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Yamaha FZ-16 2015, Service Manual

The Yamaha FZ-16 2015 Service Manual is a comprehensive user manual for owners of this powerful motorcycle. Packed with detailed instructions and diagrams, this manual offers valuable information on maintenance, repairs, and troubleshooting. Download this manual for free from manualshive.com and enhance your riding experience with confidence.

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Summary of Contents for FZ-16 2015

Page 1: ...MANUAL SERVICE FZ 16 21C F8197 EO ...

Page 2: ...FZ 16 SERVICE MANUAL All rights reserved Anyreprintingorunauthorizedusewithoutthe writtenpermissionofYAMAHAMOTORINDIA PVT LTD isexpresslyprohibited ...

Page 3: ...med of any amendments and substantial changes occur in specifications or procedures and these will be included in future editions of this manual when necessary NOTE Designs and specifications subject to change without notice IMPORTANT INFORMATION HEREIN Particularly important information is distinguished in this manual by the following symbols Safety alert symbol means ATTENTION BE ALERT YOUR SAFE...

Page 4: ...r in smaller print than the section title To help identify parts and clarify procedure steps there are diagrams exploited 3 at the start of each removal and disassembly section The numbers 4 are given in the order of jobs in diagrams exploited A number indicates a disassembly step Symbols 5 indicates the parts to be lubricated or replaced See SYMBOLS A table of work instructions 6 accompanies the ...

Page 5: ... 2 Type of liquid 3 Lubricant 4 Special Tool 5 Torque 6 Wear limit tolerance 7 Engine speed 8 Electrical 9 Motor oil 10 Gear oil 11 Molybdenumdisulfideoil 12 Brake fluid 13 Bearing Grease 14 Grease with lithium soap base 15 Molybdenum disulfide grease 16 Silicone Grease 17 Apply locking agent LOCTITE 18 Replace the part with a new one 9 10 E G 11 12 M BF 13 14 B LS 15 16 M S 17 18 LT New ...

Page 6: ...3 TABLEOFCONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 INSPECTIONS And adjustments CHASSIS 4 MOTOR 5 CARBURETOR 6 ELECTRICAL7 TROUBLESHOOTING 8 ...

Page 7: ...ENGINE SERIAL NUMBER 1 1 LCD METER 1 2 IMPORTANT INFORMATION 1 3 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 3 REPLACEMENT PARTS 1 3 GASKETS OIL SEALS RINGS I 1 3 SAFETY WASHERS LOCKNUTS AND PINS 1 3 BEARINGS AND OIL SEALS 1 4 Sealing rings 1 4 CHECKING THE CONNECTIONS 1 5 SPECIAL TOOLS 1 6 ...

Page 8: ...DENTIFICATION NUMBER chassis number The vehicle identification number 1 is stamped on the chassis ENGINE SERIAL NUMBER The engine serial number 1 is stamped on the crankcase NOTE Designs and specifications are subject to change without notice 1 ...

Page 9: ...A fuel gauge which indicates the level of fuel available in the fuel anque NOTE Be sure to turn the key to ON before using the SELECT button MODE odometer and tripmeter A light pulse less than one second in the SELECT button switches the display between odometer and tripmeter Fuel meter 1 1 Fuel meter The fuel gauge indicates the amount of fuel in the fuel tank The sec com ments fuel meter disappe...

Page 10: ...and ensure the correct assembly of the pieces 5 Keep all parts away from any fire source REPLACEMENT PARTS Use only genuine Yamaha parts in all changes Use oil and grease recommended by Yamaha for all services Other brands may be similar in function and appearance but inferior in quality GASKETS OIL SEALS AND O RINGS 1 When assembling the engine replace all gaskets oil seals and O rings All packag...

Page 11: ...oap base In bearings apply oil if requested PREACAUCIÓN Donotturnthebearingwithcompressedair and this will damage the surfaces Sealing rings Before assembling carefully check all sealing rings and replace that are damaged or twisted Always replace the sealing rings of the piston pin after one use When installing a sealing ring 1 make sure that the sharp corners 2 are placed on the opposite side 3 ...

Page 12: ...s Connect and disconnect several times 3 Check Allconnections Loose connection Connectadequately NOTE If crimp the pin 1 of the terminal fold up 4 Connect Cable Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity With the multimeter NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 through 3 As a quick fix use a spray contac...

Page 13: ...o hold the tappet screw to adjust valve clearance Tappet adjustment wrench YSST 806A This tool is used to loosen and tighten the nut on the tappet Thickness gauges YSST 815 This tool is used to adjust the valve clearance in an engine Adjuster rear shock YSST 821 This tool is used for adjusting the rear shock preload Magneto Holder YSST 601B This tool is used to hold the magnet to remove or install...

Page 14: ...e crankcase Clutch Hub Fixer YSST 733 This tool is used to lock the clutch hub while installing or removing the locking nut of the clutch hub Lamp flicker This instrument is used to check the ignition timing Manometer This instrument is used to measure the compression of the engine Scraper YSST 612 This tool is used to scrape the tip seal crankcase mating surface Compressor valve spring YSST 603 T...

Page 15: ...test and verify the vacuum of air induction system Nut wrench address YSST 721 This tool is used to loosen and tighten the stem nut Key in T 813 YSST This tool is used to hold the plunger of the front fork to loosen or tighten the hex bolt Assembly tool oil seal front fork YSST 875 This tool helps you to install the oil seal of the front fork Dynamic spark tester This instrument is used to verify ...

Page 16: ...dhesive is used on the contact surfaces while the housings assembled 1 and 2 of the engine Loctite Three Bond 1322 This adhesive is used for added strength Torx screws for adjustment Base for piston YSST 604 This tool is necessary to support the piston in the cylinder mounting Crankshaft key cap YSST 625 This tool is used to remove install the plug left crankcase cover 1 LH ...

Page 17: ...CIFICATIONS 2 9 ELECTRICAL 2 12 TORQUE 2 14 SPECIFICATIONS TORQUE ON 2 14 ENGINETORQUE 2 16 TORQUECHASSIS 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 LUBRICATION SYSTEM TABLES AND CHARTS 2 24 ENGINE LUBRICATION TABLE 2 24 LUBRICATION DIAGRAMS 2 25 Cable routing 2 27 ...

Page 18: ...NERAL MODEL Model 21C1 Dimensions Total length 1973mm Total width 770mm Height totall 1045mm Seat Height 790mm Wheelbase 1334mm Ground clearance 160mm Minimum turning radius 2340mm Weight With gasoline and oil 135 0kg Peak load 195 0kg ...

Page 19: ...unleaded regular gasoline Fuel Tank Capacity 12 0 L Reserve capacity 1 4 L Motor oil Lubrication system Wet sump Type SAE20W50 Recommended grade of motor oil Quantity of engine oil Periodic change YAMALUBE Grade SG 1 00 L Total change 1 20 L Oil filter Type oil filter Paper Oil pump Type of oil pump Troco ide Internal rotor clearance to the outer rotor Less than 0 15mm Limit Clearance external rot...

Page 20: ...40 14 00cm Maximum deformation 0 03mm Camshaft Traction system Transmission chain left Dimensions of camshaft lobes Admission 31 342 31 44 2mm Limit 31 342mm Admission B 25 166 25 26 6mm Limit Escape A Limit Escape B Limit 25 136mm 31 110 31 210mm 31 080mm 25 096 25 19 6mm 25 066mm B A Strain Limit 0 03 mm camshaft ...

Page 21: ... 23 60mm A Face width valve B Admission 1538 2 138mm Face width valve B Escape 1538 2 138mm B Width C valve seat Admission 0 90 1 10mm Seat width valve C Escape 0 90 1 10mm C Margin thickness D Valve Intake 0 50 0 90mm Thickness of the valve margin D Escape 0 50 0 90mm D Diameter of valve stem Admission 4975 4 990mm Limit 4 950mm Diameter of valve stem Escape 4960 4 975mm Limit 4 935mm Internal di...

Page 22: ...spring constant K2 Admission 44 40N mm Spring Spring constant K1 Escape Spring Spring constant K2 Escape 35 08 N mm 44 40 N mm Force compression spring installed Admission 160 184 N Force compression spring installed Escape 160 184 N Tilting the compression spring Admission 2 5 1 7mm Tilting the compression spring Escape 2 5 1 7mm Address threading Admission Clockwise Address threading Escape Cloc...

Page 23: ... Top ring Ring type Barrel Dimensions B T 0 80 x 2 30 mm B T Distance between ends installed 0 10 to 0 25 mm Limit 0 40 mm Ring side clearance 0030 0065 mm Limit 0 100 mm Second Aro Ring type Conical Dimensions B T 0 80 x 2 40 mm B T Distance between ends installed 0 10 to 0 25 mm Limit 0 40 mm Ring side clearance 0020 0055 mm Limit 0 100 mm Aro oil Dimensions B T 1 50 x 2 25 mm B T Distance betwe...

Page 24: ...0 3 10 mm wear limit 2 80 mm Number of discs 4 pcs Thickness of clutch plates 1 85 2 15mm Number of discs 3 pcs Flatness Limit 0 20 Free length of clutch springs 41 60 mm 40 60 mm Minimum length of springs 4 pcs Quantity Flexion maxim of the dipstick of push 0 500 mm Transmission Transmission Type 5 speed constant mesh Primary reduction system spur Primary reduction ratio 75 22 3409 Secondary redu...

Page 25: ...26X1 Identification mark 21C1110 Main jet 112 5 Main jet air 0 9 Needle 4D1Z11 Needle seat P 1M Output Supplier 0 8 Pilot Supplier 15 Pilot screw turns 3 1 4 Sizeofthevalveseat 1 5 Power Supplier 1 35 Supplier Power 2 0 7 Trigs of the valve of accelerator 1 25 Idle Condition Engine idling 1300 1500 r min Oil temperature 75 0 85 0 C CO 2 0 6 0 Emptyadmission Temperature 27 9 33 3 kPa plug base 110 ...

Page 26: ...mm Rear Wheel Wheel Type Casting wheel Rimsize 17 M CXMT3 50 Material of rim Aluminum wheel travel 120 0mmradialdeviation limitwheel 1 0 mm lateral deviation limit wheel 0 5 mm Front wheel Type TubelessSize 100 80 17M C52P Manufacturer Model MRF ZAPPER X Rear tire Type Tubeless Size 140 60 R 17 M C 63P Manufacturer Model MRF ZAPPER X RevZ Air pressure of the tires Measure cold Lead 200 kPa 28psi R...

Page 27: ...the brake drum 130 0 mm Limit 131 0 mm coating thickness of shoes 4 0 mm brake interior Limit 2 0 mm free length spring shoes 52 0 mm Free length of spring shoes 2 48 0 mm Address Bearing type steering Ball bearing Angle stop left 39 0 angle stop right 39 0 º Front fork Type Telescopic fork Type damper spring Oil damper coil spring Front fork travel FreeLength130 0mmforkspring Necklacelength254 4m...

Page 28: ...ength 178 0 mm spring tension K1 120 0N mmspringK1Race 0 0 20 0 mm Rocker Free game at the end of the swingarm Limit axial 2 4 mm Drive chain Type manufacturer R428HBSX LGB Number of links 128 Clearance transmission chain 30 0 40 0 mm Limited in length 15 links 191 5 mm ...

Page 29: ...stator winding 0464 0 696Ù at 20 C Regulator rectifier Regulator Type Semiconductor Closed Circuit Regulated voltage CD 13 7 14 7 V rectifier capacity 20 0 A Battery Model AB5L B voltage capacity 12 V 5 0 Ah rate amperage 10 hours 5 0A Lamp bulb Bulb type Halogen bulb Voltage wattagebulbandquantity Streetlight 12 V 35 W X 1 W 35 0 Tail Brake 12 V 5 0 W X 1 W 21 0 Front directional light 12 V 10 0 ...

Page 30: ...3 51 4 29Ù Horn Horn type FlatAmount Maxim um Amperage 1 pc 1 5A Turn signal relay Type of relay Transistor relay Integrated self cancellation device No Signal frequency of blinking 70 100 cycles min Fuel Gauge Unit resistance meter 19 0 21 0Ù Resistance at 20 meter unit 137 0 143 0Ù at 20 C Ignition cut relay Coil Resistance 90 0 110 0Ù Fuse Fuse 15 0 A ...

Page 31: ...rtion cross clamping sets with multiple attachment points in progressive stages until the specified torque If not otherwise specified for torque Threads must be clean and dry The components in turn should be at room temperature A Face to face B Outer diameter of the thread A nut B pin General tightening torques Nm m kg ft lb 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 ...

Page 32: ... 10 Nm 1 0 m kg 7ft Ib Elementcoverscrews M6 1 10 Nm 1 0 m kg 7ft Ib Sprocketcoverscrews M6 2 10 Nm 1 0 m kg 7ft Ib Screwsmanifold M6 2 10 Nm 1 0 m kg 7ft Ib ScrewAirFilter Chassis M6 2 10 Nm 1 0 m kg 7ft Ib Screwsthrough M6 2 10 Nm 1 0 m kg 7ft Ib AISsystemscrews M6 1 7 Nm 0 7 m kg 5ft Ib Silencer comp nut side butt M8 2 15 Nm 1 5 m kg 11ft Ib Silencer comp screw bottom right M8 1 12 Nm 1 2 m kg ...

Page 33: ... Thepressureplatescrews1 M6 4 8 Nm 0 8 m kg 6ft Ib Screwpushrod1 M6 1 8 Nm 0 8 m kg 6ft Ib Clutch Nut M14 1 70 Nm 7 0 m kg 51ft Ib Screwdrivesprocket M6 1 10 Nm 1 0 m kg 7ft Ib Screwthecoverplateta M6 2 7 Nm 0 7 m kg 5ft Ib Screwcaplever M6 1 10 Nm 1 0 m kg 7ft Ib Shiftcamscrew M6 1 12 Nm 1 2 m kg 9ft Ib Screwthestator M6 3 10 Nm 1 0 m kg 7ft Ib Screwspulsecoil M6 2 10 Nm 1 0 m kg 7ft Ib Nut Magne...

Page 34: ...PARES DE APRIETE DE MOTOR 2 17 Sequence cylinder head tightening 5 Torque Sequence magneto cover 7 8 1 6 5 9 4 3 2 10 Tightening sequence clutch cover 1 9 8 10 11 7 12 6 5 4 3 15 13 2 14 ...

Page 35: ...PARES DE APRIETE DE MOTOR 2 18 9 Crankcase tightening sequence A B 14 1 6 7 8 15 5 2 12 4 10 3 13 11 A Carter left B Right side crankcase ...

Page 36: ...5 m kg 40ft Ib Screwtopenginemount M8 3 30 Nm 3 0 m kg 22ft Ib Swingarm pivot nut M12 1 46 Nm 4 6 m kg 33ft Ib Rear shock lower nut M12 1 60 Nm 6 0 m kg 43ft Ib Rear shock top nut M12 1 40 Nm 4 0 m kg 29ft Ib And tilt tension bar M8 1 20 Nm 2 0 m kg 14ft Ib Screwfuelcock M6 2 7 Nm 0 7 m kg 5ft Ib Ignitioncoilscrew M6 2 7 Nm 0 7 m kg 5ft Ib Screwthecoverlater M6 1 2 Nm 0 2 m kg 1ft Ib ScrewBatteryC...

Page 37: ...g 25ft Ib BrakeDiscScrews M8 6 30 Nm 3 0 m kg 22ft Ib Screwsmastercylinder M6 2 10 Nm 1 0 m kg 7ft Ib Brake pedal and footrest M10 1 30 Nm 3 0 m kg 22ft Ib Screwfootrestisandchassis M8 2 35 Nm 3 5 m kg 25ft Ib Nut lateral support M10 1 44 Nm 4 4 m kg 32ft Ib Nut central support M10 2 46 Nm 4 6 m kg 33ft Ib Shift pedal nut M8 1 2 Nm 2 0 m kg 22t Ib Nut holder side bracket and chassis M10 1 44 Nm 4 ...

Page 38: ...m ends intake and exhaust M Rocker Shaft E Inner surface of the rocker shaft M Pin decompression lever M Oil Seal Clutch cover E Gear oil pump E Rotor oil pump internal and external E Pinion thrust surface free starter clutch E Freewheel shaft starter clutch E And internal surface of the pinion thrust surface clutch Boot E Starter clutch rollers E Clutch thrust cam E Primary pinion inner surface E...

Page 39: ...tion Lubricant Crankshaft Position Sensor washer assembly stator lead Yamaha Adhesive No 1215 Three Bond No 1215R Contact surface of carcasses Yamaha Adhesive No 1215 Three Bond No 1215R Screwschaintensionerdistribution Yamaha Adhesive No 1215 Three Bond No 1215R ...

Page 40: ...f the pivot brake lever LS Bearings of the steering column and the edges of the cover upper bearing LS Dust of the steering column LS Threads of nuts and bolts relay arm and calls LS Threads of nuts and bolts Biela and relay arm LS Threads of nuts and bolts rear shock and relay arm LS Threads of nuts and bolts relay and rocker arm LS Threads of nuts and bolts Biela and tilt LS Edges of oil seals r...

Page 41: ... LUBRICACIÓN Y TIPOS DE LUBRICANTE LUBRICATION SYSTEM TABLES AND CHARTS TABLE OF ENGINE OIL LUBRICATION 5 3 4 2 6 1 7 1 Oil Strainer 2 Oil pump 3 Oil Filter Element 4 Crankshaft 5 Camshaft 6 Main shaft 7 Driven shaft ...

Page 42: ...25 PUNTOS DE LUBRICACIÓN Y TIPOS DE LUBRICANTE LUBRICATION DIAGRAMS 1 2 A 3 4 5 6 7 1 Clutch thrust lever 2 Main shaft 3 Drive shaft 4 Crankshaft 5 Oil filter 6 Oil pump 7 Oil Strainer A Towards the head ...

Page 43: ...2 26 PUNTOS DE LUBRICACIÓN Y TIPOS DE LUBRICANTE LUBRICATION DIAGRAMS 1 2 3 4 1 Camshaft 2 Crankshaft 3 Main shaft 4 Driven shaft ...

Page 44: ...2 27 GUIADO DE CABLES 7 6 3 1 4 A 3 F 2 2 12 1 A 4 4 2 3 1 B 10 9 6 5 C 8 G 6 11 5 RR C 8 7 13 D 5 14 11 9 9 D R R 12 B H 1 I ...

Page 45: ...st 14 Cable Auxiliary Light A Go through the right guide bracket lamp RHS B Go through the right guide bracket lamp RHS C GothroughtheleftguidebracketlampLHSD GothroughtheleftguidebracketlampLHSE Hold the bracket clamp lamp F Run the cable from the right front directional guidance through G Pass the cable through the left front directional guide H Pass the wire harness cables handlebar switch the ...

Page 46: ... 29 GUIADO DE CABLES 3 17 17 17 13 2 5 4 13 E E B B D D C C 1 A 3 2 4 B C 14 S S 15 J 16 L I G H 5 F E D C E D C M N D 6 M 7 13 14 11 16 15 L 2 Februa ry 12 J 11 8 F2 E 10 9 13 14 16 15 S S 12 N 6 6 M M ...

Page 47: ...er cable through the guide D Attach the AC magneto lead frame bracket E Pass the breather hose from the battery and the carburetor drain hose through the holes in the hose joint F Pass the overflow pipe through the guide G Pass the wire harness cable sensor unit cables handlebar switch through the guide H Pass the speaker wire after spending the overflow tube through the guide I Pass the wire harn...

Page 48: ...2 31 GUIADO DE CABLES 6 9 10 8 5 11 February 3 4 1 7 10 3 20 A 19 13 18 17 16 15 21 22 12 14 15 A A ...

Page 49: ...15 Cable right rear directional light 16 Cover the seat lock 17 Cable lock seat 18 Relay circuit starter cut 19 CDI Unit 20 Carburetor vent hose 21 Rear fender 22 Rear fender cover A Insert the breather hose into the hole carburetor air filter B Fix cables handlebar switch and clutch with handlebar clamp C Fix cables handlebar switches and front brake lever clamping D Route the taillight wires thr...

Page 50: ...2 33 GUIADO DE CABLES 25 31 16 29 17 28 16 5 30 10 H H K K U U TT 30 251 31 A18 19 B10 C 21 24 27 23 26 22 E U 5 T T 16 P M N 15 H 29 14 L 13 K 6 K O 8 7 F 9 G I H J 10 K Dec 11 ...

Page 51: ...box C Adjust the white mark wire harness with a clamp D Tighten the clamp on the rear engine mount chassis 1 E Opposite the clamp white painted detection vacuum hose 1 F Routethestarterrelayandthestarterthroughtheclamponthe batterybox G Pass the breather hose from the battery and the carburetor drain hose through the engine exterior H Pass the breather hose from the battery and the carburetor drai...

Page 52: ...BREATHER TUBE HEAD 3 12 CHECK THE EXHAUST SYSTEM 3 12 Check the filter of the fuel tap 3 13 REAR BRAKE ADJUSTMENT 3 14 CHECKING THE BRAKE FLUID LEVEL 3 14 CHECKING THE FRONT BRAKE PADS 3 15 CHECKING THE FRONT BRAKE HOSE 3 15 CHECKING THE REAR BRAKE PADS 3 15 SWITCH ADJUSTMENT REAR BRAKE LIGHT 3 15 BLEEDING THE HYDRAULIC BRAKE 3 15 CLEARANCE ADJUSTING THE DRIVE CHAIN 3 16 DRIVE CHAIN LUBRICATION 3 ...

Page 53: ... 22 INSPECTION AND CHARGING 3 22 Fuse inspection 3 22 BULB REPLACEMENT FAROLA 3 22 SETTING THE BEAM BULB FAROLA 3 23 AUXILIARY BULB REPLACEMENT 3 23 BULB REPLACEMENT TAILLIGHT BRAKE LIGHT 3 23 LIGHT BULB REPLACEMENT INDICATOR 3 24 ...

Page 54: ...e electrolyte specific gravity 䌮 䌮 䌮 䌮 䌮 6 Clutch Check operation Adjust Lubricate lever 䌮 䌮 䌮 䌮 䌮 䌮 7 Front brake Check operation fluid level and leakage 䌮 䌮 䌮 䌮 䌮 䌮 Replace brake pads Always to the limit wear 8 Back brake Check operation of the brake shoes brake 䌮 䌮 䌮 䌮 䌮 䌮 Change the brake shoes Always to the limit wear 9 Hose brake Check for cracked or damaged 䌮 䌮 䌮 䌮 䌮 Change Every 4 years 10...

Page 55: ... Front and rear brake Check operation 䌮 䌮 䌮 䌮 䌮 䌮 25 Pieces phones and Lubricate 䌮 䌮 䌮 䌮 䌮 䌮 26 Grip housing throttle and cable Check operation and free play Adjust the free play of the throttle cable if necessary Lubricate the throttle grip housing and 䌮 䌮 䌮 䌮 䌮 䌮 27 Air Induction System Check the air cut off valve the reed valve and pipe damage Replace damaged parts if necessary 䌮 䌮 䌮 䌮 䌮 28 Lig...

Page 56: ... 4 Remove Screwaccesstimetothemark 1 toaccesstheendscrew ofthecrankshaft 2 1 2 5 Measure Valve clearance OOS Adjust Valve clearance Cold Admission 0 08 to 0 12 mm Exhaust 0 12 to 0 16 mm a Rotate the crankshaft in the opposite direction of the b When the piston is at top dead center TDC of the compression stroke align the a in the magnet with the fixed point b of the magneto cover b to c Verify th...

Page 57: ...Direction b Reduces valve clearance Tappet screw holder YSST 706 Wrench adjustment screw YSST 806A Hold the adjusting screw to prevent it from moving and tighten the nut to specification Locknut 13 Nm 1 3 m kg 9 lb ft d Recheck the valve clearance e If the valve clearance is out of specification repeat the adjustment until the specified clearance 1 Start the engine and warm it up for a few minutes...

Page 58: ...See free play adjusting THROTTLE CABLE on page 3 6 Freeplay 3 0 5 0 mm throttle cable CO measurement and adjustment 1 Start the engine and leave calendar for the equivalent of walking 4 kms 2 Install Tachometerinthesparkplugwire Density CO 2 0 6 0 Out of specification Adjust 5 Fit Adjust the density of CO through the mixture screw Turn the mixture tronillo 5 inward or outward until the value speci...

Page 59: ...ting nut on the side of the handlebar Keep upright handlebars Handlebar side a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until you obtain the specified free play in the throttle cable Direction a The free play is increased throttle cable Direction b The free play is decreased throttle cable 2 Adjustment b 3 Throttle cable slack 1 to 2 Carbu...

Page 60: ... brush 6 Measure Clearance of spark plug electrodes a With a feeler gauge OOS Adjust Distance between the electrodes of the spark plug 0 8 0 9 mm 7 Install Spark Plug 13 Nm 1 3 m kg 9 4 NOTE Before installing the spark plug clean the spark plug and gasket 8 Connect The spark plug cap ON INSPECTION TIME NOTE Before checking the ignition timing check the connection of all wires around the ignition s...

Page 61: ...MPRESSION PRESSURE NOTE Insufficient compression pressure will result in performance loss 1 Measure Valve clearance OOS Adjust Refer to ADJUSTING Valve clearance on page 3 3 2 Start the engine and leave for a few minutes calendar and then off 3 Disconnect Spark plug 4 Remove The spark plug 6 Measure Compression pressure Out of specification See steps C and d Compression pressure 1200 kPa at sea le...

Page 62: ...nimum level mark add engine oil of the recommended type to the specified level Note Before checking the engine oil level wait a few minutes until the oil has settled Do not screw the dipstick 1 when Check the oil level 1 CAUTION Do not allow foreign matter entering the crankcase 4 Start the engine warm it up for several minutes and then shut 5 Check the engine oil level again NOTE Before checking ...

Page 63: ...Oil quantity amount Periodic oil change 1 00 lt Total quantity of oil FREE PLAY ADJUSTMENT CABLE CLUTCH 1 Check Game clutch cable free to Out of Specification Adjust וי Free play the clutch lever 10 0 15 0 mm 9 Assembly Engine oil meter 10 Arranque the engine warm it up for several minutes and then shut 11 Verifique Engin e Engine Oil Leak 12 Verificar Engine Oil Level Refer to CHECKING AND ENGINE...

Page 64: ...ch cable NOTE Keep the right handlebar 1 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Remove Cover the air filter box 1 air filter element 1 1 to b 2 3 Clean Air filter element 1 Apply dry compressed air from the internal surface of the outside of the air filter element c Tighten the locknut Locknut 9 Nm 0 9 m kg 6 5 ft lb CLEANING THE AIR FILTER ELEMENT NOTE There inspection hose 1 at the...

Page 65: ...וי 3 Assembly Fueltank Seat Refer to GENERAL CHASSIS on page 4 2 CHECK THE EXHAUST SYSTEM 1 Verify Silencer 1 Cracks damage Replace וי Exhaust seal 2 Exhaust gas leaks 1 2 Check Torque Muffler Nuts 3 muffler screw 4 Muffler Screw 5 Replace 3 Assembly 2 Fueltank Side cover Seat MufflerNut 15 Nm lower left Muffler Screw 20 Nm 2 0m kg 15ft lb Screwthemuffler bottomright 12 Nm 1 2m kg 9ft lb 2 Refer t...

Page 66: ...damage Replace וי 3 1 Fuel filter 1 Contaminated Damaged Replace וי the Fuel wash 2 a Turn fuel valve to OFF b Remove the cup filter fuel valve 3 c Drain fuel d Check the filter of the fuel tap If dirty וי Clean Impaired Replace וי e Install the filter bowl of the fuel tap ...

Page 67: ...e only recommended brake fluid other brake fluids may cause damage to the rubber seals causing leakage and loss of braking efficiency Refill with the same type of brake fluid that is already in the system the fluid mixture can cause a harmful chemical reaction that would cause a malfunction of the brakes When refilling be careful not to get water in the master cylinder The water significantly decr...

Page 68: ...ain body 1 switch U Rear brake and turn the adjusting nut 2 T U T in the sense a or b until the brake light comes on at the right time 2 Direction a Brake light comes on before Direction b Brake light comes on after 2 Verify Caliper brake hose Loose connections Tighten וי screw clamp 3 Hold the vehicle and apply the front brake several times 4 Check Brake Hose Brake fluid leak וי Replace Refer dam...

Page 69: ...h the recommended brake fluid b Assemble reservoir diaphragm brake master cylinder c Securely attach clear plastic hose 1 in the bleed screw 2 2 1 d Place the other end of the hose into a container e Slowly actuate the brake lever several times f Pull the lever fully without releasing brake Bleed screw 6 Nm 0 6 m kg 4 3 ft lb k Fill the brake fluid reservoir to the proper level with the recommende...

Page 70: ... Free pedal brake Refer to ADJUSTING THE REAR BRAKE on page 3 14 6 Align the rear axle a To maintain proper alignment of the shaft Reference lines 1 in the swingarm must correspond with the same outer diameter of the washer 2 on both sides 1 2 b After adjusting tighten each nut adjustment Then tighten the axle nut to the specified torque LUBRICATING THE DRIVE CHAIN The drive chain consists of many...

Page 71: ...D on page 4 43 4 Fit S t e e r i n g c o l u m n a Remove the lock washer 1 upper ring nut 2 and the rubber washer 3 4 Nut wrench address YSST 721 Lowerringnut initialtighteningtorqued 33 Nm 3 3 m kg 24 ft lb c Loosen the lower ring nut 4 completely then tighten to specification with nut wrench the steering column WARNING Do not overtighten the lower ring nut Lowerringnut finaltorque 22 Nm 2 2 m k...

Page 72: ...e applies to both wheels 1 Check Tire pressure OOS וי Adjust WARNING The pressure should be checked and corrected when the tire temperature is equal to room temperature The pressure should be in accordance with the total weight including cargo rider passenger and accessories and conduction velocity of the vehicle Drive vehicle overload can damage tires loss of control or a major accident NEVER OVE...

Page 73: ...PER RevZ WARNING New tires have a relatively low grip tread lightly until they are worn So you should be driving about 100 km at normal speed before speeding NOTE For rims with rotation mark 1 Assemble tire marked pointing the sense of rotation of the wheel Align the mark 2 with the mounting of the valve INSPECTION AND LUBRICATION OF CABLES The following procedure applies to internal and external ...

Page 74: ...t and the metal metal moving parts of the lever Recommended lubricant Soap based grease Lithium LUBRICATING THE REAR SUSPENSION Lubricate the pivot point and the metal metal moving parts of the lever Recommended lubricant Soap based grease Lithium ADJUSTING THE REAR SHOCK The following procedure applies to the adjustment of the rear cushion WARNING Securely support the vehicle so there is no risk ...

Page 75: ...ulb and high beam 1 Remove Side cover 1 4 Remove Lamp 1 lamp holder 2 1 2 1 5 Remove Lamp bulb cover 1 Lamp bulb holder 2 2 Disconnect Connecting the turn indicator signal 1 from the end 1 2 1 6 Lamp bulb holder 2 Streetlight bulb 1 1 3 Remove Screw the lamppost 1 from the end Screw adjusting light 2 1 WARNING Since the lamp bulb may be 2 extremely hot keep products flammable and hands away from t...

Page 76: ...lies to the low beam bulb and high beam 1 Remove Side Covers see Changing the bulb of the lamp on page 3 22 The connections of the indicator signal turn see Changing the bulb of the lamp on page 3 22 2 Remove auxiliary Bulb 1 as shown in illustration BEAM ADJUSTMENT OF FAROLA The following procedure applies to adjust the light beam of the streetlight Loosen the screw and move the lamppost lamppost...

Page 77: ...CETHEREARLIGHT 3 Remove Coupler taillight 1 Screws 2 frominsidethefender 2 2 1 CHANGING THE LIGHT BULB turn indicator 1 Remove Screw 1 fromtheindicatorlight Lens 2 of light 2 Push the bulb 3 and gently rotate counterclockwise 3 2 1 ...

Page 78: ...0 REMOVING THE FRONT BRAKE CALIPER 4 21 REMOVAL OF THE FRONT BRAKE CALIPER 4 21 CHECKING THE FRONT BRAKE CALIPER 4 21 ASSEMBLY FRONT BRAKE CALIPER 4 22 MOUNTING FRONT CALIPER 4 22 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 23 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 23 ASSEMBLY FRONT BRAKE MASTER CYLINDER 4 23 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 23 REAR BRAKE 4 26 CHECKING THE REAR BRAK...

Page 79: ...4 45 COLUMN MOUNT DIRECTION N 4 45 REAR SHOCK 4 47 REMOVING THE REAR SHOCK 4 48 CHECKING THE REAR SHOCK 4 48 Rear shock mounting 4 48 TILTING 4 49 SWINGARM REMOVAL 4 51 CHECKING THE ROCKER 4 51 TILT MOUNT 4 51 DRIVE CHAIN 4 53 CHECKING THE DRIVE CHAIN 4 54 FITTING THE DRIVE CHAIN 4 55 ...

Page 80: ... m lkg 5ft lIb 5 2 Nm 0 2 m lkg 1ft lIb 6 9 3 7 2 Nm 0 2 m lkg 1ft lIb 2 Nm 0 2 m lkg 1ft lIb 2 Order Procedure Parts to remove Amount Observations 1 Seat 1 2 Side cover 1 2 1 1 3 Side cover 3 4 1 1 4 Tail cover 1 5 Manigueta 1 6 Mud Protector 1 7 Air intake Support 1 8 Airintake 1 9 Footrest Protector 1 For assembly reverse the disassembly procedure ...

Page 81: ...rocedure Parts to remove Amount Observations Side cover 1 2 Seat Refer to GENERAL CHASSIS on page 4 1 1 FuelTankCap 1 2 FuelTankCap 2 3 Side Covers Fuel Tank LH RH 1 4 Upper Deck Fuel Tank 1 NOTE Disconnect the fuel lines and fuel drain pipe before combustib le removing tank 5 Fueltank 1 For assembly reverse the disassembly procedure ...

Page 82: ... m lkg 1ft lIb 3 5 2 Nm 0 2 m lkg 1ft lIb 4 7 1 2 1 7 Nm 0 7 m lkg 5ft lIb Order Procedure Parts to remove Amount Observations 1 Side covers 2 2 Full Farola 1 3 License Plate 1 Disconnect 4 Support license plate 1 5 Connection Meter 1 6 Meter 1 7 Support lamppost 1 For assembly reverse the disassembly procedure ...

Page 83: ...kg 5ft lIb Order Procedure Parts to remove Amount Observations Seat side cover 1 2 Refer to GENERAL CHASSIS on page 4 1 1 Filter box cover 1 2 Filterhousingcover 1 3 Stamps air filter 2 4 Air filter 1 5 Resonator 1 6 Hose Clamp air filter 1 7 Air Cleaner Hose 1 8 Air Filter Housing 1 For assembly reverse the disassembly procedure ...

Page 84: ...GENERAL DEL CHASIS 4 5 INSTALLING THE AIR FILTER BOX 1 Install C l a m p u n i o n a i r f i l t e r NOTE Align the projection a on the air filter box with slot b at the junction of the air filter to b ...

Page 85: ... 3 5 L T 1 7 Nm 0 7 m lkg 5ft lIb 6 2 7 LS 60 Nm 6 0 m lkg 43 ft lIb 6 4 Order Procedure Parts to remove Amount Observations 1 Cable clamp speed sensor 1 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front Wheel 1 5 Speed sensor 1 6 Spacer 1 7 Brake disc 1 For assembly reverse the disassembly procedure ...

Page 86: ... RUEDA DELANTERA Disassembly of the front wheel 4 3 LS 2 New 1 Order Procedure Parts to remove Amount Observations 1 Oil Seal 1 2 Tread 1 3 Spacer 1 4 Tread 1 For assembly reverse the disassembly procedure ...

Page 87: ... oil seal 1 with a flathead screwdriver NOTE To avoid damaging the wheel placing a cloth 2 between the screwdriver and the wheel surface c Remove the wheel bearings with a bearing puller VERIFICATION FRONT WHEEL 1 Check W h e e l a x l e Roll the wheel axle on a flat surface Warping Replace וי WARNING Do not attempt to straighten a wheel axle 2 Check R i m F r o n t W h e e l Damage wear Replace ו...

Page 88: ...e just outside the track 3 NOTE Use a wrench 4 to match the outside diameter of the bearing and oil seal FRONT WHEEL ASSEMBLY DISC 1 Assemble l D i s c o front brake Screwsfrontbrakedisc 30 Nm 3 0 m kg 22 ft lb LOCTITE NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check D i s c o Front brake Refer to CHECKING THE FRONT BRAKE DISC on page 4 19 3 Lubricate W h e e l H u b...

Page 89: ...slots respectively 6 Assembly W h e e l lead NOTE Make sure the slot a enters the outer tube and fits over the top b in the unit b to 7 Tighten S h a f t wheel Wheel Hub 60 Nm 6 0 m kg 43 ft lb WARNING Make sure the brake hose is guided properly CAUTION Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly ...

Page 90: ...4 11 RUEDA DELANTERA ...

Page 91: ...4 1 13 5 2 12 10 14 8 9 LS Order Procedure Parts to remove Amount Observations 1 Adjusting nut brake rod 1 2 Brakerod 1 3 Spring 1 4 Pin 1 5 ROD 1 6 Nut 1 7 Washer 1 8 Rear wheel axle 1 9 Washer 1 10 Chaintensioner 2 11 Spacer 1 12 Spacer 1 13 Rear Wheel 1 14 Porta bands 1 For assembly reverse the disassembly procedure ...

Page 92: ...ear wheel Order Procedure Parts to remove Amount Observations 1 Rear wheel sprocket 1 2 Necklace 1 3 Oil Seal 1 4 Tread 1 5 RWD Cube 1 6 Shock rear drive hub 4 7 Tread 2 8 Spacer 1 9 Oil Seal 1 For assembly reverse the disassembly procedure ...

Page 93: ...eplace the whole transmission chain sprocket and the sprocket of the rear wheel Teeth bent וי Replace the entire transmission chain sprocket and larueda rear wheel sprocket 3 Remove Rear Wheel NOTE Push the rear wheel forward and remove the drive chain from the rear wheel sprocket VERIFICATION REAR WHEEL 1 Check Wheel Hub Rear Wheel b Correct 1 Transmission roller chain 2 Sprocket of the rear whee...

Page 94: ... 58 ft lb 6 Fit Free pedal brake Refer to ADJUSTING THE DRUM BRAKE on page 3 14 Free pedal brake 15 0 20 0 mm Recommended lubricant Soap based grease Lithium 2 Assembly Rear sprocket Refer to CHECKING AND REPLACING THE GEAR REAR WHEEL on page 4 14 3 Lubricate Wheel Hub Wheel Bearings Recommended lubricant Soap based grease Lithium 4 Fit Clearance transmission chain Refer to ADJUSTING THE CLEARANCE...

Page 95: ...brake pads Order Procedure Parts to remove Amount Observations 1 Fastener brake hose 1 2 Screwthefrontbrakecaliper 2 3 Front Caliper 1 4 Clip of brake pads 2 5 Brake Pad Pin 1 6 Front brake pads 2 7 Spring brake 1 For assembly reverse the disassembly procedure ...

Page 96: ...er to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 1 Right rear view mirror 1 2 Tankcoverbrakemastercylinder 1 3 Bra Tank diaphragm brake master cylinder 1 4 Reservoir diaphragm brake master cylinder 1 5 Brake Light Switch 1 6 Combinationscrewbrakehose 1 7 Copper washer 2 8 Front brake hose 1 9 Brake Lever 1 10 Clamp the front brake master cylinder 1 11 Front brake master cylinder 1 For assemb...

Page 97: ...e front brake master cylinder 2 4 1 5 3 7 6 Order Procedure Parts to remove Amount Observations 1 Smock 1 2 Pushrod 1 3 Spring 1 4 Pin lock 1 5 Complete piston 1 6 Spring 1 7 Cylinder Body 1 For assembly reverse the disassembly procedure ...

Page 98: ...ove Front Wheel Refer to FRONT WHEEL on page 4 6 2 Check Disc Brake Damaged scratched Replace וי 3 Measure Deformation of the brake disc OOS Correct וי deformation Brake disc or replace the brake disc Limit brake disc deformation of 0 10 mm a Place the vehicle on a suitable stand so that the front wheel is lifted b Before measuring the deformation of the front brake disc rotating the handlebar to ...

Page 99: ...terior 4 5 mm Limit 0 8 mm Coating thickness of the brake pads outside 4 5 mm Limit 0 8 mm NOTE Assemble the new brake pads and new brake pads spring a Securely attach clear plastic hose 1 in the bleed screw 2 Place the other end of the hose into a container b Loosen the bleed screw and push the piston brake caliper with your fingers c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg 4 3 ft lb d ...

Page 100: ...ECKING THE BRAKE CALIPER Plan recommended replacement brake components Brake pads If required Piston seals Every two years Overalls Every two years Brake Hose Each four years Brake fluid Every two years and whenever the brake is disassembled 1 Check Piston brake caliper 1 Roughness scratches wear Replace וי pistons in the brake caliper Cylinders caliper 2 Scratches wear Replace וי clamp Brake Body...

Page 101: ... THE FRONT BRAKE on page 4 20 4 Fill Deposit brake master cylinder with the specified amount and recommended brake fluid Recommended liquid DOT 3 or DOT 4 WARNING Use only the recommended brake fluid other brake fluids may cause damage to the rubber seals causing leakage and loss of braking efficiency Refill with the same type of brake fluid that is already in the system the fluid mixture can caus...

Page 102: ...Combinationscrewbrakehose Copper Washers Brake Hose NOTE To collect the remaining brake fluid place a container under the master cylinder and the end of the brake hose 2 Check Kit brake master cylinder Damage scratches wear R e p l a c e י ו 3 Check Deposit brake master cylinder Damage scratches wear R e p l a c e י ו Diaphragm brake master cylinder Damage wear R e p l a c e י ו 4 Check Brake Hose...

Page 103: ...brake hose Tighten the union of the brake hose as shown Turn the handlebar to the left and right to make sure that the brake hose does not touch other parts eg wire harness cables conductors Correct if necessary Fluid can cause a chemical reaction harmful that would cause a malfunction of the brakes When refilling be careful not to get water in the master cylinder The water significantly decreases...

Page 104: ...4 25 FRENO DELANTERO See PURGING hydraulic brake system on page 3 15 ...

Page 105: ...Nm 4 3 m lkg 31 ft lIb LS Order Procedure Parts to remove Amount Observations Porta full bands Refer to REAR WHEEL on page 4 12 1 Brake bands 2 2 Spring full bands 2 3 Lever brake camshaft 1 4 Wear indicator of the brake bands 1 5 Brake Camshaft 1 6 Plate holder bands 1 For assembly reverse the disassembly procedure ...

Page 106: ...i a m e t e r o f t h e b r a k e d r u m t o O u t o f S p e c i f i c a t i o n Replace וי the wheel to 4 Check Inner surface of the brake drum Deposits Oil Clean וי Remove the oil with a rag soaked in lacquer thinner or solvent Scratch וי Repair Lightly and evenly polish the scratches with emery cloth 5 Check Brake camshaft Damage wear Replace וי HOLDER ASSY REAR BRAKE BANDS 1 Assembly Tree bra...

Page 107: ...ke bands as shown Limit check WEAR BRAKE DRUM REAR WHEEL NOTE After assembling new brake bands the inner diameter of the brake drum can be check this within the wear limit a by the wear indicator holder in the brake bands to WARNING No coating of grease applied to the brake bands 1 Check The position at which to install the camshaft lever brake the brake camshaft Reinstall the camshaft lever brake...

Page 108: ...ake pedal all the way down push the lever brake camshaft completely in the direction of the arrow and check that the wear indicator brake bands not wear indicator reaches the drum brake Not enough וי still can be used Reach Replace וי the wheel ...

Page 109: ...cedure Parts to remove Amount Observations 1 Rearview mirror 2 2 HandlebarPlug 2 3 Right handlebar switch 1 4 Throttle Cable 1 5 Throttle grip 1 6 Switch front brake light 1 7 Clamp the front brake master cylinder 1 8 Front brake master cylinder 1 9 Clutch cable 1 10 Clutch switch coupler 1 Disconnect 11 Cable boot 1 12 Left handlebar switch 1 13 Handlebar grip 1 14 Clutch Lever 1 ...

Page 110: ...Nm 2 6 m kg 19 ft Ib 7 16 LS 5 3 LS 1 LS 4 10 13 17 8 6 9 12 2 15 Nov 14 LS 7 Nm 0 7 m kg 5ft Ib Order Procedure Parts to remove Amount Observations 15 Support the clutch lever 1 16 Handlebar clamp upper 2 17 Handlebar 1 For assembly reverse the disassembly procedure ...

Page 111: ...cks damage Replace וי WARNING Securely support the vehicle so there is no risk of falling 2 Assemble l Handlebar 1 Handlebar clamp upper 2 Screw top handlebar clamp 26 Nm 2 6 m 䞉 kg 19 ft 䞉lb CAUTION First tighten the screws on the front of the handlebar clamp and then in the back Turn the handlebars to the left and right If no contact with the fuel tank adjust the handlebar position NOTE Aligning...

Page 112: ...of the handlebar c Wipe off any excess rubber adhesive with a clean cloth WARNING Do not touch the handlebar grip until the rubber adhesive is completely dry NOTE There should be less than 3 mm of clearance a between the handlebar handle and the end Handlebar 㻚 The throttle cable 2 The right handlebar switch 3 HandlebarPlug NOTE Lubricate the throttle cable end and the inside of the throttle grip ...

Page 113: ...able free play Refer clutch FREE PLAY ADJUSTMENT CABLE CLUTCH on page 3 10 Free play the clutch lever 10 0 15 0 mm 10 Fit Cable free play Refer throttle FREE PLAY ADJUSTMENT THROTTLE CABLE on page 3 6 Set throttle cable free 3 0 5 0 mm ...

Page 114: ... 1 4 6 Nm 0 6 m kg 4ft Ib Order Procedure Parts to remove Amount Observations The following procedure applies to both front fork legs Front Wheel Refer to REAR WHEEL on page 4 6 1 Front fender 1 2 Screwtopbracket 1 Loosen 3 Screwbottombracket 1 Loosen 4 Front fork legs 1 For assembly reverse the disassembly procedure ...

Page 115: ...cedure Parts to remove Amount Observations The following procedure applies to both front fork legs 1 Screwcap 1 2 O ring 1 3 Spacer 1 4 Washer 1 5 Fork spring 1 6 Smock 1 7 Oil Seal Clip 1 8 Screwthedamperrod 1 9 Copper washer 1 10 Damperrod 1 11 Oil flow obturator 1 12 Inner tube 1 13 Oil Seal 1 14 Oil Seal Washer 1 ...

Page 116: ...ILLA DELANTERA Disassemble the front fork legs New 1 2 12 3 4 6New 7 13 New 14 New 5 10 15 11 9 8 Order Procedure Parts to remove Amount Observations 15 Outer tube 1 For assembly reverse the disassembly procedure ...

Page 117: ...l of the stop screws first loosen the top bracket then loosen the cap slightly without loosening the bottom bracket while the front fork is installed in the vehicle 2 Drain Fork Oil NOTE Press the outer tube several times while leaving the fork oil 3 Remove Dust 1 Oil Seal Clip 2 With a flathead screwdriver CAUTION Do not scratch the inner tube 1 1 2 4 Remove Screwthedamperrod 1 Damperrod 2 3 Remo...

Page 118: ... straighten a bent inner tube as dangerously weakened 2 Measure Spring free length a OOS Replace וי Spring Free Length 254 4 mm BARS ASSY FRONT FORK The following procedure applies to both front fork legs WARNING Make sure the oil levels in both front fork legs are equal Different oil levels can result in little loss of maneuverability and stability NOTE During assembly of the front fork legs be s...

Page 119: ...re installing the oil seal lubricate the edges with soap base grease lithium Lubricate the inner tube outer surface with oil suspension Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during assembly 4 Assembly Bushing outer tube 1 New Washer 2 With the Mounting tool seal Front fork oil Assembly tool oil seal front fork YSST 875 New 5 A...

Page 120: ...Recommended oil Suspension Oil 10W or equivalent Quantity 459 cm3 CAUTION B e s u r e t o u s e t h e r e c o m m e n d e d o i l s u s p e n s i o n O t h e r o i l s m a y h a v e a n a d v e r s e e f f e c t o n t h e p e r f o r m a n c e o f t h e f r o n t f o r k W h e n d i s a s s e m b l i n ga n d a s s e m b l i n g t h e f r o n t f o r k l e g s p e r r m i t a n o f o r e i g n m a...

Page 121: ...cap of the fork 2f ront lubricate the O ring with grease BARS ASSY FRONT FORK The following procedure applies to both front fork legs 1 Assembly Delanter fork legs Temporarily tighten the screws on the top and bottom brackets 2 Tighten 1 Topbracketscrew 1 Screw top bracket 25 Nm 2 5 m kg 18 ft lb Lowerbracketscrew 2 Screw bottom bracket 25 Nm 2 5 m kg 18 ft lb NOTE To give the correct torque to ca...

Page 122: ...kg 5ft lb 22 Nm 2 2 m kg 16 ft lb Order Procedure Parts to remove Amount Observations Full Farola Refer to section GENERAL CHASSIS on page 4 1 Front fork legs Refer to FRONT FORK on page 4 40 1 Screwsteeringcolumn 1 2 Upper Bracket 1 3 Lockwasher 1 4 Upper ring nut 1 5 Grommet 1 6 Lower ring nut 1 7 Bottom Bracket 1 8 Bearing cover 1 9 Upper bearing inner race 1 10 Upper bearing 1 11 Lower bearing...

Page 123: ... column 22 Nm 2 2 m kg 16 ft lb 1 22 Nm 2 2 m kg 16 ft lb 2 13 LS 11 14 3 4 New 15 5 6 8 12 9 10 7 7 Nm 0 7 m kg 5ft lb 22 Nm 2 2 m kg 16 ft lb Order Procedure Parts to remove Amount Observations 13 Lower bearing outer race 1 14 Lower bearing inner race 1 15 Smock 1 For assembly reverse the disassembly procedure ...

Page 124: ...ring with a chisel 2 and the hammer c Install bearing races and a new coat CAUTION If the bearing races are not installed properly it could damage the tube steering column NOTE Always replace bearings and bearing races as a set Each time the column is removed 1dirección replace the dust 4 Check Upper Bracket Bottom Bracket Along with the steering stem Curves cracks damage Replace וי 2 Check Bearin...

Page 125: ...ING THE STEERING HEAD on page 3 18 3 Assemble Upper Bracket Nut of the steering column 4 Assemble Front fork bars Refer to FRONT FORK on page 4 35 NOTE Temporarilytightenthemountingboltstopandbottom 5 Tighten Nut of the steering column Nutofthesteeringcolumn 110 Nm 11 0 m kg 80 ft lb ...

Page 126: ...40 Nm 4 0 m kg 29 ft lb Order Procedure Parts to remove Amount Observations Seat side covers 1 2 mud guard Refer to GENERAL CHASSIS on page 4 1 1 Nut bolt rear upper shock 1 1 2 Washer 1 3 Nut rear lower shock bolt 1 1 4 Washer 1 5 Spacer 1 6 Rear Shock 1 For assembly reverse the disassembly procedure ...

Page 127: ...berrod Deformation damageReplace וי the rear shock Rear shock Oil Leaks Replace וי the rear shock Spring Damage wear Replace וי the rear shock Hubs Damage wear Replace וי the rear shock Screws Curves damage wear Replace וי Rear shock mounting 1 Assembly Rear Shock 2 Tighten Rear shock absorber upper nut Rearshockabsorberuppernut 40 Nm 4 0 m kg 29 ft lb Rear shock lower nut Rearshocklowernut 60 Nm ...

Page 128: ...cedure Parts to remove Amount Observations Rear Wheel Rear Shock Refer to REAR SHOCK on page 5 1 Rear fender Refer to REAR WHEEL on page 4 12 1 Pivot axle nut 1 2 Pivot shaft 1 3 Support the right footrest 1 4 Left footrest support 1 5 Seal stores 1 6 Rocker 1 7 Oil Seal 2 8 Dust Cover 2 9 Bushing 2 10 Tread 2 For assembly reverse the disassembly procedure ...

Page 129: ... the rocker 60 Nm 6 0 m kg 43 ft lb 10 Nm 1 0 m kg 7 ft lb 1 3 5 2 4 10 Nm 1 0 m kg 7 ft lb 30 Nm 3 0 m kg 22 ft lb Order Procedure Parts to remove Amount Observations 11 Tread 2 For assembly reverse the disassembly procedure ...

Page 130: ...moving the swingarm from side to side c If you look at the swingarm side play check the spacers bearings and overall 3 Wash Pivot shaft Overalls Spacers Bearings Recommended cleaning solvent Kerosene 4 Check Overalls Spacers Oil Seals Damage wear Replace וי Bearings Damage pitting Replace וי SWINGARM ASSY 1 Lubricate Bearings Spacers Overalls Pivot shaft CHECKING THE ROCKER 1 Check Rocker Curves d...

Page 131: ...t B Right side to 4 Assembly Rear Shock ROD Rear Wheel See section SHOCK BACK on page 4 47 and REAR WHEEL on page 4 12 5 Fit Clearance of the transmission chain see section CLEARANCE DRIVE CHAIN on page 3 16 Clearance transmission chain 30 40 mm ...

Page 132: ... Order Procedure Parts to remove Amount Observations Rear Wheel Refer to REAR WHEEL on page 4 12 Support the right footrest left footrest support Refer to SWINGARM on page 4 49 Rear fender 1 Chain cover 1 2 Retention of the drive sprocket 1 3 Gear 1 4 Transmission chain 1 For assembly reverse the disassembly procedure ...

Page 133: ... Calculate the length c of section 15 links in the chain of transmission using the following formula c length a between the inner faces of the rollers length b between the outer faces of the rollers 2 NOTE When measuring the segment of 15 links in the chain of transmission ensure that the drive chain is taut Perform the measurement in two or three different points each time Roller transmission cha...

Page 134: ...rive sprocket 10 Nm 1 0 m kg 7 2 ft lb 3 Assemble Rocker Refer to SWINGARM on page 4 49 Rear Wheel Refer to REAR WHEEL on page 4 12 4 Fit Chain slack transmission See CLEARANCE DRIVE CHAIN on page 3 16 Clearance transmission chain 30 40 mm CAUTION A string stretched excessively load the engine and other vital parts and a loose chain can go out and damage the swingarm or cause an accident Therefore...

Page 135: ...CAMSHAFT 5 14 VALVES AND VALVE SPRINGS 5 15 REMOVING THE VALVES 5 16 CHECKING THE VALVES AND VALVE IAS GU 5 16 CHECKING THE VALVE SEATS 5 17 CHECKING THE VALVE SPRINGS 5 18 VALVE ASSEMBLY 5 19 CYLINDER AND PISTON 5 21 Piston Removal 5 22 INSPECTION PISTON CYLINDER D 5 22 CHECKING THE PISTON RINGS 5 23 Piston pin INSPECTION 5 24 ASSEMBLY PISTON AND CYLINDER 5 24 STARTING AND MAGNETO GEAR 5 26 MAGNE...

Page 136: ...45 MOUNT OIL PUMP 5 46 SHIFT SHAFT 5 47 SHIFT SHAFT INSPECTION 5 48 INSPECTION OF POSITION LEVER 5 48 SHIFT SHAFT ASSEMBLY 5 48 BALANCER SPROCKET 5 49 PRIMARY DRIVE GEAR REMOVAL AND BALANCER SPROCKET 5 51 PRIMARY DRIVE GEAR INSPECTION AND GEARS OF BALANCE ADOR 5 51 ASSEMBLY BALANCER DRIVEN GEAR 5 51 PRIMARY DRIVE GEAR REMOVAL AND BALANCER SPROCKET 5 51 CASES 5 53 SEPARATION OF CASES 5 56 INSPECTIO...

Page 137: ...T INSPECTION 5 59 CRANKSHAFT ASSEMBLY 5 59 TRANSMISSION 5 61 CHECKING THE SHIFT FORKS 5 64 CHANGE DRUM INSPECTION 5 64 Transmission Inspection 5 64 MOUNT push rods 5 65 MAIN SHAFT ASSEMBLY AND DRIVE SHAFT 5 65 FITTING THE DRUM FORKS AND CHANGES 5 65 ...

Page 138: ...er Removal 1 2 12 Nm 1 2 m kg 9 ft Ib 4 3 15 Nm 1 5 m kg 11 ft Ib 20 Nm 2 0 m kg 14 ft Ib Order Procedure Parts to remove Amount Observations 1 Air Duct 2 2 Air Guide 1 3 Silencer 1 4 Exhaust gasket 1 For assembly reverse the disassembly procedure ...

Page 139: ...ive cable from the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 34 Drain See ENGINE OIL REPLACEMENT on page 3 9 Refer to FUEL TANK on page 4 2 1 Fueltank 1 Disconnect 2 Spark plug 1 Disconnect 3 Starter Cable 1 Disconnect 4 Throttle Cable 1 Disconnect 5 TPS 1 Disconnect 6 Connector stator coils crankshaft sensor connector 7 Neutral switch connector 1 Disconnect 8 Clutch Cable 1 Dis...

Page 140: ...Amount Observations Silencer Refer to ENGINE REMOVAL on page 5 1 Fueltank Refer to GENERAL CHASSIS on page 4 2 1 Screw nutassemblyofthemotor Front Side 4 4 2 Screw nutassemblyofthemotor Bottom side rear 1 1 3 Screw nutassemblyofthemotor Rear upper side 1 1 4 Screw nutassemblyofthemotor Upper side 3 3 5 Engine 1 For assembly reverse the disassembly procedure ...

Page 141: ...y tighten the screws and nuts ARM ASSEMBLY OF CHANGES 1 Install changes Arm 1 Screw changes arm 10 Nm 1 0 m kg 7 2 ft lb 1 3 4 1 2 5 2 Tighten Motor mounting nut upper side Motormountingnut Rear upper side 30 Nm 3 0 m kg 22 ft lb Motor mounting nut Underside rear Motormountingnut Bottom side rear 55 Nm 5 5 m kg 40 ft lb Nut mounting the engine front side Motormountingnut Front Side 55 Nm 5 5 m kg ...

Page 142: ... 2 M E 12 14 13 4 15 14 10 Nm 1 7 m kg 7 ft Ib 3 7 Nm 7 0 m kg 5 ft Ib Order Procedure Parts to remove Amount Observations Seat side cover 1 side cover 2 Refer to GENERAL CHASSIS on page 4 1 Fueltank Throttle cable starter cable clutch cable Disconnect Refer to REMOVAL MOTOR on page 5 2 Carburetor Manifold Refer to CARBURETOR on page 6 1 Silencer Refer to ENGINE REMOVAL on page 5 1 1 Spark plug 1 ...

Page 143: ...kg 7 ft Ib 3 7 Nm 0 7 m kg 5 ft Ib Order Procedure Parts to remove Amount Observations 4 Accessscrewcrankend 1 5 Head cover 1 6 Gasket head cover 1 7 Dowel pin 1 8 Tensordistributionchain 1 9 Tensioner Gasket chain 1 10 Camshaft sprocket 1 11 Decompression cam 1 12 Butt 1 13 Cylinder head gasket 1 14 Dowel pin 2 15 Guide the distribution chain exhaust side 1 For assembly reverse the disassembly pr...

Page 144: ...o prevent the chain from falling into the crankcase with a cable hold 4 Remove Butt NOTE to Loosen the screws in the correct sequence as shown Loosen each bolt 1 2 turn each time When all bolts are completely loose remove them d 6 6 4 4 2 c 3 1 5 5 d HEAD INSPECTION c 1 Delete Carbon deposits from the chamber combustion with a rounded scraper NOTE Do not use sharp instrument to avoid damage or scr...

Page 145: ...r timing chain by hand NOTE While pressing the tensioner rod chain turn to the right with a screwdriver 1 until it stops c If the limit is exceeded the butt rectified as follows d Place a wet sandpaper 400 600 on the rectifying plate and the cylinder head surface with a pattern of sanding a figure eight NOTE To ensure a level surface turn the head several times INSPECTION CAMSHAFT SPROCKET AND CHA...

Page 146: ...w and check that the decompression cam does not project from the camshaft exhaust cam as shown in illustration B CYLINDER ASSEMBLY 1 Assembly Butt NOTE Timing chain pass through the cavity of the distribution chain 2 Tighten 1 Headbolts 1 Head bolts 22 Nm 2 2 m kg 16 ft lb Headbolts 2 Head bolts 10 Nm 1 0 m kg 7 2 ft lb NOTE A Lubricate the threads of the cylinder head bolts with engine oil 2 Tigh...

Page 147: ...en the screw shaft sprocket camshaft f Remove the cable from the distribution chain 4 Install Tensioner Gasket chain New Tensordistributionchain d Remove the screwdriver make sure the rod chain tensioner return distribution 5 Turn Crankshaft Several times clockwise 6 Check I mark a Align the I of the magnet with the brand stationary b in the magneto cover I mark c Align the I of the camshaft sproc...

Page 148: ... Nm 2 0 m kg 14 ft lb PRCAUCIÓN Be sure to tighten the screw on the camshaft sprocket with the specified torque to avoid the possibility that the screw loosening and damaging the motor 8 Measure Valve clearance OOS Adjust וי Refer to ADJUSTING THE VALVE CLEARANCE on page 3 3 ...

Page 149: ... 7 ft Ib 7 6 1 13 Nm 1 3 m kg 9 ft Ib 3 2 2 1 M M 5 E 4 E M Order Procedure Parts to remove Amount Observations Butt See HEAD on page 5 5 1 Locknut 2 2 AdjustingScrew 2 3 Retainer camshaft bearing 1 4 Camshaft 1 5 Rocker 2 6 Intake rocker 1 7 Exhaust Rocker 1 For assembly reverse the disassembly procedure ...

Page 150: ...166 25266 mm Limit 25 136 mm Escape A 31110 31210 mm Limit 31 080 mm Escape B 25096 25196 mm Limit 25 066 mm b 1 2 CAMSHAFT INSPECTION 1 Check Camshaft Lobe Blue discoloration pitting scratches R e p l a c e י ו the camshaft 2 Measure Dimension of the lobes Camshaft A and b OOS Replace וי the camshaft to 3 Check Oil passage camshaft Blocked Blow וי compressed air 㻚 CHECKING THE ROCKER ROCKER AND A...

Page 151: ...the rocker arm and rocker aje 0009 0034 mm Limit 0 08 mm ASSEMBLY CAMSHAFT AND ROCKER 1 Lubricate Rocker Rocker shafts Recommended lubricant Inner surface of the rocker molybdenum disulfide oil to the rocker shaft Motor oil 2 Lubricate Camshaft Recommended lubricant Camshaft Oil molybdenum disulfide camshaft bearings Motor Oil 3 Install Intake and exhaust rocker arms Rocker Shaft 5 Calculate Clear...

Page 152: ... 5 Order Procedure Parts to remove Amount Observations Butt See HEAD on page 5 5 Rocker Camshaft Refer to CAMSHAFT on page 5 12 1 Pin Valve 4 2 Upper spring seat of the valve 2 3 Valve spring 2 4 Inlet valve 1 5 Exhaust valve 1 6 Seal valve stem 2 7 Lower spring seat valve 2 8 Valve guide 2 For assembly reverse the disassembly procedure ...

Page 153: ... valve spring compressor adapter valve 2 Compressor valve spring YSST 603 Adapter valve spring compressor A 803 YSST 2 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place INSPECTION valves and valve guides The following procedure applies to all valves and valve guides 1 Measure Clearance between the valve stem and valve guide OOS Replace וי th...

Page 154: ...the valve is removed or replaced always replace the stem seal the valve Limit deformation of the valve stem 0 010 mm CHECKING THE VALVE SEATS The following procedure applies to all valves and valve seats 1 Delete Carbon deposits From the valve face and valve seat 2 Check Valve Seat Pitting wear Replace וי the butt 3 Measure Width of the valve seat C to Out of specification Replace וי the butt Widt...

Page 155: ...ide oil to the valve stem g Install the valve in the cylinder head h Pressing the valve through the end of the valve guide and the valve seat to make a clear print i Measure the width of the valve seat c again If the width of the valve seat out of specification and correct it again lapping the valve seat c Install the valve in the cylinder head d Turn the valve until the valve face and valve guide...

Page 156: ... of the spring installed in valve OOS Replace וי the valve spring End of the valve stem With an oil stone Force compression spring installed Admission 160 184 Force compression spring installed Escape 160 184 Installed length Admission 34 50 mm Installed length Escape 34 50 mm b Installed length 3 Measure Tilt the valve spring to Out of Specification Replace וי the valve spring 2 Lubricate Valve s...

Page 157: ...a upwards b Short end 4 Install Pines valve 1 NOTE Install the valve pin compressing the valve spring with the spring compressor and the valve spring compressor adapter valve 2 1 5 To ensure the valve pin in the valve stem lightly tap the valve tip with a soft faced hammer CAUTION Hitting the valve tip with excessive force could damage the valve Compressor valve spring YSST 603 Adapter valve sprin...

Page 158: ...6 5 E New 4 4New 1 E E 2New 3 3 Order Procedure Parts to remove Amount Observations Butt See HEAD on page 5 5 1 Cylinder 1 2 Cylinder Gasket 1 3 Dowel pin 2 4 Piston pin 2 5 Piston pin 1 6 Piston 1 7 Top Ring 1 8 Second ring 1 9 Ring oil 1 For assembly reverse the disassembly procedure ...

Page 159: ...TION cylinder and piston 1 Check Piston wall Cylinder wall Vertical scratches Replace וי cylinder the piston and piston rings as a whole 2 Measure Piston cylinder clearance a Measure cylinder bore C with the cylinder with the cylinder diameter meter 2 1 3 2 Remove Top Ring Second ring Ring oil NOTE Measure cylinder bore C verifying measurements from side to side and front to back measurements of t...

Page 160: ...s piston and rings Piston Rings Top Ring Ring Side Clearance 0030 0065 mm Limit 0 100 mm Second ring Ring Side Clearance 0020 0055 mm Limit 0 100 mm b 5 0 mm 0 20 in from the lower edge of the piston Piston Diameter D 53970 53985 mm d If out of specification replace the piston and piston rings as a set e Calculate the clearance with the cylinder piston following formula Piston cylinder clearance C...

Page 161: ...iston pin and then check the lubrication system 2 Measure Outer diameter of piston pin a Out of specification Replace וי piston pin Outer diameter of piston pin 14995 15000 mm Limit 14 975 mm 3 Measure Inner diameter of the piston pin hole a Out of specification Replace piston וי Bore piston pin hole 15002 15013 Limit 15 043 mm 4 Calculate Piston pin clearance inner diameter of piston pin OOS וי R...

Page 162: ...f the cylinder Before installing the piston pin pin cover the crankcase opening with a clean to prevent the pin from falling into the crankcase 1 to 2 5 Install Dowel pin Head gasket New Cylinder 1 NOTE While compressing the piston rings with one hand install the cylinder with the other hand Pass the chain and guide the chain intake side through the cavity of the distribution chain 3 Lubricate Pis...

Page 163: ...0 m lkg 7ft lIb l l Order Procedure Parts to remove Amount Observations Motor oil Drain See ENGINE OIL REPLACEMENT on page 3 9 Cover transmission chain See chain of transmission on page 4 53 1 Connector stator coil 1 Disconnect 2 Connector crankshaft position sensor 1 Disconnect 3 Cable connector neutral switch 1 Disconnect 4 Screwaccesstothetimestamp 1 5 Accessscrewcrankend 1 6 Magneto cover 1 7 ...

Page 164: ...6 New 18 New 5 E 14 Nm 1 4 m lkg 10 ft lIb New LS 20 E 11 70 Nm 7 0 m kg 51 ft lb 10 Nm 1 0 m lkg 7ft lIb l l Order Procedure Parts to remove Amount Observations 12 Woodruff key 1 13 Starter Clutch Sprocket 1 14 Tread 1 15 Washer 1 16 Shaft freewheel clutch starter 1 17 Washer 1 18 Pin lock 1 19 Freewheel clutch starter 1 20 Starter Clutch 1 For assembly reverse the disassembly procedure ...

Page 165: ...r remove the starter clutch bolts 1 1 Magnet holder YSST 601B 2 Remove Rotor magnet 1 With the magneto puller 2 Woodruff key CAUTION To protect the end of the crank placing a suitably sized wrench between the extractor and the crankshaft magnet NOTE Make sure the exhaust is centered on magneto magneto rotor STARTER CLUTCH INSPECTION 1 Check The starter clutch rollers 1 Clutch Covers Spring Starter...

Page 166: ...ckwise A the starter clutch and the starter clutch gear should mesh otherwise the starter clutch to is defective and must be replaced c When turning the starter clutch pinion counterclockwise B should turn freely otherwise the starter clutch is faulty and must be replaced MOUNTING MAGNETO 1 Install A 1 B Woodruff key magnet rotor Rotor Washer Magneto rotor nut STARTER CLUTCH ASSEMBLY 1 Install Sta...

Page 167: ...or nut 1 7 1 6 5 1 9 4 3 2 10 2 3 Apply Sealant In the crankshaft position sensor the buttonhole for mounting the stator wire Yamaha Adhesive No 1215 TG 1215 LS 4 Install Magneto cover Screw magneto cover 10 Nm 1 0 m kg 7 2 ft lb NOTE Tighten the magneto cover in the proper tightening sequence as shown ...

Page 168: ...ECTRIC START Removing the starter motor 2 Nm 0 2 m kg 1ft Ib 10 Nm 1 0 m kg 7ft Ib 2 2 1 Order Procedure Parts to remove Amount Observations 1 Starter 1 2 Starter Cable 1 Disconnect For assembly reverse the disassembly procedure ...

Page 169: ...r Procedure Parts to remove Amount Observations 1 Starter 1 2 Cover Package 1 3 Set of carbon brushes 1 4 Support carbon brushes 1 5 Oil Seal 1 6 Pin lock 1 7 Stop washer 1 8 Washer 1 9 Tread 1 10 Front cover starter 1 11 Starter 1 For assembly reverse the disassembly procedure ...

Page 170: ...itch Dirt Cleaning וי with 600 grit sandpaper 2 Measure Diameter of the switch a OOS R e p l a c e י ו the starter a Measure the resistance of the armor with the multimeter Multimeter Armor Coil Resistance of the switch 1 Ù 0 0315 to 0 0385 at 20 C 68 F Limit 17 6 mm b If the resistance is out of specification R e p l a c e י ו starter to 3 Measure Mica recess a OOS וי Undercut the mica to the pro...

Page 171: ... pinion 7 Check Tread Oil Seal Damage wear Replace וי cover front starter brush holder assembly STARTER ASSY 1 Install Front cover starter Brush holder assembly 1 Starter Deck 2 NOTE Align the marks a in the starter cover and front cover starter bracket assembly 1 2 to ...

Page 172: ...kg 7ft Ib 10 Nm 1 0 m kg 7ft Ib Order Procedure Parts to remove Amount Observations Motor oil Drain See ENGINE OIL REPLACEMENT on page 3 9 1 Clutch cable 1 Disconnect 2 Oil Seal 2 3 Oil filter cover 1 4 Oil filter 1 5 Dowel pin 2 6 Clutch cover 1 7 Gasket clutch cover 1 For assembly reverse the disassembly procedure ...

Page 173: ... remove Amount Observations 1 Locknut 1 2 Clutch Spring 4 3 Pressure Plate 1 4 ShortrodClutchthrust 1 5 Fastener the clutch pushrod 1 6 Ball 1 7 Friction Disc 1 2 8 Clutch disc 3 9 Friction Disc 2 2 10 Nut disc holder 1 11 Lockwasher 1 12 Disc holder 1 13 Thrust Washer 1 14 Clutch 1 15 Conical spring washer 1 For assembly reverse the disassembly procedure ...

Page 174: ... 2 3New E LS 4New 5 Order Procedure Parts to remove Amount Observations Clutch Refer to CLUTCH on page 5 35 1 Clutch thrust lever 1 2 Spring clutch push lever 1 3 Pin lock 1 4 Oil Seal 1 5 Tread 1 For assembly reverse the disassembly procedure ...

Page 175: ...as an assembly NOTE Measure the friction plates in four places Thickness of the friction plates 1 2 2 90 3 10 mm Wear limit 2 80 mm B B Friction Disc 2 X The space between the friction material coating on the friction disc 1 And The space between the friction material coating on the friction disc 2 NOTE The space X must be less than the disc space and one friction and friction disc 2 respectively ...

Page 176: ...CH INSPECTION caddy 1 Check Lace the clutch disc carrier Damage pitting wear Replace וי the tray clutch NOTE Stings in the caddy lace clutch will cause erratic operation of the clutch PRESSURE PLATE INSPECTION 1 Check Pressure Plate Cracks damage Replace וי dish pressure CHECKING THE CLUTCH BELL 1 Check Lace clutch of 1 Damage pitting wear Deburring וי lace of the clutch or replace the clutch NOTE...

Page 177: ...re the corners with sharp edges of the thrust washer a is placed opposite the clutch disc holders 1 to 3 Install Clutch disc carrier 1 Lockwasher 2 New Nut caddy NOTE Lubricate the threads of the nut and clutch disc holder contact surfaces of the lock washer with engine oil 1 Align the notch a in the washer with a lower rib b in the tray clutch New 2 1 CLUTCH ASSEMBLY 1 Install Conical spring wash...

Page 178: ...cushion clutch spring and damper spring clutch as shown in the illustration First install a friction disk and then switch between a clutch plate and friction disc b If the projection a is not aligned with the mark b aligned as follows Loosen the locknut 2 With the push lever clutch completely pushed in the direction c turn the push rod clutch short 3 inward or outward until the projection a is ali...

Page 179: ... Install Clutch cover Clutch coverscrew 10 Nm 1 0 m kg 7 2 ft lb NOTE Tighten the cover screws clutch in the proper tightening sequence as shown 1 9 8 10 11 7 12 6 5 13 Fit 13 4 3 15 2 14 Freeplay clutch cable See FREE PLAY ADJUSTMENT CABLE CLUTCH on page 3 10 ...

Page 180: ...m 1 0 m kg 7ft Ib 10 Nm 1 0 m kg 7ft Ib Order Procedure Parts to remove Amount Observations Clutch Refer to CLUTCH on page 5 35 Primary drive gear pinion balancer See BALANCER SPROCKET on page 5 49 1 Oil deflector plate 1 2 Oil pump 1 3 Primary drive gear oil pump 1 For assembly reverse the disassembly procedure ...

Page 181: ... 1 E Order Procedure Parts to remove Amount Observations 1 Housing cover oil pump 1 2 Pin 1 3 Primary driven gear oil pump 1 4 Internal rotor of the oil pump 1 5 External rotor of the oil pump 1 6 Pump housing oil 1 For assembly reverse the disassembly procedure ...

Page 182: ...outer rotor and the casing of the oil pump 0 13 to 0 19 mm Limit 0 15 mm Clearance between the casing of the oil pump and the inner and outer rotors 0 06 to 0 11 mm Limit 0 15 mm 3 Check Pump operation Rough movement Repeat וי Steps 1 and 2 or replace the defective part ASSEMBLY OIL PUMP 1 Lubricate 1 Internal rotor 2 External rotor 3 Housing oil pump Internal rotor of the oil pump External rotor ...

Page 183: ... 3 Check Operation of the oil pump Refer to CHECKING THE OIL PUMP on page 5 45 MOUNT OIL PUMP 1 Install Oil pump Screw oilbulges 4 Nm 0 4 m kg 2 4 ft lb CAUTION After tightening the screws make sure the oil pump rotates smoothly ...

Page 184: ... 3 L T 4 5 1 9 Nm 0 9 m kg 7ft Ib Order Procedure Parts to remove Amount Observations Clutch Refer to CLUTCH on page 5 35 Shift arm 1 Axis of changes 1 2 Pin lock 1 3 Shift shaft spring 1 4 Lever cap 1 5 Stopper lever spring 1 6 Oil Seal 1 For assembly reverse the disassembly procedure ...

Page 185: ...turns roughly Replace וי the top of the lever Stopper lever spring Damage wear Replace וי CHANGES Shaft Assembly 1 Install Topofthelever 1 Stopper lever spring 2 NOTE Hook the ends of the spring lever stop at the top of the lever and the crankcase boss 3 Engage the lever stop the drum segment changes 3 21 2 Install Axis of changes 1 NOTE Hook the end of the shift shaft spring on the spring axle st...

Page 186: ...rocedure Parts to remove Amount Observations Clutch Refer to CLUTCH on page 5 35 1 Primary drive gear nut 1 2 Nut balancer drive gear 1 3 Washer 1 4 Primary drive gear 1 5 Primary balancer drive gear 1 6 Cotter straight 1 7 Lockwasher 1 8 Plate 1 of the balancer driven gear 1 9 Balancer driven gear 1 10 Cup stop 1 11 Spring 4 12 Dowel pin 2 13 Cotter straight 1 14 Plate 2 balancer driven gear 1 ...

Page 187: ...m kg 43 ft Ib Removing the balancer sprocket and primary drive gear 6 5 15 13 10 4 14 3 9 12 E 11 8 45 Nm 4 5 m kg 33 ft Ib 7New 2 Order Procedure Parts to remove Amount Observations 15 Spacer 1 For assembly reverse the disassembly procedure ...

Page 188: ...bly Glass ceiling 1 Primary balancer driven gear 2 NOTE Align the punch mark a in the glass ceiling with the punch mark b on the balancer driven gear primary 2 to 1 1 b to 2 MOUNT BALANCER GEARS AND GEAR 3 PRIMARY CONDUCTOR 1 Install INSPECTION PINION BALANCER GEARS AND GEAR PRIMARY CONDUCTOR 1 Check Primary balancer drive gear Primary balancer driven gear Cup stop Spring Primary balancer drive ge...

Page 189: ...5 m kg 33 ft lb primary drive gear 60 Nm 6 0 m kg 43 ft lb NOTE Place an aluminum plate a between the primary balancer drive gear 3 and the primary balancer driven gear 4 and then tighten the nut on the balancer driven gear primary Place an aluminum plate b between primary balancer drive gear 3 and the primary balancer driven gear 4 and then tighten the nut on the balancer driven gear primary 3 4 ...

Page 190: ... and piston Refer to CYLINDER AND PISTON on page 5 21 Clutch Bell Refer to CLUTCH on page 5 35 Oil pump Refer to OIL PUMP on page 5 43 Axis of changes Refer to SHIFT SHAFT on page 5 47 Electric Start See ELECTRIC START on page 5 31 Sprockets balancer See BALANCER SPROCKET on page 5 49 Magneto See MAGNETO AND STARTER CLUTCH on page 5 26 1 Guide the chain intake side 1 2 Chain cover 1 3 Timing Chain...

Page 191: ... 0 m kg 7 ft Ib 4 10 Nm 1 0 m kg 7 ft Ib 5 6 10 Nm 1 0 m kg 7 ft Ib 3 1 5 7 2 10 Nm 1 0 m kg 7 ft Ib Order Procedure Parts to remove Amount Observations 5 Dowel pin 2 6 Left housing 1 7 Nozzle 1 For assembly reverse the disassembly procedure ...

Page 192: ... 5 ft Ib 3 E 2 3 3 3 3 L T 1 3 E LS Order Procedure Parts to remove Amount Observations Crankshaft Balancer See Crankshaft on page 5 58 Transmission See Transmission on page 5 61 1 Oil Seal 1 2 Bearing retainer 1 3 Tread 7 For assembly reverse the disassembly procedure ...

Page 193: ...ace וי Cheap oil distribution Obstruction Blow וי with compressed air INSPECTION OF THE TIMING CHAIN AND CHAIN GUIDE DISTRIBUTION 1 Check The distribution chain Damage stiffness Replace וי chain distribution and the camshaft sprocket A Housing right as a whole B Left housing 2 Spin Changes drum segment NOTE Rotate the drum segment changes 1 to the position shown in the illustration In this positio...

Page 194: ...ent changes touch with the casing during assembly of sump 1 Bearingretainerscrew 7 Nm 0 7 m kg 5 1 ft lb LOCTITE 4 Install to CrankcaseBolts Crankcase Bolts 10 Nm 1 0 m kg 7 2 ft lb 1 NOTE Tighten each screw 1 4 turn at a time on stage and in the correct sequence as shown M6 70 mm 7 9 11 CRANKCASE ASSEMBLY 1 Clean all contact surfaces of the seals and crankcase 2 Apply Sealant On the crankcase mat...

Page 195: ...HAFT Remove Crankshaft and balancer 2 E E LS 1 New LS New Order Procedure Parts to remove Amount Observations Sump Refer to CRANKCASE on page 5 53 1 Balancer 1 2 Crankshaft 1 For assembly reverse the procedure disassembly ...

Page 196: ...earance D 0110 0410 mm Tool for removing the crankshaft YSST 265 3 Measure Crankshaft Width OOS וי Replace the crankshaft 2 1 CRANKSHAFT INSPECTION 1 Measure Crankshaft Deformation OOS Replace וי the crankshaft bearing or both NOTE Slowly turn the crankshaft Crankshaft Width A 47 95 48 00 mm 4 Check Crankshaft sprocket Damage wear Replace וי the crankshaft Tread Cracks damage wear Replace וי the c...

Page 197: ...he edges of oil seals with grease lithium soap base and each bearing with engine oil NOTE Maintain the rod in the upper dead center TDC with one hand while rotating the nut screw assembly of the crankshaft with the other Turn mounting the crankshaft screw until the bottom of this against the bearing crankshaft ...

Page 198: ... E E 3 Order Procedure Parts to remove Amount Observations Sump Refer to CRANKCASE on page 5 53 1 Barra claw guide changes 2 2 Spring 4 3 Shiftdrum 1 4 Right shift fork 1 5 Shift fork Center 1 6 Left shift fork 1 7 Drive shaft 1 8 Main shaft 1 9 Longpushrodclutch 1 For assembly reverse the disassembly procedure ...

Page 199: ...7 M 6 M 5 4 3 2 1 Order Procedure Parts to remove Amount Observations 1 Second Pinion 1 2 Fifth gear 1 3 Sprocket third 1 4 Pin lock 1 5 Toothed washer 1 6 Sprocket quarter 1 7 Main shaft sprocket first 1 For assembly reverse the disassembly procedure ...

Page 200: ...Order Procedure Parts to remove Amount Observations 1 Pin lock 1 2 Washer 1 3 Second gear 1 4 Fifth Gear 1 5 Washer 1 6 First gear 1 7 Necklace 1 8 Washer 1 9 Fourth gear 1 10 Pin lock 1 11 Washer 1 12 Third gear 1 13 Drive shaft 1 For assembly reverse the disassembly procedure ...

Page 201: ...um changes 2 Check l Bar fork guide changes Roll the guide bar shift fork on a flat surface Curves Replace וי WARNING Do not attempt to straighten a guide bar bent shift fork Transmission Inspection 1 Measure l Shaft Deformation main With a centering device and dial indicator 1 OOS Replace וי shaft principal Shaft limit deformation main 0 03 mm 3 Check l Movement of the shift fork Displacement alo...

Page 202: ...ngages in its respective gear wheel Wrong Reassemble וי the axes of the transmission NOTE Press the second pinion on the main shaft 2 as shown in the illustration Mounting depth a 106 85 107 05 mm 5 Check l Movement of transmission gears Rough movement Replace וי parts defective CHECKING THE CLUTCH PUSH ROD 1 Check l Longpushrodclutch Cracks damage wear Replace וי the long push rod of the clutch 2...

Page 203: ...cing the right side of the engine and be in the following sequence R C L 2 Check lTransmission Rough movement וי repair NOTE lApply engine oil to each gear and bearing lBefore assembling the crankcase make sure the transmission is in neutral and the gears turn freely ...

Page 204: ...EMBLY 6 2 CARBURETOR INSPECTION 6 4 CARBURETOR ASSY 6 6 CARBURETOR ASSEMBLY 6 7 MEASURING AND ADJUSTING THE FUEL BLE 6 7 INSPECTION FUEL WRENCH 6 8 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 6 9 REMOVAL AIR INDUCTION SYSTEM 6 10 INSPECTION SYSTEM AIR INDUCTION 6 11 ...

Page 205: ... Observations Seat side covers 1 2 fuel hose Refer to GENERAL CHASSIS on page 4 1 1 Fuel overflow hose 1 Disconnect 2 Fuel Hose 1 3 Clampboltcarburetorunion 1 Loosen 4 Screwclamp 1 5 Throttle Cable 1 6 Cable boot 1 7 TPS connector 1 8 Carburetor 1 For assembly reverse the disassembly procedure ...

Page 206: ... Observations Disassemble the carburetor Remove the parts in the order listed 1 Diaphragm cover 1 2 Diaphragm spring 1 3 Needle Valve 1 4 Piston valve 1 5 Diaphragm 1 6 Ring 1 7 Drainbolt 1 8 Float chamber 1 9 O ring 1 10 Support sprayer 1 11 Main jet 1 12 O ring 1 13 Main Nozzle 1 ...

Page 207: ...rocedure Parts to remove Amount Observations 14 Float Pin 1 15 Float 1 16 Set needle 1 17 Throttlestopscrew 1 18 Washer 1 19 Spring 1 20 Pilot Supplier 1 21 O ring 1 22 Washer 1 23 Spring 1 24 O ring 1 25 Strainer 1 26 Cover plunger 1 27 Support guide 1 ...

Page 208: ...dure Parts to remove Amount Observations 28 O ring 1 29 Plunger spring 1 30 Plunger 1 31 Spring washer 1 32 Throttlestop 1 33 Stop washer 1 34 Spring 1 35 TPS 1 36 O ring 1 37 Pin lock 1 38 Washer 1 39 Washer 1 For assembly reverse the disassembly procedure ...

Page 209: ...ning Blow out all passages and jets with compressed air 3 Verificar Diaphragm Valve 1 Cracks damage Replace 4 Verificar Camera body float 1 Dirt Clean 5 Verificar Rubber gasket float chamber 1 Cracks damage wear Replace NOTE Always replace the gasket with a new one 6 Verificar Float 1 Damage Replace 7 Verificar Needle Valve 1 Seat needle valve 2 O ring 3 Damage obstruction wear Replace needle valv...

Page 210: ...re screw 1 Damage wear Replace 1 CARBURETOR ASSY CAUTION Before assembling the carburetor clean all parts with a petroleum solvent Always use new gaskets 1 Install Throttlescrew 1 Jet pilot 2 Main nozzle 3 O ring 4 Main nozzle 5 Main jet 6 12 Check throttle screw 1 Damage wear Replace 1 1 13 Verificar YTPS 1 Damage defective Replace Butterfly Butterfly axis 2 movement Obstruction damage wear Repla...

Page 211: ...at chamber 4 Float chamber 5 3 2 2 1 5 4 3 Instalar Needle valve 1 1 5 Instalar Diaphragm Valve 1 CAUTION Do not overtighten any screws this can damage gaskets and O rings This can lead to fuel leakage 1 A B NOTE Make sure the raised A under the diaphragm must be aligned with the slot B in the body of the carburetor ...

Page 212: ...adjust the level of the pin bending float float 1 e Install the carburetor f Measuring the fuel level again g Repeat steps a through f until the fuel level is within specifications MEASURING AND ADJUSTING THE FUEL 1 Medir Fuel level a 1 Out of specification adjust Fuel level below the contact surface of the float chamber 6 0 7 0 mm a Place the vehicle on a flat surface b Place the vehicle on a sui...

Page 213: ...DUCCIÓN DE AIRE AIR INDUCTION SYSTEM 5 1 2 4 3 3 2 5 1 4 1Hose air induction system air filter 2Vacuum hose from the air induction system 3Through the air induction system to the engine 4Air Filter 5Air Induction System ...

Page 214: ...rvations Seat side cover Side cover 1 2 Refer to GENERAL CHASSIS on page 4 1 Fueltank Refer to GENERAL CHASSIS on page 4 2 1 Hose air induction system air filter 1 2 Vacuum hose from the air induction system 1 3 Duct air induction Towards the butt 1 4 Air Induction System 1 For assembly reverse the disassembly procedure ...

Page 215: ...shutoff valve closes automatically to protect against yield loss due to self Exhaust Gas Recirculation EGR Cracks damage Replace וי 3 way junction Cracks damage Replace וי 2 Check Reed valve Topofthevalvesheet Seat valve sheet Cracks damage Replace וי valve sheets 3 Check Air Switching Valve Cracks damage Replace וי 4 Check Operation of the air shutoff valve Not working Replace וי a Blow air throu...

Page 216: ... 12 SISTEMA DE INDUCCIÓN DE AIRE Air Switching Valve Replace valve opens air cutting Air shutoff valve closed The air cut valve is OK 1 NOTE This test should be done when the pressure is less than 50 kPa ...

Page 217: ...TION OF THE ENGINE WARNING LIGHT 7 24 TROUBLESHOOTING METHOD 7 24 SETTLEMENT DETAIL pro blems 7 25 ELECTRICAL COMPONENTS 7 28 CHECKING SWITCHES 7 30 CHECKING THE BULBS AND SOCKETS OF BULBS 7 33 CHECKING THE FUSE 7 34 CHECKING AND CHARGING 7 34 CHECKING THE RELAYS 7 37 VERIFICATION OF RELAY TURN SIGNAL 7 38 CHECKING THE SPARK PLUG CAP 7 39 CHECKING THE IGNITION COIL 7 39 VERIFICATION OF DISTANCE sp...

Page 218: ...IGHT 31 PO OFF ON Sb 7 L VCC A nd GIS BL SGND B 20 BL 19 BL L Y 21 LW LB OFF RW Br LWWBBL BLACK YW TC Lg DIAG VB GND 5 LW 23 RW LW BLACK 22 B Or RW YWLg BL L LY Y RW 27 RB LB LB RW 13 NEUTRAL Br Sb LB RW Sb Black 24 ORW BL Br Br2 YW W Y Dg Lg GB Ch Bl Sb Br TACHO BRB 9 11 BLACK 28 P 10 12 GY GY Br Br Br ILLMI GND W SPEED YW TC L B1 Black B Black BRW Br RED RED VCC BL SGND BRW P WB Br Dg Ch And 12V...

Page 219: ...SISTEMA DE ENCENDIDO 7 2 1 Magneto CA 3 Unit Regulator Rectifier 4 Main fuse 5 Battery 6 Main switch 7 CDI Unit 8 Ignition Coil 19 TPS 20 Plug 21 Cable Positive 22 Negative cable 30 Engine stop switch ...

Page 220: ...ap See section Checking the spark plug cap on page 7 39 OK t 5 Check the ignition coil See section CHECKING THE IGNITION COIL on page 7 39 OK t 6 Check the crankshaft position sensor Refer to the CHECKING CRANKSHAFT POSITION SENSOR on page 7 40 OK t 7 Check main switch See section MAIN switch check on page 7 30 OK t 8 Check the TPS See section CHECKING TPS on page 7 43 OK t NG NG NG NG NG NG NG NG...

Page 221: ... Verifying SWITCHES on page 7 30 OK t 10 Verificar wiring the entire ignition system See section CIRCUIT DIAGRAM on page 7 1 OK t Replace the CDI NG NG The engine stop switch is faulty Replace the switch 㻚 right handlebar Connect or repair wiring ignition system 㻚 ...

Page 222: ...FF ON Sb 7 L VCC A nd GIS BL SGND B 20 BL 19 BL L Y 21 LW LB OFF RW Br LWWBBL BLACK YW TC Lg DIAG VB GND Br Rw 5 WB LW LW 23 L B RW LW BLACK 22 B Or RW YWLg BL L LY Y RW 27 RB LB LB RW 13 NEUTRAL Br Sb LB RW Sb Black 24 ORW BL Br Br2 YW W Y Dg Lg GB Ch Bl Sb Br TACHO BRB 9 11 BLACK 28 P 10 12 GY GY Br Br Br ILLMI GND W SPEED YW TC L B1 Black B Black BRW Br RED RED VCC BL SGND BRW P WB Br Dg Ch And...

Page 223: ...RRANQUE ELÉCTRICO 7 6 2 Neutral switch 4 Main fuse 5 Battery 6 Main switch 21 Cable Positive 22 Negative cable 23 Starter relay 24 Starter 26 Start switch 27 Starter cut relay 28 Clutch switch 30 Engine stop switch ...

Page 224: ...ion is in neutral neutral switch is closed Pull the clutch lever to the handlebar the clutch switch is closed Cutting the ignition system prevents the starter motor when any of the above conditions are not met In this case the starting circuit is open then the current fails to reach the starter When at least one of the above conditions is met the starting circuit is closed and you can start the en...

Page 225: ...7 8 a When the transmission is in neutral b When the lever is pulled CLUTCH HANDLEBAR 1 Battery 2 Fuse 3 Main switch 4 Engine stop switch 5 Starter cut relay 6 Clutch switch 7 Neutral switch 8 Start switch 9 Starter relay 10 Starter ...

Page 226: ...on page 7 40 NG t 4 Checkthe enginestarts See Verifying STARTER on page 5 33 OK t 5 Check the circuit starter cut relay See the Verifying RELAYS on page 7 37 OK t 6 Check the starter relay See the Verifying RELAYS on page 7 37 OK t 7 Check main switch See Verifying SWITCHES on page 7 30 OK t NG NG OK NG NG NG NG Replace the fuse Clean the battery terminals 㻚 Recharge or replace the battery The sta...

Page 227: ...1 Verificar the start switch See the Verifying SWITCHES on page 7 30 OK t 12 Verificar wiring the ignition system See section CIRCUIT DIAGRAM on page 7 5 OK t The starting system circuit is OK 㻚 NG NG NG NG NG The engine stop switch is faulty Replace r i n t e r u p t o r 㻚 right handlebar Replace the neutral switch Replace the clutch switch The ignition switch is faulty Replace the switch right H...

Page 228: ...T 31 PO OFF ON Sb 7 L VCC A nd GIS BL SGND B 20 BL 19 BL L Y 21 LW LB OFF RW Br LWWBBL BLACK YW TC Lg DIAG VB GND 5 LW 23 RW LW BLACK 22 B Or RW YWLg BL L LY Y RW 27 RB LB LB RW 13 NEUTRAL Br Sb LB RW Sb Black 24 ORW BL Br Br2 YW W Y Dg Lg GB Ch Bl Sb Br TACHO BRB 9 11 BLACK 28 P 10 12 GY GY Br Br Br ILLMI GND W SPEED YW TC L B1 Black B Black BRW Br RED RED VCC BL SGND BRW P WB Br Dg Ch And And 14...

Page 229: ...SISTEMA DE CARGA 7 12 1 Magneto CA 3 Regulator rectifier 4 Main fuse 5 Battery 21 Cable Positive 22 Negative cable ...

Page 230: ...operation of the stator coil Refer to Checking the stator coil on page 7 41 OK t 4 Check the regulator rectifier See Verifying REGULATOR RECTIFIER on page 7 41 OK t 5 Check the wiring of the charging system See section CIRCUIT DIAGRAM on page 7 11 OK t The circuit charging system is OK 㻚 NG NG NG NG NG Replace the fuse Clean the battery terminals 㻚 Recharge or replace the battery Change the positi...

Page 231: ...HT 31 PO OFF ON Sb 7 L VCC A nd GIS BL SGND B 37 BL 19 BL L Y 21 LW LB OFF RW Br LWWBBL BLACK YW TC Lg DIAG VB GND 5 LW 23 RW LW BLACK 22 B Or RW YWLg BL L LY Y RW 27 RB LB LB RW 13 NEUTRAL Br Sb LB RW Sb Black 24 ORW BL Br Br2 YW W Y Dg Lg GB Ch Bl Sb Br TACHO BRB 9 11 BLACK 28 P 10 12 GY GY Br Br Br ILLMI GND W SPEED YW TC L B1 Black B Black BRW Br RED RED VCC BL SGND BRW P WB Br Dg Ch And And 1...

Page 232: ...SISTEMA DE LUCES 4 Main fuse 5 Battery 6 Main switch 13 Meter 15 Streetlight 18 Taillight 21 Cable Positive 22 Negative cable 31 Light Switch 34 Light switch ...

Page 233: ...D CHARGING THE BATTERY on page 7 34 NG NG NG Replace the bulb s and the socket of the bulb s Replace the fuse Clean the battery terminals 㻚 Recharge or replace the battery Okt 4 Checkmain switch See Verifying SWITCHES on page 7 30 Okt 5 Check the light switch See the Verifying SWITCHES on page 7 30 Okt 6 Check the switch happened See Verifying SWITCHES on page 7 30 Okt 7 Check the wiring of the li...

Page 234: ... SGND B 20 BL 19 BL L Y 21 LW LB OFF RW LWWB B L Br BLACK An d YW TC Lg DIAG VB GND 5 LW 23 RW L W BLACK 22 B O r RW YWLg BL L LY Y RW 27 RB LB LB RW 13 NEUTRAL Br Sb LB RW Sb Black 24 ORW Br B L Lg YW W B Br2 and DG GB Ch Bl Sb Br TACHO BRB 9 11 BLACK 28 P 10 GY GY B1 B 12 Br Br Br2 ILLMI GND W SPEED YW TC L Black Black BRW Br RED RED VCC BL SGND BRW WB Br Dg Ch P And BRW P WB Br Dg Ch And 14 PAS...

Page 235: ... Relay turn signal 11 Frontbrakeswitch 12 Rear brake switch 13 Meter 16 Front turn indicator light LH 17 Front light turn indicator RH 21 Cable Positive 22 Negative cable 25 Speed sensor 29 Fuel Gauge 32 Backlight turn indicator LH 33 Backlight turn indicator RH 35 Horn switch 36 Switch turn signal ...

Page 236: ...G Replace the fuse Clean the battery terminals 㻚 Recharge or replace the battery Okt 3 Check main switch See Verifying SWITCH on page 7 30 NG Replace the main switch Okt 4 Check the wiringcircuitsignaling system See under SIGNAL SYSTEM CHECK 㻚 Okt Check the status of each of the signaling system circuits See Verifying the signaling system NG Connect or repair the signaling system wiring Signalling...

Page 237: ...NG Replace the bulb brake light rear of the socket or both Replace front brake switch Replace the rear brake switch Okt 4 Check the wiring of the signaling system See section CIRCUIT DIAGRAM on page 7 17 Okt The system circuit is OK 㻚 NG Connect or repair wiring 㻚 signaling system The turn indicator light indicator light turning both or no flash 1 Check the indicator light bulb and socket pivot Re...

Page 238: ...ct or repair wiring 㻚 signaling system The neutral indicator light does not light 1 Check the light bulb and socket neutral Refer to the section Verifying the bulbs and sockets bulbs on page 7 33 NG Replace light bulb in neutral the socket or both Okt 2 Check neutral switch See Verifying SWITCH on page 7 30 NG Replace the neutral switch 㻚 Okt 3 Verificar t h e s i g n a l i n g s y s t e m w i r i...

Page 239: ...SISTEMA DE SEÑALIZACIÓN 7 22 2 Check the signaling system wiring See section CIRCUIT DIAGRAM on page 7 17 Okt Replace the meter 㻚 NG Connect or repair wiring 㻚 signaling system ...

Page 240: ...s detected in the system for the self diagnostic function to alert the driver of the malfunction detected warning light illuminated with engine trouble After the engine has stopped the error code number appears on the warning light engine trouble It will be stored in system memory until it is deleted 1 1 Warning light engine failure Identification Code fault warning light engine trouble 10 Digits ...

Page 241: ... The warning light comes on engine failure for 3 seconds after the main switch is turned to ON If the warning light does not come on in these conditions the communication cable is disconnected or the LED warning light may be defective to b c d c a Switch to OFF b Switch to ON c Warning Light Engine trouble off d Warning Light Engine trouble on for 3 seconds TROUBLESHOOTING METHOD Motor operation i...

Page 242: ...sensor CDI connector on the harness Check the coupler terminals that may have emerged Check the lock status coupler If there is a malfunction repair and connect the coupler seugra form 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Among the connector position sensor accelerator and the CDI connector black blue black blue yellow yellow Blue blue 4 Th...

Page 243: ...ce job Method reintegration 1 Connections Connector Ignition Coil Primary coil side CDI connector on the harness Check connector terminals and coupler that may have emerged Check the connector lock and coupler If there is a malfunction repair and connect the coupler securely Start the motor 2 Cable Harness for open or short circuit Repair or replace if there is a circuit open or shorted Between co...

Page 244: ...and activate the speed sensor pony endo op erating the vehicle 2 Connections Speed sensor coupler Cable Coupler main harness Check that the coupler terminals may have left Check the lock status of the couplers If there is a malfunction repair and connect the coupler 3 Open wire or short circuit Repair or replace if there is an open or short circuit Enter the speed sensor coupler and coupler wiring...

Page 245: ...7 28 COMPONENTES ELÉCTRICOS ELECTRICAL COMPONENTS 1 2 3 4 5 10 11 12 6 9 14 13 8 7 ...

Page 246: ...ÉCTRICOS 1 Front brake switch 2 Fuel Gauge 3 Starter cut relay 4 CDI Unit 5 Main switch 6 Horn 7 Starter relay 8 Neutral switch 9 Rear brake switch 10 Battery 11 Regulator rectifier 12 Fuse 13 Spark plug 14 Ignition Coil ...

Page 247: ...ENTES ELÉCTRICOS OFF ON Br Dg W B Br W An P Ch PASS SWITCH INSPECTION 1234 BBr R B B BLACK B RBr GY BR Br YY RED 5 Sb 12 PO OFF ON 11 Br L W 10 L W B R W W B 9 Br R W 87 W B And G 6 BRP C D H G B r W An d G B L B ...

Page 248: ...LÉCTRICOS 1 Clutch switch 2 Main switch 3 Front brake switch 4 Rear brake switch 5 Neutral switch 6 Switch turn signal 7 Horn switch 8 Light switch 9 Light Switch step 10 Engine stop switch 11 Startswitch 12 Light Switch ...

Page 249: ...mage the cables Multimeter NOTE l Before checking for continuity set the multimeter in continuity mode When checking the continuity toggle switch positions several times Switches and terminal connections are illustrated in the following example of the main switches Positions a shown in the left column and the switch lead colors B are shown in the top row The continuity ie a closed circuit between ...

Page 250: ... away from them until they have cooled CAUTIONN Be sure to hold the socket firmly when removing the bulb bulb Never pull the cord if it can be pulled out of the terminal on the coupler Avoid touching the glass of a lamp bulb and keep it free from oil otherwise the transparency of glass the life of the bulb and the luminous flux will be adversely affected If the bulb of the lamp is dirty clean it t...

Page 251: ...RAL CHASSIS on page 4 1 2 Check Fuse a Connect the meter to the fuse and check for continuity NOTE Set the multimeter to Ù 1 Multimeter b If the meter indicates 䌲 replace the fuse 3 Replace Blown fuse WARNING Never use a fuse with a rating other than that specified Improvising or using a fuse with the wrong amperage can cause serious damage to the electrical system causing a malfunction in the lig...

Page 252: ...rminal וי Negative battery Example Open circuit voltage 12 0 V Charging time 5 10 hours Charging the battery 20 30 A Open circuit voltage V B Charging time hours C Relationship between the open circuit voltage and the charging time at 20 C 68 F D These values vary with the temperature the state of the battery plates and the electrolyte level A Open circuit voltage V B Condition of Battery Charge C...

Page 253: ...cuit voltage V B Time minutes C Load D Ambient temperature of 20 C 68 F E Check the open circuit voltage Charging method with a charger voltage variable a Measuring the open circuit voltage prior to charging NOTE The voltage should be measured after 30 minutes without using the battery b Connect a charger and an ammeter to the battery and start charging c Make sure that the current is higher than ...

Page 254: ...eryterminals Sulfation Clean with hot water Loose connection Connect וי correctly 9 Lubricate Batteryterminals Recommended lubricant Dielectric grease 10 Instalar Seat and right side cover Refer to GENERAL CHASSIS on page 4 1 CHECKING THE RELAYS Check continuity of each switch pocket tester If the continuityreading is incorrect replace the relay Multimeter 1 Disconnect the relay harness cable asse...

Page 255: ...rn signal OOS וי The from circuit switch to the relay coupler turn signal is faulty and must be repaired InputvoltagerelayturnsignalDC12V a Connect the multimeter to the terminal relay turn signal as shown Multimeter Positive tester probe וי coffee 1 Negative tester probe וי land 2 Check The output voltage relay turn signal OOS Replace וי a Connect the multimeter to the terminal relay turn signal ...

Page 256: ... resistance OOS Replace וי Primary coil resistance Ù 0 32 to 0 48 at 20 C 68 F a Disconnect connectors of the ignition coil the terminals of the ignition coil b Connect the multimeter Ù 1 to the ignition coil as shown Multimeter Positive tester probe וי orange 1 Negative tester probe וי land 2 c Measure the secondary coil resistance 2 Check secondary coil resistance OOS Replace וי Secondary coil r...

Page 257: ...tween the spark plug electrodes from 0 8 to 0 9 mm NOTE If the distance between the spark plug electrodes is within specifications the circuit of the ignition system is operating normally a Disconnect the spark plug cap from the spark plug b Connect the dynamic spark tester 1 as shown Dynamic spark tester 1 2 Spark plug c Turn the ignition switch to ON and the engine stop switch to position d Meas...

Page 258: ...OS Replace וי the sensor Crankshaft position stator assembly Resistance of the stator winding Ù 0464 0696 to 20 C 68 F b Measuring the resistance of the stator coil CHECKING THE REGULATOR RECTIFIER 1 Check Charge Voltage OOS Replace וי the regulator rectifier ChargeVoltage 13 7 14 7 V at 5000 r min a Connect the engine tachometer to the spark plug wire b Connect the multimeter to the coupling of t...

Page 259: ...0 C 68 F Unit resistance meter empty 137 143 Ù to 20 C 68 F Positive tester probe וי horn terminal 1 Negative tester probe וי horn terminal 2 a Connect the multimeter Ù 100 in the fuel gauge coupling as shown Multimeter Positive tester probe וי 1 orange white 1 Negative tester probe וי green black 2 2 c Measure the resistance of the speaker 2 Check Sound the horn Sound Adjust or replace defective ...

Page 260: ... the end of the cable harness as shown Multimeter Positive tester probe white 1 Negative tester probe blue black 2 Positive tester probe וי 1 blue 1 W L Negative tester probe וי BL black blue terminal 2 2 L W Inputvoltagesensor throttle position BL 5 V Azul negro azul d While slowly opening the throttle check that the voltage output of the throttle position sensor increase The voltage does not cha...

Page 261: ...mance in medium and high speed 8 2 GEAR FAILURE ELBCIAOMDE 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPING GEARS 8 2 CLUTCH FAILURE 8 2 OVERHEATING 8 2 Supercooling 8 3 PERFORMANCE POBREFREENNEALDO 8 3 FAILURE HORQEULILALNATEDRA 8 3 UNSTABLE HANDLING 8 3 FAILURE OF LIGHTING SYSTEM OR SIGNALLING 8 4 WIRING DIAGRAM 8 5 ...

Page 262: ...contaminated Fuel dispenser clogged Carburetor out of adjustment Electrical System 1 Battery Battery discharged Battery failure 2 Fuse Blown damaged or incorrect improperly installed fuse 3 Plug Improper plug cap heat range spark plug incorrect Faulty spark plug Worn or damaged electrode worn or damaged insulation Spark plug defective 4 Ignition Coil Body of the ignition coil cracked or fractured ...

Page 263: ...shift fork stuck Sweep guide bent shift fork Transmission transmission gear attached Foreign objects between transmission gears Incorrect assembly of the transmission JUMPING GEARS Axis of changes Shift Pedal Position incorrect The return lever stop improperly Forks of changes Worn shift fork Shiftdrum Axial wrong Wear drum grooves changes Transmission Wear lace Gear Clutch CLUTCH FAILURE slips 1 ...

Page 264: ...oupling screws loose Damage to the brake hose Grease or oil on the brake disc Grease or oil on brake pads Brake fluid level incorrect FRONT FORK FAILURE oil leak Inner tube bent damaged or corroded broken or damaged outer tube Oil seal installed incorrectly Edges damaged oil seal Incorrect oil level high Screw loose cushion rod copper washer damper rod damaged O ring screw cap damaged Malfunction ...

Page 265: ...lb taillight brake incorrect Many electrical accessories Bad connection Bulb taillight brake light cast Light Bulb melt rotation Bad connection Damaged or faulty wiring harness Grounding circuit Battery failure Fuse broken damaged or incorrect Light turn signal flashes slowly turn signal relay defective Defective main switch turn signal switch defective turn signal bulb incorrect Signal light rema...

Page 266: ...R ON R OFF START RW LWWB B Br L BLACK RUN PO ON BL SGND An d YW TC Lg DIAG VB GND 5 LW 23 RW LW 22 RwBr WBLW L B BLACK B Or RW YWLg BL L LY Y RW 27 RB LB LB RW 13 NEUTRAL BRSB LB RW Sb Black 24 ORW Br B L Lg YW W B Br2 and DG GB Ch Bl Sb Br TACHO BRB 911 BLACK 28 P 10 GY GY B1 B 12 BR BR Br2 ILLMI GND W SPEED YW TC L Black Black RED RED VCC BL SGND BRW P WB Br Dg Ch And And 14 PASSON OFF DIMMER 34...

Page 267: ...ed sensor 26 Start switch 27 Starter cut relay 28 Clutch switch 29 Fuel Gauge 30 Engine stop switch 31 Light Switch 32 Backlight turn indicator L H 33 Backlight turn indicator R H 34 Light switch 35 Horn switch 36 Switch turn signal B Br Black Coffee ChChocolate Dark green Dg G Green GyGris LgVerde clear O L Blue Orange Rosa P Red R Blue sky Sb W White And Amarillo B L Black Blue Br L Coffee Blue ...

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