mm 0 5 Below the Venturi Axis Engine idle speed 1 300 1 500 r min Intake vaccum New Vehicle 26 0 31 4 kPa Market Run Vehicle 31 3 36 7 kPa Lubrication sys...

Page 24: ...3 6 Intake Manifold Bolt M6 2 10 1 0 7 2 Carburetor Joint Manifold Screw M4 1 2 0 2 1 5 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 C...

Page 25: ...case Right hand Left hand t TIGHTENING TORQUE ENGINE Part to be tightened Parts Thread Q ty Tightening torque Remark name size Nm m kg ft lb 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 È Á Â Ã À Ä Ä Å Æ Â Ã À Á ...

Page 26: ...pension Shock Absorber travel 90 mm Spring free length 343 2 2 mm Fitting length 231 9 mm Spring rate K1 15 08 N mm K2 22 64 N mm Stroke K1 0 38 mm K2 38 90 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 1 0 mm Lateral 0 5 mm Rear wheel Type Spoke wheel Rim size 1 6 x 18 Rim material Steel Rim rounout li...

Page 27: ... mm Spring 2 63 0 mm 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 Spring 1 52 0 mm Spring 2 48 0 mm Free Plays Brake Lever free play At lever end 25 30 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 28: ...ront Fender M 6 X 1 0 7 0 7 5 1 Speedometer Cable and Speedometer M 12 X 1 0 2 5 0 25 2 Handle Crown and Main Switch M 6 X 1 0 13 1 3 9 4 Front Wheel Axle Nut M 14 X 1 5 59 5 9 43 Rear Wheel Axle Nut M 14 X 1 5 91 9 1 66 Wheel Sprocket and Clutch Hub M 8 X 1 25 40 4 0 29 Tensioner Bar M 8 X 1 25 19 1 9 14 Camshaft Lever M 6 X 1 0 9 8 0 98 7 1 Fuel Cock M 6 X 1 0 7 0 7 5 1 Ignition Coil M 6 X 1 0 3...

Page 29: ...lywheel Magneto Model Manufacturer 5YY DENSO Charging Voltage 14 15V 5000 RPM Charging Coil Resistance 0 75 Ω 20 68ºF Lighting Lighting Voltage 14 V 0 5 5000 RPM Lighting Coil Resistance 0 62Ω 20 68ºF Rectifier Regulator Type Semi conductor Short Circuit Type Model Manufacturer 5YY M s Nappino Auto No load regulated voltage 14 5 0 5 V at 5000 rpm Capacity 8A Withstand voltage 400 V Battery Specifi...

Page 30: ...SPEC MAINTENANCE SPECIFICATIONS Circuit Breaker Type Fuse Amperage for individual circuit X quantity Main 10A X 1pc Reserve 10A X 1pc 2 14 ...

Page 31: ...mblied 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 specificati...

Page 32: ...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 TYP...

Page 33: ...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 34: ...SPEC ENGINE LUBRICATION ROUTE Engine Lubrication route 2 18 WARNING CAUTION DO NOT DAMAGE CRANK CASE SURFACES OTHERWISE OIL LEAKAGE WILL START ...

Page 35: ...SPEC ENGINE LUBRICATION ROUTE Engine Lubrication route 2 19 WARNING CAUTION FOR IMPROVED PERFORMANCE ALWAYS USE YAMALUBE OIL ...

Page 36: ...SPEC ENGINE BEARINGS ENGINE BEARINGS 2 20 ...

Page 37: ...ht lead left Ê Flasher Light Ë Flasher light lead right A Pass the Clutch Cable À Starter wire Á and Handle bar Switch Lead 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 Clamp Wireharness È and front fork D Pass the Wireharness È and Clutch Cable À 2 21 À Â Ã Ä Å Æ Á Ä À Ë É Ç...

Page 38: ...Ð Air Induction system A Pass the wireharness through the cable guide B Pass the speedometer cable Á and front brake cable Î through the Cable Guide C Align the white marking of Wireharness with the frame clamp D Connect the battery negative lead and positive lead with the wireharness E Pass the battery breather hose Ì through the hole of the lower left side of the Battery Box F Pass the magneto l...

Page 39: ... Ä Speedometer Å Brake switch lead Æ Clutch cable Ç Rr Brake Switch A Pass the high tension cord À through the cable guide and starter wire B Pass the throttle cable and starter wire É through cable guide C Pass the clutch cable Æ through cable guide D Pass breather hose through upper right side hole of frame bracket engine 2 23 À Á Æ Ê Ç Â É È Ã Å Ä D C B A ...

Page 40: ...r regulator Á Flasher relay Â Flasher light lead A Clamp the Wire Harness lead B Pass the Wire Harness between Frame and Rear Fender Ã Stop tail light lead Ä Wireharness Å Carburettor Air Vent Æ Tail Light Assembly À Å Ä Á Â Æ Â Ã Ä A B 2 24 ...

Page 41: ...ENT 3 13 ENGINE OIL LEVEL INSPECTION 3 14 ENGINE OIL REPLACEMENT 3 14 AIR FILTER CLEANING 3 15 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 SPO...

Page 42: ...ct it if necessary 14 WHEEL BEARING Check Bearing assembly fo looseness damage 15 STEERING RACE Check Race Ball Assy for loosness Tighten BALL Replace if necessary 16 FRONT FORK Check operation oil leakage Repair if necessary 17 REAR SHOCK Check operation oil leakage Replace if ABSORBER necessary I II III IV V VI EVERY 2000 km Every 10 000 kms Repack grease Replace Oil Repack grease Repack grease ...

Page 43: ...on and lubricate if necessary AND SIDE STAND 21 BATTERY Check electrolyte level and top it up with distilled water if necessary Check specific gravity Check Breather Pipe for blockage and routing 22 CONTROL CABLES Check operation free play Cable damage THROTTLE Readjust or replace as required CLUTCH FRONT BRAKE I II III IV V VI EVERY 2000 km EVERY MONTH It is recommended that above be serviced by ...

Page 44: ... for removing the Lug Â from the Chassis ææææææææææææææææææææææææææææææææææ SIDE COVERS SEAT AND FUEL TANK SIDE COVERS SEAT AND FUEL TANK 3 3 REMOVAL SIDE COVER RH 1 Remove Side Cover RH ææææææææææææææææææææææææææææææææææ Removal steps Remove the Screw Pull the lug À Lug Á towards you to remove it from the Fuel Tank Slide the Side Cover towards the front side of the Motorcycle for removing the lug...

Page 45: ...he OFF disconnect the Fuel Hose Place a rag cloth under the Fuel Line to ab sorb any spilt fuel REMOVAL SEAT 1 Remove Side Cover LH and RH Bolts 2 Nos Bolts and À from LH RH side 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 À...

Page 46: ... Tighten Screw Á Bolt fuel tank 20 Nm 2 0 mkg 14 4 ft lb Bolt Seat 3 8 Nm 0 38 mkg 3 0 ft lb NOTE Keep the projection on plate Á downward 2 Install Scoop Bracket Bolts 2 Nos 3 Install Seat Bolts 2 Nos NOTE Insert the projection ç on the rear of the seat into the respectable è on the Chassis then push down front of the seat and tighten the bolts 4 Install Side Cover LH and lock with Key À Á Â Á À ç...

Page 47: ...n 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 Á Exhaust side Â 3 Remove Timing Check Plug with O ring Center Plug with O ring À 4 Measure Valve clearance Intake and Exha...

Page 48: ...djust 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 ææææææææææææææææææææææææ...

Page 49: ...ne 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 Increase 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 Valve cover int...

Page 50: ...ration 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 st...

Page 51: ...s medium to light tan color 4 Clean Spark Plug with Spark Plug cleaner or wire brush 5 Measure Spark Plug gap ç 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 WARNING CAUTI...

Page 52: ...ue 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 12 5 Nm 1 25 mkg 9 ftlb Timing light SKC S14 ...

Page 53: ...d 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 observed it con firms that the CDI unit is defective Auto Ad vance mechanism ...

Page 54: ...s 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 to...

Page 55: ...the 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 th...

Page 56: ...hten 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 6 Nos Loose damage Ÿ Tighten replace AIR FILTER CLEANING NOTE On the bottom of the Air Filter Case there is a Drain Hose If dust and or water collects in this Drain Hose clean the Air Filter Element and Air Filter Case 3 15 Drain plug 20 N...

Page 57: ...ment on 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 p...

Page 58: ...end then adjust it by using Adjuster below the Carburettor Below the Carburettor Remove Side Covers Seat and Fuel Tank Detach Clutch Cable from Push Lever Loosen the Locknut Á Turn the adjuster Â 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 Install...

Page 59: ...ree play Brake Lever 25 30 mm at Brake Lever end Free Play 20 30 mm FRONT BRAKE ADJUSTMENT 1 Check Brake Lever free play a Out of specification Ÿ Adjust 2 Adjust Brake Lever free play ææææææææææææææææææææææææææææææææææ Adjustment steps Lever Side Loosen the Locknut Turn the Adjuster À in or out until the speci fied free play is obtained NOTE If not possible to achieve the specified free play in Br...

Page 60: ...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 timin...

Page 61: ... 2 Check Drive chain slack ç Out of specification Ÿ Adjust 3 Remove Cotter pin 4 Loosen Axle Nut À Adjuster Locking Nut Á Â 5 Adjust Drive Chain slack 6 Align Chain adjuster marsk LH RH Side ææææææææææææææææææææææææææææææææææ Make sure that mark of chain adjuster should be same position on LH RH side chain adjuster by Adjusting Nut Â ææææææææææææææææææææææææææææææææææ 3 20 WARNING CAUTION Too litt...

Page 62: ...he alignment there are marks on Chain Adjuster Ã 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 À 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 7 Adjust Brake Pedal ...

Page 63: ...ly rock the Fork Assembly Looseness Ÿ Adjust the Steering Head 4 Loosen Pinch Bolt Handle Crown 5 Remove Bands Bolts Handlebar Upper holders À 4 Nos Handlebar upper holders Á 2 Nos Handlebar Â Handle crown bolts Ã Handle crown Ä 5 Adjust Steering head ææææææææææææææææææææææææææææææææææ Adjustment steps Remove the lock washer Remove the Ring Nut À upper and Dumper Rubber Á then loosen the Ring Nut ...

Page 64: ...ned Install the Lock Washer NOTE Make sure the lock washer tab is placed in the slots of Ring Nut 6 Install Handle crown Handle Crown bolt À Handlebar Á Handlebar upper holder Â 2 Nos Bolts handlebar upper holders Ã 4 Nos Bands Ä 2 Nos 3 23 WARNING Avoid over torquing Ring nut lower final tightening 23 Nm 2 3 m kg 17 ft lb Bolts handle crown and inner tube 23 Nm 2 3 m kg 17 ft lb Bolt handle crown...

Page 65: ...s Unsmooth operation 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 a plain rod 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 poor handling an...

Page 66: ...orber 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 NEVE...

Page 67: ...ng 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 type tyres only Tyre failure and personal injury may result from sud den deflation WARNING After mounting a Tyre ride conservatively for a while to give the Tyre time to ...

Page 68: ...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 Tighting Tool YSST 629 Nipple Tighting Torque 2 Nm 0 2 m kg 1 5 ft lb ...

Page 69: ...ter 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 connections...

Page 70: ...ore 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 for 15 minut...

Page 71: ... Switch 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 replac...

Page 72: ...s NOTE Unhook the Bulb spring 4 Install Bulb new Secure 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 until it cools down WARNING CAUTION Avoid touching glass part of bulb Also keep it away from oil otherwis...

Page 73: ...SHAFT 4 9 C D I MAGNETO 4 10 CRANKCASE 4 11 TRANSMISSIONAND 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 PISTONS 4 22 PISTON RINGS 4 23 PISTO...

Page 74: ... 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 ...

Page 75: ... REPLACEMENT section in Chapter 3 Page no 3 14 BATTERY 1 Remove Fuse Negative terminal Black À Battery Breather Hose Á Battery Â CARBURETOR 1 Loosen Air cleaner case mounting bolts 4 Nos Hose Clamp assy À 2 Remove Throttle Cable Á Carburetor Mounting Clamp Â Air vent hose Carburetor Ã Refer to the CARBURETOR section in Chap ter 5 Page no 5 2 NOTE Cover the Carburetor with a clean cloth to pre vent...

Page 76: ... 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 inner Cl...

Page 77: ...ark Plug Cap ENGINE REMOVAL 1 Remove Engine Mount Bolt front centre Bolt Engine Mount stay front upper À Bolt Engine Mount stay front lower Á Engine Mount Bolt front lower Â Engine Mount stay Ã Engine Mount Bolt bottom rear Ä Engine Mount Bolt upper rear Å Engine mount stay upper Æ Bolt AIS Mounting on stay Ç 2 Nos Engine Mount Stay È 3 Remove Engine Assembly 4 Mount Engine on Engine Stand À À À Á...

Page 78: ...ston 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 compression stroke...

Page 79: ...Remove Guide Stopper 1 Dowel Pins À Gasket Cylinder Head Á Cylinder Â 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 Reomve the Bolt...

Page 80: ...nkcase cavity 9 Remove Dowel Pins 2 Nos 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 Piston ...

Page 81: ...lding the Clutch Boss À with the Clutch Holder Clutch Hub Holder YSST 233 À À À Á Á CLUTCH NOTE The Clutch Assembly can be removed while the Engine is mounted on the Motorcycle by remov ing the following parts and draining the Engine oil Kick Starter 1 Remove Nut kick Crank assy Kick Crank Assy À Bolts Crankcase Cover 2 R H Á 9 nos Crankcase Cover RH NOTE Hold Kick Crank Assy at extreme down posi ...

Page 82: ...ket oil pump Oil strainer Â 8 Remove Nut Plate Washer Primary Drive Gear Key À Rotary Filter Á 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 Magneto Holder YSST 627 A 7 Loosen Nut Primary Drive Gear NOTE Open the Nut Primary Drive Gear by holding the Magneto with Magneto Holder Ä À Á Â Ã À Á À Á Â ...

Page 83: ... following parts Shift Pedal Kick Crank Assy Crankcase Cover 2 RH Clutch 1 Remove Shift Shaft Torsion Spring À Bolt stopper lever Á Stopper Lever Â 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 i...

Page 84: ... Puller 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 627 Magneto Puller YSST 628 Torx Bit YSST 611 À À À Á ...

Page 85: ... 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 Balancer À 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 driver ...

Page 86: ...asher Push Lever Assembly Lock Oil Seal 3 Remove Neutral switch Gasket neutral switch 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 Removal ...

Page 87: ...OTE 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 ports Ch...

Page 88: ...o 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 Â Valve Spring Seat Ã NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place Valve Spring Compressor YSST 603 À ...

Page 89: ...ification 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 pa...

Page 90: ...to 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 refac...

Page 91: ...hile 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 th...

Page 92: ...ring 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 ç ...

Page 93: ...ide 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 25 881 25 981 mm limit 25 851 mm è 21 195 21 295 m...

Page 94: ... 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 ææææææææææææææææææææææææææææææææææ ...

Page 95: ... 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 make sure that the Tensioner Ro...

Page 96: ... 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 to Cylinder clea...

Page 97: ...e 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 07 mm 2nd Ring Limit...

Page 98: ...ecification 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 Pist...

Page 99: ...rank 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 end si...

Page 100: ...es as a set 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 Thickness Friction Plate 3 0 3 1 mm Limit 2 8 mm Warp limit Clutch Plate Less than 0 05 mm BALAN...

Page 101: ...ear 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 Free length Clutch Spring 32 0 mm Limit 30 5 mm 4 Inspect Clutch Springs Damage Ÿ Replace the Clutch springs as a set 5 Measure Free length Clutch Spring ç Out of specification Ÿ Replace the Clutch springs ...

Page 102: ...ment 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 Â Shift Cam Ã Shift fork cam follower Ä Roll the Guide Bar on a flat surface Bent Ÿ Replace WARNING Do not attempt to straighten a Bend ...

Page 103: ...gs 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 2 kg R...

Page 104: ... 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 choked Ÿ Replace Contamination Ÿ Clean with flushing oil Tip clearance ç 0 15 mm Limit 0 20 mm Side c...

Page 105: ...ss 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 delivery...

Page 106: ...USTMENTS 4 32 VALVES ROCKER ARM AND CAMSHAFT Valve Cotters À Valve Spring Retainer Á Valve Springs Â Valve Stem Seal Ã 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 Ì Bearing Ì ...

Page 107: ...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 Â Spring retainer Ã NOTE Install the Valve Spring with the small pitch è facing downward ç facing upwards è facing down...

Page 108: ...m disulfide 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 Multigrade engine oil Molybdenum disulfide oil Bolt Plate 7 Nm 0 7 m kg 5 1 ft lb À ...

Page 109: ...ENG ENGINEASSEMBLYANDADJUSTMENTS 4 35 CRANKSHAFT Crank Pin À Crank Shaft Á Connecting Rod Â Big end Bearing Ã Crankshaft Bearing Ä Wood ruff Key Å Gear Balancer Æ Balancer Assy Ç Bearing ...

Page 110: ...H 5 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 267 4 Install Balancer shaft NOTE When installing the balancer shaft align the punched ma...

Page 111: ...NSMISSION Drive Sprocket À Oil Seal Á Bearing Â 4th Wheel Gear Ã Drive Axle Ä 2nd Wheel gear Å 3rd Wheel Gear Æ Clutch Dog Ç 1st Wheel Gear È Bearing É Bearing Ê 4th Pinion Gear Ë 3rd Pinion Gear Ì 2nd Pinion Gear Í Main axle Î Plate Ï Bearing ...

Page 112: ...ENG ENGINEASSEMBLYANDADJUSTMENTS 4 38 SHIFTER Shift Fork Guide Bar long À Shift Fork R Á Shift Fork L Â Shift Cam Ã Segment Ä Shift Fork Guide Bar short Å Shift fork C Æ Torx Screw Ç Pin Shaft Cam ...

Page 113: ...s 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 with the e...

Page 114: ...ENG ENGINEASSEMBLYANDADJUSTMENTS 4 40 CRANKCASE Crankcase 1 LH À Dowel Pins Á Crankcase Breather Hose Â Crankcase 2 RH Ã Holder Clutch Cable Tightening Sequence Â Ä Æ Å Ã Á À È Ç ...

Page 115: ...th the Crankcase 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 Unsmooth operation Ÿ R...

Page 116: ...ENG ENGINEASSEMBLYANDADJUSTMENTS 4 42 CDI MAGNETO Timing Chain À Guide Stopper 1 and 2 Á CDI Rotor Assy Â Wood Ruff Key Ã Stator Assy Ä Gasket Å Dowel Pin Æ Cover Crankcase 1 ...

Page 117: ...per 2 À with spacer Tighten the bolt Á C D I MAGNETO INSTALLATION 1 Install Woodruff Key 2 Install C D I Magneto Washer À Nut Á 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 YSST 627 Nut CDI Magneto 70 Nm 7 0 m kg 51 ft lb Drive sprocket Holder YSST 605 Bolt Sprocket Drive...

Page 118: ...YANDADJUSTMENTS 4 44 SHIFT SHAFT AND KICK STARTER Shift Shaft À Torsion Spring Á Stopper Lever Â Return Spring Ã Segment Ä Kick Starter Assembly Å Circlip Æ Washer Ç Kick Idle Gear È Kick Shaft Assy É Cover Crankcase 2 ...

Page 119: ...r 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 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 Tool YSST ...

Page 120: ...ius side towards the compo nent refer Chapter 1 Page no 1 3 KICK STARTER INSTALLATION 1 Install Kick axle Ratchet gear with return spring À Shim Á Ratchet gear Â Shim Ã Torsion spring Ä Spacer Å 2 Install Kick Axle Assembly Kick Gear Clip À Torsion Spring Á NOTE Turn the Torsion Spring clockwise and hook into the proper hole ç in the Crankcase Å Ä Ã Â Á À À Á ç ...

Page 121: ... Â Push Rod 1 Ã 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 122: ...l 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 À 3 Tighten Screw 2 nos Á 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 Holder YS...

Page 123: ... 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 Spacer Primary Driven Gear À Thrust Washer Á Clutch Boss Â Lock Washer Ã Clutch Boss Nut Ä CLUTCH INSTALLATION 1 Install Oil Seal Circlip Push Leve...

Page 124: ...talling 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 the Lock Nut T...

Page 125: ...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 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 Crankcase Cover 2 RH Bolts Crankcase Cover 10 Nm 1 0 m kg ...

Page 126: ...ENG ENGINEASSEMBLYANDADJUSTMENTS 4 52 Cylinder À Gasket Cylinder Á Dowel Pins Â Piston Rings Ã Piston Pin Circlips Ä Piston Å Pin Piston Æ O Ring CYLINDER AND PISTON ...

Page 127: ...LYANDADJUSTMENTS 4 53 Bolt Flange À Washer Á Bolt Â Valve Cover intake Ã 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 128: ...ENG ENGINEASSEMBLYANDADJUSTMENTS 4 54 CAM SPROCKET AND TIMING CHAIN Gasket À Timing Chain Tensioner Assembly Á Guide Stopper 2 Â Cam Sprocket Ã Timing Chain Ä Guide Stopper 1 ...

Page 129: ... Rings so that the RN mark is located on the upper side of the 2nd 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 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 Cover the Crankcase opening w...

Page 130: ...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 À YSST 604 Piston Base YSST 604 À Á New ...

Page 131: ... 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 WARNING CAUTI...

Page 132: ...æææææææææææææææææææææææææææææææææ 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 Gasket À and the Chain Tensioner Á and tighten the Bolt Â with Copper Washer to the specified torque Release the Chain Tensioner Rod by Screw dri...

Page 133: ...th 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 1 0...

Page 134: ...ssy 3 Install Engine Mount Bolt front centre Bolt Engine Mount stay front upper À Bolt Engine Mount stay front lower Á Engine Mount Bolt front lower Â Engine Mount stay Ã Engine Mount Bolt bottom rear Ä Engine Mount Bolt upper rear Å Engine mount stay upper Æ Bolt AIS Mounting on stay Ç 2 Nos Engine Mount Stay È 4 Tighten Bolts Foot Rest Assembly Spark Plug 12 5 Nm 1 25 m kg 12 6 ft lb Plug Drain ...

Page 135: ...section in Chapter 3 Page no 3 20 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 55 Nm 5 5 m kg 40 ft lb Bolts Exhaust Pipe 10 Nm 1 0m kg 7 2 ft lb Bolt Muffler 15 Nm 1 5 m kg 11 ft lb Bolt Shift Pedal 10 Nm 1 0m kg 7 2 ft lb Bolt cable stay 7 Nm 0 7 m kg 5 1 ft l...

Page 136: ... 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 Connect t...

Page 137: ...5 CARBURETION CARBURETOR VIEW 5 1 REMOVAL 5 2 DISASSEMBLY 5 3 INSPECTION 5 4 ASSEMBLY 5 6 INSTALLATION 5 7 TUNING 5 8 FUEL LEVEL ADJUSTMENT 5 9 THROTTLE POSITION SENSOR TPS 5 10 AIR INDUCTION SYSTEM 5 12 CARBURETION ...

Page 138: ...HOSE 19 THROTTLEPOSITIONSENSOR TPS KIT 20 PILOTSCREW 21 SPRING 22 O RING 23 WASHER 24 PILOT JETASSY 25 HOLDER 26 IDLEADJUSTERSPRING 27 IDLEADJUSTERSCREW 28 MAINJET 29 NEEDLE VALVE ASSY KIT 30 FLOAT ASSEMBLY 31 FLOATPIN 32 FLOATPINFIXINGSCREW 33 FCBO RING 34 FLOAT CHAMBER BODY ASSY 35 DRAINSCREW 36 FCB FIXING SCREW 37 CLIPFORDRAINHOSE 38 DRAINHOSE 39 NEEDLESETKIT 40 STARTER SETKIT 13 14 16 17 18 19...

Page 139: ...er Flow Hose Á 5 Remove Starter wire Nut Â WARNING Petrol is highly flammable Avoid spilling fuel on the hot Engine REMOVAL 1 Remove Side Covers LH RH Refer to the SIDE COVER SEAT AND FUEL TANK section in Chapter 3 Page No 3 3 2 Close Fuel 3 Drain Fuel from Float Chamber NOTE Place a rag under the over flow hose to absorb the spilt fuel À Á Â ...

Page 140: ...pected without Carburetor Disassembly Throttle Cable Starter Plunger Assembly Fuel Hose Air vent Hose over flow Hose Before disassembly of Carburetor clean the outer surface of Carburettor and Check the Starter cable operator 3 Open Screw Float chamber 3 Nos 4 Remove Float Chamber Body À Seal Float Chamber Á 5 Remove Screw Float Pin À Float Á 5 3 Á À Á À À Á Â ...

Page 141: ... Stop Screw with Spring À INSPECTION Carburetor Float Chamber Body 1 Inspect Cracks damage Ÿ Replace Fuel Starter Passage Blockage Ÿ Clean with petrol and compressed air Contamination in Starter jet Ÿ Clean ææææææææææææææææææææææææææææææææææ Cleaning Steps ó Wash the Carburetor in petroleum based sol vent Do not use any caustic cleaning solu tion ó Blow all passages and Jets with compressed air ææ...

Page 142: ...Float 1 Inspect Damage Leakage Ÿ Replace Jets Screws Diaphragam 1 Inspect Jet Needle Main Nozzle À Main Jet Á Pilot jet Â Throttle Stop Screw Ã Pilot screw with O Ring spring and washer Ä Needle Valve Å valve seat Bends wear damage Replace Blockage Ÿ Blow the Jets with compressed air 2 Inspect Diaphragam damage Æ Replace 5 5 Throttle Valve 1 Check Free movement with throttle lever Ÿ Clean and Lubr...

Page 143: ...ys use new o Rings 2 Install Pilot screw assembly ASSEMBLY 7 Install Throttle stop screw assembly 6 Install Seal Float chamber Float chamber À Screw 3 Nos Á 5 Tighten Screw float Pin Å 3 Install Main Nozzle Main Jet À Pilot Jet Á 4 Install Needle valve assembly Â Float Ã Float Pin Ä 5 6 Ã Ä Å Á À New À Â Á ...

Page 144: ...Connect Over Flow Hose Á Air Vent Hose Â Fuel Hose Ã 8 Install Piston Valve Assy with Diaphragm NOTE Hold the piston Valve Assy with diaphragm open condition and Aligns the diaphragn match mark with carburetor mark Then put the pan head with spring on Top of diaphragn press the spring to same holding position of piston Valve and tighten the screw pan head After Tighting the screw Release the pisto...

Page 145: ...t 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 Â If out of specification Ÿ adjust 5 Adjust CO density through pilot screw ææ...

Page 146: ...uel 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 vertically next...

Page 147: ...ENSOR Check adjust the idle rpm 1300 1500 Remove the TPS Coupler from TPS Unit mounted at carbruettor Check TPS resistance at idling throttle position without starting the engine Make connection as below Multimeter YTPS Terminal of Blue wire Terminal of Black wire À Check TPS resistance at full throttle position without starting engine Multimeter YTPS Terminal of Yellow wire Terminal of Black wire...

Page 148: ...ications adjust YTPS Angle with in specifications by loosening YTPS screw Check adjust the idle rpm 1300 1500 Remove side covers seat fuel tank Check TPS input output voltage at idling full throttle position without starting the engine at CDI unit Check TPS Input voltage Make connection as below Input Voltage 5 V 0 05 V Output Voltage 0 7 V 0 05 V CARBURETOR TUNING 5 11 ...

Page 149: ...essure at the exhaust port the reed valve opens allowing secondary air to flow into the exhaust port The required temperature for burning the unburned exhaust gases is approximately 600 to 700º C 1 Air Filter Case 2 AIS Unit À 3 Exhaust Port Á CHECKING THE AIR INDUCTION SYSTEM 1 Check hose Â Loose connection Ÿ Connect Properly Crack Damage Ÿ Replace Pipes Ã Crack damage Ÿ Replace Clamps Ä for prop...

Page 150: ...ION 6 14 DRIVE CHAIN AND SPROCKETS 6 15 REMOVAL 6 16 DRIVE CHAIN INSPECTION 6 17 CLUTCH HUB INSPECTION 6 18 DRIVEN SPROCKET ASSEMBLY 6 18 DRIVEN SPROCKETAND DRIVE CHAIN INSTALLATION 6 18 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 REMOVAL ...

Page 151: ...CHAS FRONT WHEEL Cotter Pin À Axle Nut Á Speedometer Cable Assy Â Wheel Axle Ã Spacer Ä Brake Shoe Plate Assy Å Dust Seal Collar Æ Front Wheel FRONT WHEEL AND FRONT BRAKES 6 1 ...

Page 152: ...CHAS FRONT BRAKE Brake Shoe Assy À Oil Seal Á Gear drive Â Lever Camshaft Ã Indicator Plate Ä Camshaft FRONT WHEEL AND FRONT BRAKES 6 2 Å Bush Æ Plate Washer Ç Gear Meter È O Ring Ç Æ Å È Ã Ä Á À Â ...

Page 153: ...e Front Wheel Axle Brake Shoe Plate Assembly À Dust Seal Collar Á Front Wheel Â 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 end Nut Spring Take out Brake wire from slot of Brake Plate 6 3 REMOVAL 4 Remove Cotter Pin Nut À 5 Lift Front Wheel NOTE Plac...

Page 154: ...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 4 Wheel Axle Bendi...

Page 155: ...e Oil 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 Drive Gear Meter Gear À 6 5 Front Wheel runout limits Radial ç 1 5 mm max Lateral è 1 5 mm max Nipple Tightening T...

Page 156: ...hoes 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 Brake L...

Page 157: ...eedom 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 not to damage ...

Page 158: ...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 Stopper...

Page 159: ...t Brake 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 À Â À Á ...

Page 160: ...juster À Pin Á CompressionSpring Â Cotter Pin Ã Tension Bar Ä Axle Nut Å Chain Puller Æ Spacer 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 161: ...CHAS REAR BRAKE Brake Shoe Kit À Cam Lever Á Indicator Plate Â Camshaft Ã Spring REAR WHEEL AND REAR BRAKE 6 11 Ã ...

Page 162: ...pper and lower À 2 Loosen Chain Adjuster Á 3 Remove Nut Rear Brake Cotter Pin À Nut Á with Bolt Tension Rod Â Compression Spring Ã Brake Rod Ä 4 Remove Cotter Pin Nut Wheel Axle À Wheel Axle Á Collar Â 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 Remove the Rear Wheel Hub with chain and spacer À Á À Á Â Ã...

Page 163: ...RONT 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 Limit...

Page 164: ...Rear Wheel Hub Damper fits over the tabs on the Clutch 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 NO...

Page 165: ...KETS Chain Case À Crankcase Cover 3 Á Drive Sprocket Â Clip Chain Joint Ã Link Plate Ä Chain Joint Å Drive Chain Æ Spacer Ç Driven Sprocket Assembly È Chain Tensioner Adjuster É Circlip Ê Oil Seal DRIVE CHAIN AND SPROCKETS 6 15 ...

Page 166: ...int Á Drive Chain Â 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 À Á Â À Á ...

Page 167: ... 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 the...

Page 168: ...Swinging fork Driven Sprocket Spacer with Drive Sprocket Assembly Axle Rear Wheel À with Washer 2 Install Brake Shoe plate with Spacer RH Side DRIVEN SPROCKET ASSEMBLY 1 Install Driven Sprocket on Clutch Hub Lock Washer À New Nut Á Bolt Â 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 À Á Â À ...

Page 169: ...n 6 19 3 Install Drive Chain Chain Joint À Plate Á Chain Joint Clip Â 4 Install Clip New 5 Install Chain Case upper Chain Case lower Crank Case Cover 3 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 Â Á À ...

Page 170: ...t Fender À Cap Bolt with Gromet Á Holder Cable Â O Ring Ã 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 Á À ...

Page 171: ...per 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 Rubber Cap LH RH Pinch Bolt Inner Tube 2 Nos Cap Bolt Under Bracket 2 Nos 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 Á À À Á ...

Page 172: ...r Oil Seal using Oil Seal Remover À 5 Remove Bolt Damper Rod Washer À Cylinder complete Fornt Fork Á Spindle Taper Â Spring Sub Ã 4 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 À À Á Â Ã À ...

Page 173: ...e Ÿ Replace Spring Sub Á Spindle Taper Â 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 free le...

Page 174: ...r Tube Â 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 Bolt Damper Rod À Recommended lubricant F...

Page 175: ...e À 6 Install Oil Seal New Using TFF Oil Seal Installation Tool À 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 recheck...

Page 176: ...ket 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 Bolt ...

Page 177: ...ight Ã 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 Tightening Steps Tighten the ring nut Lower 33 Nm 3 3 m kg 25 ft lb Loosen One turn Retighten The ring nut Lower 23 Nm 2 3 m kg 17 ft lb Ã ...

Page 178: ...Remove Starter wire Switch Handle À 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 Bolt Steering Bolt Cap U...

Page 179: ...SPECTION 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 Rack Balls upper Á Lower Bracket Â Rack Balls lower Ã 8 Remove Ring Nut lower Use a Ring Nut W...

Page 180: ...as 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 Â Refer to STEERING HEAD INSPECTION section in Chapter 3 Page no 3 22 3 Install Bush...

Page 181: ...s 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 ADJUSTMENT...

Page 182: ...CHAS REAR SHOCK ABSORBER AND SWING ARM REAR SHOCK ABSORBER AND SWINGARM Rear Shock Absorber À Axle Nut Á Swing arm Â Tension Bar Ã Seal Guard 6 32 ...

Page 183: ...AT 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 Â WARNING Securely support the Motorcycle on a level sur face 6 33 À Á Â ...

Page 184: ...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 185: ... 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 186: ...ELEC CIRCUIT DIAGRAM 7 1 ...

Page 187: ...Á C D I Unit Assy Â Battery Ã Fuse Ä Stop Switch Rear Å Neutral Switch Assy Æ Rectifier Regulator Assy Ç Ignition Coil Assy È Spark Plug Cap É Horn Ê Throttle Position Sensor TPS LOCATION OF ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 7 2 Ê ...

Page 188: ...wo 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 7 ...

Page 189: ...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 10 Tachometer Circuit 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 190: ...ANCE 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 Cap O...

Page 191: ...nnect the Multimeter to the Ignition Coil Check the secondary coil resistance Multimeter lead Ÿ High Tension lead Multimeter lead Ÿ Green 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 re...

Page 192: ...CE 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 7 7 Sensor coil resistance 240 Ω Ω Ω Ω Ω 20 at 20ºC Charging coil resista...

Page 193: ...ONS 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 Replace the Harness IF CORRECT IGNITION SYSTEM CHARGING SYSTEM 7 8 æ 10 TACHOMETER Check Tachometer Operation and entire connec...

Page 194: ...ed 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 OU...

Page 195: ... 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 196: ...ler 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 cont...

Page 197: ...ndition of individual 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 5000 RPM Measure the lighting Voltage with full load by switching on the Headlight Multimeter lead Ÿ Blue terminal Multimeter lead Ÿ Black ter...

Page 198: ...ulbs and Bulb sockets for continuity 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 CONTINUIT...

Page 199: ...ICATOR 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 200: ...upler 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 CORRECT C...

Page 201: ...he 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 SPECIFICATION Horn is OK OUT OF SPECIFICATION ...

Page 202: ...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 203: ...nd 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 at t...

Page 204: ...een 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 ter...

Page 205: ...icator 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 Termin...

Page 206: ...OOR IDLE SPEED PERFORMANCE 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 POOR SPEED PERFORMANCE 8 3 CLUTCH SLIPPING DRAGGING 8 3 FAULTY GEAR SHIFTING 8 4 OVER HEATING 8 4 FAULTY BRAKE 8 4 FRONT FORK MALFUNCTION 8 5 UNSTABLE HANDLING 8 5 FAULTY SIGNAL AND LIGHTING SYSTEM 8 6 ...

Page 207: ... 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 Clogge...

Page 208: ...ned 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 Coil Faulty Ignition Coil Valve s...

Page 209: ...RAGGING 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 p...

Page 210: ...og 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 viscosit...

Page 211: ... 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 Tyre...

Page 212: ...NK 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 Ma...

Page 213: ...YAMAHA MOTOR INDIA PVT LIMITED 19 6 Mathura Road Faridabad 121 006 INDIA PRINTED IN INDIA 5YY FAZER 1Y16 WM 01 204 10 04 E ...

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