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Yamaha FZ-16, Service Manual

The Yamaha FZ-16 Assembly Manual is an essential guide for enthusiasts looking to assemble their powerful motorcycle with ease. This comprehensive manual provides step-by-step instructions, ensuring a seamless assembly process. Download the manual for free from our website and unlock the full potential of your Yamaha FZ-16.

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AIR INDUCTION SYSTEM

 

AIR INDUCTION SYSTEM

 

5

 

1

 

2

 

3

 

4

 

3

 

2

 

5

 

1

 

4

 

1

 

2

 

3

 

4

 

5

 

Hose air induction system (air filter).

 

Vacuum hose of the air induction system.

 

Through the air induction system (to the motor)

 

Air filter

 

Air induction system.

 

6-9

 

Summary of Contents for FZ-16

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

Page 2: ...FZ 16 SERVICE MANUAL All rights reserved Any reproduction or unauthorized use without the written consent of YAMAHA MOTOR INDIA PVT LTD is strictly prohibited ...

Page 3: ... will be informed of any amendments and changes substantial occur in specifications or procedures and these are included in future editions of this manual when necessary NOTE Designs and specifications subject to change without notice IMPORTANT INFORMATION ABOUT THIS MANUAL Particularly important information in this manual are distinguished by the following symbols Safety alert symbol means ATTENT...

Page 4: ...n smaller print than the section title To help identify parts and clarify procedure steps there are diagrams exploited 3 at the beginning of each of the sections of removal and disassembly 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 acco...

Page 5: ...2 Liquid fill 3 Lubricant 4 Special Tool 5 Torque 6 Wear limit tolerance 7 Engine speed 8 Electrical data 9 Motor oil 10 Gear oil 11 Molybdenum disulfide oil 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 new one T R 7 8 9 E 10 G 11 M 12 BF 13 B 14 LS 15 M 16 S 17 LT 18 New ...

Page 6: ...TABLE OF CONTENTS GENERAL INFORMATION 1 2 3 4 5 6 7 8 SPECIFICATIONS INSPECTIONS NEWSPAPERS AND ADJUSTMENTS CHASSIS ENGINE CARB ELECTRICAL TROUBLESHOOTING ...

Page 7: ... 1 ENGINE SERIAL NUMBER 1 1 LCD METER 1 2 INFORMATION IMPORTANT 1 3 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 3 REPLACEMENT PARTS 1 3 PACKING OIL SEALS RINGS I 1 3 LOCK WASHERS LOCKNUTS AND PINS 1 3 BEARINGS AND OIL SEALS 1 4 RING CLOSING 1 4 INSPECTION CONNECTION 1 5 SPECIAL TOOLS 1 6 ...

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

Page 9: ...eset A fuel gauge indicating the available fuel level within the anque fuel NOTE Be sure to turn the key to ON before using the SELECT TOTAL ODOMETER MODE Odometer A light pulse less than one second on the button SELECT the display changes between odometer and tripmeter Fuel Gauge 1 1 Fuel Gauge The fuel gauge indicates the amount of fuel in the fuel tank Segments fuel meter disappear towards E Em...

Page 10: ...st always grouped be reused or replaced altogether 2 During assembly place the oil specified on all parts and bearings carefully and lubricate the edges of the oil them with grease 4 During disassembly clean all pieces and place them in trays in the order of removal This will speed up assembly and allow the correct assembly of all parts 5 Keep all parts away from any fire source REPLACEMENT PARTS ...

Page 11: ...thium soap base In the bearings apply oil if requested PREACAUCIÓN Do not turn the bearing with compressed air and this will damage the surfaces LOCKING RING Before joining check carefully All sealing rings and replace those are damaged or twisted Always replace sealing rings piston pin after a use When installing a sealing ring 1 make sure the sharp corners 2 are placed on the opposite side 3 to ...

Page 12: ... and disconnect several times NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick fix use a spray cleaner contacts is available in most parts stores 3 Check All connections Loose connection Properly connect NOTE If you crimp the pin 1 from the terminal fold upwards 4 Connect Cable Coupler Connector NOTE Make sure all connections are tig...

Page 13: ...ew taque to adjust the valve clearance Tappet adjusting wrench YSST 806A This tool is used to loosen and tighten the nut the tappet Thickness gauges YSST 815 This tool is used to adjust the valve clearance a motor Adjuster rear shock YSST 821 This tool is used for adjusting the preload Rear shock Magnet Holder YSST 601B This tool is used to hold the magnet to removing or installing the magneto sec...

Page 14: ...Fixer clutch hub YSST 733 This tool is used to set the clutch hub while installing or removing the hub nut fastener clutch Stroboscope lamp This instrument is used to check the time of lit Gauge This instrument is used to measure the compression motor Scraper YSST 612 This tool is used to scrape the edge of the seal bonding surface of the crankcase Valve spring compressor YSST 603 This tool is use...

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

Page 16: ...contact surfaces while assembling the covers 1 and 2 engine Loctite Three Bond 1322 This adhesive is used to provide greater resistance to Torx screws for adjustment Basis for piston YSST 604 This tool is needed to support the piston during assembly of the cylinder Crankshaft key cap YSST 625 This tool is used to remove install the plug of the left cover of the crankcase 1 L H 1 9 ...

Page 17: ...IFICATIONS 2 9 ELECTRICAL 2 12 TORQUE 2 14 ON GENERAL TORQUE 2 14 ENGINE TORQUE 2 16 CHASSIS TORQUE 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 TABLES AND DIAGRAMS LUBRICATION SYSTEM 2 24 ENGINE LUBRICATION CHART 2 24 LUBRICATION DIAGRAMS 2 25 CABLE GUIDED 2 27 ...

Page 18: ...l Dimensions Total length Overall width Overall heightl Seat Height Wheelbase Ground clearance Minimum turning radius Weight With gasoline and oil Peak load 21C1 1973mm 770mm 1045mm 790mm 1334mm 160mm 2340mm 135 0kg 195 0kg 2 1 ...

Page 19: ...er As the country Unleaded regular gasoline standard 12 0 L 1 4 L Motor oil Wet system lubricaciónCárter TipoSAE20W50 Recommended grade of motor oil YAMALUBE Grade SG Number of motor oil 1 00 LCambio newspaper Change total1 20 L Oil filter Type oil filter Oil pump Type of oil pump Clearance of the inner rotor to the outer rotor Limit Clearance of the outer rotor to the housing oil pump Limit Clear...

Page 20: ...K CPR8EA 9 0 8 0 9mm 13 40 14 00cm 0 03mm Camshaft Drive System Dimensions of camshaft lobes Admission to Limit Admission B Limit Escape A Limit Escape B Limit Chain drive Left 31 342 2mm 31 44 31 342mm 25 166 25 26 6mm 25 136mm 31 110 31 210mm 31 080mm 25 096 25 19 6mm 25 066mm B A Strain limit 0 03 mm camshaft 2 3 ...

Page 21: ... of the valve B Admission Face width of the valve B Escape 1538 2 138mm 1538 2 138mm B Width of the seat valve C Admission Width of the seat valve C Escape 0 90 1 10mm 0 90 1 10mm C Thickness D of the valve margin Admission 0 50 0 90mm Thickness D of the valve margin Escape 0 50 0 90mm D Diameter of the valve stem Admission Limit Diameter of the valve stem Escape Limit Internal diameter of the val...

Page 22: ...Elasticity of the spring constant K2 Escape Force compression spring installed Admission Force compression spring installed Escape Inclination of the compression spring Admission Inclination of the compression spring Escape 39 40mm 37 40mm 39 40mm 37 40mm 34 50mm 34 50mm 35 08N mm 44 40N mm 35 08 N mm 44 40 N mm 160 184 N 160 184 N 2 5 1 7 mm 2 5 1 7 mm Thread direction Admission Thread direction ...

Page 23: ... 14995 15000 mm 14975 mm Barrel 0 80 x 2 30 mm B T Distance between ends installed Limit Ring side clearance Limit Second Ring Ring type Dimensions B T 0 10 to 0 25 mm 0 40 mm 0030 0065 mm 0 100 mm Conical 0 80 x 2 40 mm B T Distance between ends installed Limit Ring side clearance Limit Oil ring Dimensions B T 0 10 to 0 25 mm 0 40 mm 0020 0055 mm 0 100 mm 1 50 x 2 25 mm B T Distance between ends ...

Page 24: ...ur gears 75 22 3 409 Drive chain 40 14 2 857 Operation with the left foot 38 14 2 714 34 19 1 789 29 22 1 318 23 22 1 045 21 24 0 875 Type of clutch Clutch release method Clearance of the clutch lever Thickness of the friction discs Wear limit Number of disks Thickness of clutch plates Number of disks Limit of flatness Free length of the clutch springs Minimum length Number of springs Maximum defl...

Page 25: ...put Supplier Jet pilot Pilot screw turns Size of the valve seat Pump on 1 Pump on 2 So great throttle valve Idle condition Engine idle Oil temperature CO Vacuum admission Temperature of the spark plug base Type oil filter Throttle cable slack Drive mechanism and guide bar 4 76 4 89 mm Auto decompressor Dry element BS26X1 21C1110 112 5 0 9 4D1Z11 P 1M 0 8 15 3 1 4 1 5 35 0 7 1 25 1300 1500 r min 75...

Page 26: ...imit of the wheel Limit lateral deflection of the wheel Front rim Type Size Manufacturer Model Rear tire Type Size Manufacturer Model Air pressure of tires Measure Cold Diamond 25 00 101 2 mm Wheel type 17 M CXMT2 50 Aluminum 130 0 mm 1 0 mm 0 5 mm Wheel type 17 M CXMT3 50 Aluminum 120 0 mm 1 0 mm 0 5 mm Tubeless 100 80 17M C 52P MRF ZAPPER X Tubeless 140 60 R 17 M C 63P MRF ZAPPER X revz 200 kPa ...

Page 27: ... of the spring lugs Free length of spring shoes 2 Address Bearing type steering Angle stops left Angle stops right Front fork Type Type of shock spring Front fork travel Free length of the fork spring Collar length Installed length K1 spring tension K2 spring tension K1 Race Spring K2 Spring Race Outer diameter of inner tube Recommended Oil equivalent Amount Level Rear Suspension Type Type of shoc...

Page 28: ...ing tension K1 Race Spring Tilt Free play at the end of the rocker Limit axial Drive chain Type manufacturer Number of links Clearance of the drive chain Length limit of 15 links 187 0 mm 178 0 mm 120 0 N mm 0 0 20 0 mm 2 4 mm R428HBSX LGB 128 30 0 40 0 mm 191 5 mm 2 11 ...

Page 29: ...Lamp bulb Bulb type Voltage wattage of the bulb and quantity Streetlight Tail brake Front directional light Rear directional light Light Meter Auxiliary light Indicator light Neutral indicator light Directional indicator light Indicator light beam Warning light engine failure 12V DC CDI Digital 7 0 1400r min 192 288Ùat 20 C 0 32 to 0 48Ùat 20 C 5 68 8 52Ùat 20 C Resin 5kÙat 20 C 14 0V 125W 5000 rp...

Page 30: ...gear 0 25 kW 100 A 3 51 4 29 Ù Flat 1 pc 1 5 A Turn signal relay Relay type Integrated self cancellation device Sign of the flicker frequency Fuel gauge Resistance of the meter unit Resistance of the meter unit Ignition cut off relay Coil resistance Fuse Fuse Transistor relay Not 70 100 cycles min 19 0 21 0Ùat 20 C 137 0 143 0Ùat 20 C 90 0 110 0Ù 15 0 A 2 13 ...

Page 31: ...ross clamping assemblies with several fastening points in progressive stages until the specified torque Failure otherwise specified for torque The 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 Tightening general Nm 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6 15 30 55 85 130 m kg 0 6 1 5 3...

Page 32: ...ze of thread M8 M6 M10 M6 M8 M10 M6 M8 M6 M6 M6 M5 M5 M12 M6 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M6 M6 M6 M6 M14 M32 M6 M6 Amount 4 2 1 10 2 1 2 1 1 2 2 2 2 1 2 1 2 2 2 2 1 2 1 1 1 2 4 2 6 1 1 7 11 Torque 22 Nm 2 2 m kg 16ft lb 10 Nm 1 0 m kg 7ft lb 13 Nm 1 3 m kg 9ft Ib 10 Nm 1 0 m kg 7ft Ib 15 Nm 1 5 m kg 11ft Ib 45 Nm 4 5 m kg 33ft Ib 13 Nm 1 3 m kg 9ft Ib 20 Nm 2 0 m kg 14ft Ib 8 Nm 0 8 m kg 6ft Ib ...

Page 33: ...ter Size of thread M6 M12 M6 M6 M12 M6 M6 M14 M6 M6 M6 M6 M6 M6 M12 M10 M6 Amount 1 1 2 3 1 4 1 1 1 2 1 1 3 2 1 1 2 Torque 10 Nm 1 0 m kg 7ft Ib 50 Nm 5 0 m kg 36ft Ib 12 Nm 1 2 m kg 9ft Ib 14 1 4 Nm m kg 10ft Ib 60 6 0 Nm m kg 43ft Ib 8 Nm 0 8 m kg 6ft Ib 8 Nm 0 8 m kg 6ft Ib 70 Nm 7 0 m kg 51ft Ib 10 Nm 1 0 m kg 7ft Ib 7 Nm 0 7 m kg 5ft Ib 10 Nm 1 0 m kg 7ft Ib 12 Nm 1 2 m kg 9ft Ib 10 Nm 1 0 m ...

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

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

Page 36: ...5 M6 M4 M10 M8 M8 M12 M12 M12 M8 M6 M6 M6 M6 M5 M6 M6 M6 M8 M5 M5 M5 M5 M5 M6 M6 Amount 2 1 1 1 1 2 2 2 2 3 2 3 4 2 2 3 1 1 1 1 2 2 1 3 4 1 1 4 4 2 1 10 2 2 2 1 Torque 16 Nm 1 6 m kg 12ft lb 110 Nm 11 0 kg m 80ft lb 33 Nm 3 3 m kg 24ft Ib 22 Nm 2 2 m kg 16ft Ib 6 Nm 0 6 m kg 4ft Ib 7 Nm 0 7 m kg 5ft Ib 7 Nm 0 7 m kg 5ft Ib 7 Nm 0 7 m kg 5ft Ib 10 Nm 1 0 m kg 7ft Ib 1 Nm 0 1 m kg 1ft Ib 4 Nm 0 4 m ...

Page 37: ...edal nut changes Nut side support bracket and chassis Support plate nut nut footrest Union nut arm changes Nut for rear brake switch Amount 1 1 6 1 1 2 6 2 1 2 1 2 1 1 2 1 1 Torque 60 Nm 6 0 m kg 43ft Ib 90 Nm 9 0 m kg 65ft Ib 43 Nm 4 3 m kg 31ft Ib 20 Nm 2 0 m kg 14ft Ib 10 Nm 1 0 m kg 7ft Ib 35 Nm 3 5 m kg 25ft Ib 30 Nm 3 0 m kg 22ft Ib 10 Nm 1 0 m kg 7ft Ib 30 Nm 3 0 m kg 22ft Ib 35 Nm 3 5 m kg...

Page 38: ...haft Inner surface of the rocker shaft Pin the decompression lever Oil seal clutch cover Sprocket Oil Pump Rotor oil pump internal and external Pinion thrust surface free starter clutch Pinion starter clutch free Inner surface and pinion thrust surface clutch start Starter clutch rollers Clutch thrust cam Inner surface of the primary pinion Clutch Pushrod Short and Long and pellet Contact surface ...

Page 39: ...nkshaft Position Sensor washer assembly Lead stator Contact surface of carcasses Lubricant Yamaha Adhesive No 1215 Three Bond No 1215R Yamaha Adhesive No 1215 Three Bond No 1215R Yamaha Adhesive No 1215 Three Bond No 1215R Tensioner bolts distribution chain 2 22 ...

Page 40: ...e steering column and the edges of the cover upper bearing Dust of the steering column Wire nuts and bolts relay arm and calls Wire nuts and bolts Biela and relay arm Wire nuts and bolts rear shock relay arm Wire nuts and bolts relay arm and tilt Wire nuts and bolts Biela and tilt Edges of oil seals Relay arm and swingarm Bushings relay and rocker arm Pivot shafts and threads of the nut Outer surf...

Page 41: ...OINTS AND LUBRICANT TYPES TABLES AND DIAGRAMS LUBRICATION SYSTEM TABLE OF ENGINE OIL LUBRICATION 5 3 4 2 6 1 7 1 2 3 4 5 6 7 Oil strainer Oil pump Oil filter element Crankshaft Camshaft Main shaft Driven shaft 2 24 ...

Page 42: ...LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION CHARTS 1 2 3 A 4 5 6 7 1 2 3 4 5 6 7 A Push the clutch lever Main shaft Drive shaft Crankshaft Oil filter Oil pump Oil strainer Toward the head 2 25 ...

Page 43: ...LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION CHARTS 1 2 3 4 1 2 3 4 Camshaft Crankshaft Main shaft Driven shaft 2 26 ...

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

Page 45: ...ht cable Auxiliary Light Cable Go through the right guide bracket lamp RHS Go through the right guide bracket lamp RHS Passes through the left guide lamp bracket LHS Passes through the left guide lamp bracket LHS Hold the lamp support bracket Pass the cable through the right front directional guide Pass the cable through the left front directional guide Pass the wire harness cables handlebar switc...

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

Page 47: ... lead frame clamp Pass the breather hose from the battery and the carburetor drain hose to through the holes in the hose joint F Pass the overflow pipe through the guide G Pass the wire harness cable the sensor unit cables switches handlebar through the guide H Thread the speaker cord after spending the overflow pipe through the guide I Pass the wire harness cable the sensor unit cables switches h...

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

Page 49: ...ock Cable lock the seat Relay circuit court of the boot CDI Carburetor vent hose Rear fender Rear fender cover Insert the breather hose into the hole carburetor air filter Attach cables handlebar switches and the clutch clamp handlebar C Attach cables and switches front brake handlebar clamp handlebar D Pass the tail light wires through the hole of the rear fender E Set the high voltage cable and ...

Page 50: ...GUIDING CABLES 25 17 16 10 30 16 28 31 29 5 H H K K U U T T 30 January 25 31 A 18 19 B 10 C 21 26 22 E 24 27 23 U T U T 5 K 16 M N 15 H P K O 6 8 7 F 9 G I 29 14 L 13 K 12 11 J 10 H 2 33 ...

Page 51: ...white label wiring harness with a clamp D Adjust the clamp on the back of a motor support chassis E Opposite the bracket painted white The vacuum hose 1 Detection F Route the starter relay and the motor boot through the clamp on the Battery box G Pass the breather hose and battery the drain hose from the carburetor to through the exterior of the motor H Pass the breather hose and battery the drain...

Page 52: ... THE BREATHER TUBE HEAD 3 12 CHECK THE EXHAUST SYSTEM 3 12 CHECK THE FILTER FUEL SWITCH 3 13 ADJUSTING THE REAR BRAKE 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 SETTING THE REAR BRAKE LIGHT 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 15 ADJUSTING THE CLEARANCE OF THE CHAIN 3 16 CHAIN LUBE 3 ...

Page 53: ...CKING AND CHARGING THE BATTERY 3 22 FUSE INSPECTION 3 22 BULB REPLACEMENT FAROLA 3 22 SETTING THE BEAM BULB FAROLA 3 23 BULB REPLACEMENT OF AUXILIARY 3 23 BULB REPLACEMENT TAILLIGHT BRAKE LIGHT 3 23 LIGHT BULB REPLACEMENT INDICATOR 3 24 ...

Page 54: ...heck operation fluid level and leakage Replace brake pads Check operation of the shoes brake Change the brake pads READING ODOMETER X 1000 km 15 136912 1 2 3 4 5 6 Every 12000 Km Valves Air filter Battery Clutch Every 12000 Km 7 Brake front Whenever you reach the limit Wear 8 Back brake Hose brake Wheels Whenever you reach the limit Wear Every 4 years 9 10 11 Tires 12 13 Bearings Wheel Tilt 14 Cha...

Page 55: ...housing of accelerator and cable System induction air Lights signals and switches Every 12000 Km 18 19 20 21 Every 10000 km in the odometer 22 25 Lubricate Check operation and ease Adjust the free play of the throttle cable if necessary Lubricate the throttle grip housing and cable Check the air cut valve the reed valve and the tube is damaged Replace damaged parts as necessary Check operation Adj...

Page 56: ... GENERAL CHASSIS on page 4 2 2 Disconnect Hose air induction system See SYSTEM INDUCTION AIR on page 6 9 3 Remove Cylinder head cover Packing the cylinder head cover See the HEAD on page 5 5 4 Remove Screw access to the brand time 1 Access screw end of the crankshaft 2 b to c Verify that the camshaft lobes are positioned as shown in the illustration NOTE In this position both valves must have some...

Page 57: ...n b Reduces valve clearance 1 Start the engine and allow it to warm a minutes 2 Install Digital Tachometer In the spark plug wire Tappet screw holder YSST 706 Fitting key screw YSST 806A Hold the adjusting screw to prevent move and tighten the nut to specified Locknut 13 Nm 1 3 m kg 9 lb ft d Remeasure the valve clearance e If the valve clearance is outside the value specified repeat the adjustmen...

Page 58: ...cification Set 5 Fit Adjusting the density of CO through the screw Mixing Turn the mixture tronillo 5 in or out until the specified value in the density of CO 9 Fit Cable free play Refer throttle the SET FREE GAME THROTTLE CABLE on page 3 6 Turn out Density CO increases Turn inward Density CO is decreased Idle adjustment according to the specifications Cable free play 3 0 5 0 mm throttle 5 MEASURE...

Page 59: ...cable Out of specification Adjustment Side of the handlebar a Slide back the rubber cover 1 b Loosen the lock nut 2 c Turn the adjusting nut 3 direction a or B until the free play is obtained specified in the accelerator cable Direction a The free game accelerator cable increases Direction b The free game accelerator cable decreases Throttle cable slack 3 0 5 0 mm 2 Adjustment Throttle cable slack...

Page 60: ...ll cables of all the ignition system Make sure all connections are tight and free of 1 Remove Screw access to the brand time 1 3 Check Type spark plug NGK CPR8EA 9 Wrong Change 4 Check Electrode 1 Damage wear Replace the spark plug Insulation 2 5 Clean Plug With a spark plug cleaner or brush wire 6 Measure Clearance of the spark plug electrodes a With a feeler gauge Off spec Set 1 Crankshaft key c...

Page 61: ...MPRESSION NOTE 6 Measure Compression pressure Out of specification See steps C and d Compression pressure 1200 kPa sea level Insufficient compression pressure result in performance loss 1 Measure Valve clearance Out of specification Set Refer to ADJUSTING THE VALVE CLEARANCE on page 3 3 2 Start the engine and leave for calendar few minutes and then off 3 Disconnect Spark plug cap 4 Remove The spar...

Page 62: ...tainer under the screw Drain engine oil 3 Remove Meter engine oil level 1 Plug 2 9 Connect Spark plug cap CHECKING THE OIL LEVEL ENGINE 1 I placed the vehicle on a flat surface Note Place the vehicle on the main stand Make sure the vehicle is upright 2 Start the engine warm it up for some minutes and then off 3 Check Engine oil level The engine oil level should be between minimum marks a and maxim...

Page 63: ...ne Engine Oil Leak 12 Verificar Engine Oil Level Refer to CHECKING AND ENGINE OIL LEVEL in the page 3 9 13 Check Engine oil pressure a Loosen screw check oil 1 b Start the engine and idle until the oil begins to seep from the screw 3 10 T R T d Start the engine after solving the problem s and Pressure test Engine oil again e Tighten the torque verification specified Oil check screw 7 Nm 0 7 m kg 5...

Page 64: ...lutch decreases 1 1 Remove Seat Refer to GENERAL CHASSIS On page 4 1 2 Remove Cover air filter box 1 Air filter element 1 NOTE Keep the right handlebar 2 1 to b 3 Clean Air filter element 1 Apply dry compressed air from the surface outside the inner air filter element c Tighten the lock nut Locknut 9 Nm 0 9 m kg 6 5 ft lb 1 CLEANING THE FILTER ELEMENT AIR NOTE There is a hose inspection 1 on the b...

Page 65: ... Seat Refer to GENERAL CHASSIS On page 4 2 CHECK THE EXHAUST SYSTEM 1 Check Silencer 1 ReempláceloGrietas damaged Exhaust seal 2 Exhaust gas ReempláceloFugas 2 Check Torque Nuts Muffler 3 Screw the silencer 4 Screw the silencer 5 Muffler Nut 15 Nm bottom left Screw the silencer 20 Nm 2 0m kg 15ft lb Screw the silencer bottom right 12 Nm 1 2m kg 9ft lb T 1 R 3 Assembly 2 Fuel tank Side cover Seat R...

Page 66: ...rietas damaged 3 1 Fuel filter 1 Tainted Damaged fuel wash Replace the 2 a Turn fuel valve to OFF b Remove the filter cup wrench fuel 3 c Drain the fuel d Check the filter of the fuel cock Clean if dirty ReempláceloDañado e Install the filter bowl of the fuel cock 3 13 ...

Page 67: ...RNING Use only recommended brake fluid other fluids can cause damage brake in the rubber seals causing leaks and loss braking efficiency Refill with the same type Brake fluid that is already in the system the mixture of fluids can cause a chemical reaction harmful that would cause a malfunction brakes When refilling be careful not to get water in the master cylinder Significantly decreases water b...

Page 68: ...ain body 1 switch rear brake and turn the adjusting nut 2 in the direction a or b until the brake light lights at the right time U T U T 1 2 Direction a Brake light comes on before Direction b Brake light comes on later 2 Check Clamp the brake hose Loose Tighten the clamp 3 Support the vehicle and apply the brake front several times 4 Check Brake Hose Leaking brake fluid Replace See damaged hose F...

Page 69: ...id reservoir to the appropriate level with the brake fluid recommended Refer to CHECKING THE LEVEL BRAKE FLUID on page 3 14 WARNING After making the brake system purge hydraulic brake check function 2 Purge Hydraulic brake system a Fill the brake fluid reservoir to the appropriate level with the brake fluid recommended b Assemble the diaphragm tank brake master cylinder c Securely attach a plastic...

Page 70: ... swing must correspond to the same diameter outside of the washer 2 on both sides 1 2 b After adjusting tighten each adjustment nut Then tighten the axle nut to specified torque CHAIN LUBRICATION TRANSMISSION The transmission chain consists of many parts interact If the string transmission is not properly maintained will wear quickly Therefore their Maintenance should be done especially when the v...

Page 71: ...our vehicle to the center support so that the front wheel is elevated Do not overtighten the lower ring nut Lower ring nut torque final torque 22 Nm 2 2 m kg 16 ft lb 2 Check Steering column Hold the front fork legs and gently move the fork Dura flojaAjuste the column direction 3 Remove Upper yoke See COLUMN ADDRESS on page 4 43 4 Fit Steering column a Remove the lock washer 1 nut upper annular 2 ...

Page 72: ...orrected when the temperature of the rim is equal at room temperature The pressure should be in accordance with total weight including cargo driver passenger and accessories and speed driving Driving the vehicle may overload cause damage to tires loss of control or a serious accident NEVER OVERLOAD THE VEHICLE Air pressure of tires Measured on cold tires Front 200 kPa 28 psi 2 0 kgf cm Rear 225 kP...

Page 73: ...el MFR ZAPPER X Rear tire Size 140 60 R17M C 63P Manufacturer Model MFR ZAPPER revz The exterior of the damaged cable can cause corrosion in the cable and interfere with their movement Replace cables and outdoor inside damaged as soon as possible WARNING The new tires have a relatively grip under the tread to that wear slightly Therefore should flow about 100 km at a normal speed before driving at...

Page 74: ...points and moving parts metal metal of the lever Recommended lubricant Based grease lithium soap ADJUSTING THE REAR SHOCK The following procedure applies to the adjustment rear shock WARNING Support the vehicle with safety to there is no risk of falling CAUTION Adjuster rear shock YSST 821 Never go beyond the maximum or minimum adjustment positions 1 Fit Spring Preload a Turn the adjustment ring 1...

Page 75: ...lb dipped and main beam 1 Remove Side cover 1 4 Remove Lamp 1 lamp holder 2 1 2 5 Remove Lamp bulb cover 1 Lamp bulb holder 2 1 2 Disconnect Connect the turn signal indicator 1 from the end 1 2 1 6 Lamp bulb holder 2 Lamp bulb 1 1 3 Remove Screw the lamp 1 from the end Adjustment screw light 2 1 2 WARNING Since the lamp bulb may be extremely hot keep products flammable and hands away from the bulb...

Page 76: ...ing procedure applies to the bulb low beam and high beam 1 Remove Side covers See change bulb of the lamp on page 3 22 The connections of the signal indicating turn See change the bulb lamp on page 3 22 2 Remove Bulb auxiliary 1 as shown in illustration BEAM ADJUSTMENT OF FAROLA The following procedure applies to adjust the light beam of the lamp Loosen the screw and move the lamp the lamp in the ...

Page 77: ...REAR LIGHT 3 Remove Coupler taillight 1 Screws 2 from inside the mudguard 2 2 1 CHANGE INDICATOR LIGHT BULB DRAWING 1 Remove Screw 1 from the indicator light Lens 2 of light 2 Push the bulb 3 and gently turn counterclockwise 3 2 1 3 24 ...

Page 78: ...SSEMBLY OF THE FRONT BRAKE CALIPER ASSEMBLING THE FRONT BRAKE CALIPER REMOVING THE FRONT BRAKE MASTER CYLINDER CHECKING THE FRONT BRAKE MASTER CYLINDER ASSEMBLY FRONT BRAKE MASTER CYLINDER INSTALLING THE FRONT BRAKE MASTER CYLINDER REAR BRAKE CHECKING THE REAR BRAKE BANDS HOLDER ASSY REAR BRAKE BANDS LIMIT CHECKING BRAKE DRUM HANDLE REMOVING THE HANDLEBAR CHECK THE HANDLE HANDLEBAR ASSEMBLY FRONT ...

Page 79: ...MN COLUMN MOUNT DIRECTION N 4 43 4 45 4 45 4 45 REAR SHOCK REMOVING THE REAR SHOCK CHECKING THE REAR SHOCK REAR SHOCK MOUNTING SWING REMOVING THE ROCKER VERIFICATION OF OVERHEAD TILT MOUNT CHAIN CHECKING THE DRIVE CHAIN MOUNT CHAIN 4 47 4 48 4 48 4 48 4 49 4 51 4 51 4 51 4 53 4 54 4 55 ...

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

Page 81: ... lIb T R 5 Procedure Parts to remove Side Cover 1 2 Seat Fuel Tank Cap Fuel Tank Cap Side covers fuel tank LH RH Amount Observations Refer to GENERAL CHASSIS on page 4 1 1 2 1 NOTE Disconnect the fuel lines and fuel drain pipe before removing the fuel tank Upper Deck Fuel Tank 1 Fuel tank 1 For assembly reverse the procedure disassembly 4 2 ...

Page 82: ...m 0 2 m 6 2 Nm 0 2 m l l 2 1 T R 3 4 5 kg 1ft lIb T R 7 7 Nm 0 7 m l kg 5ft lIb Procedure Parts to remove Side covers Full Streetlight License plate Support the license plate Connecting the meter Meter Lamp holder T R Amount Observations 1 2 3 4 5 6 7 2 1 1 1 1 1 1 For assembly reverse the procedure disassembly Disconnect 4 3 ...

Page 83: ...Parts to remove Seat side cover 1 2 Amount 7 T 7 Nm 0 7 m l kg 5ft lIb Refer to GENERAL CHASSIS on page 4 1 R Observations 1 2 3 4 5 6 7 8 Filter Box Cover Filter housing cover Seals air filter Air filter Resonator Hose Clamp Air Filter Air Cleaner Hose Air filter box 1 1 2 1 1 1 1 1 For assembly reverse the procedure disassembly 4 4 ...

Page 84: ...GENERAL CHASSIS INSTALLING THE AIR FILTER HOUSING 1 Install Bracket air filter binding NOTE Align the projection a in the filter housing air slot b in the union of air filter to b 4 5 ...

Page 85: ...3 4 5 6 7 Sensor cable clamp speed Spindle nut of the front wheel Front wheel axle Front Wheel Speed sensor Spacer Brake disc T R 3 LT 1 7 Nm 0 7 m l kg 5ft lIb T R LS 60 Nm 6 0 m l kg 43 ft lIb T R 6 4 Procedure Parts to remove Amount Observations 1 1 1 1 1 1 1 For assembly reverse the procedure disassembly 4 6 ...

Page 86: ...NT WHEEL Disassembly of the front wheel 4 3 LS 2 New 1 Order Procedure Parts to remove Oil Seal Bearing Spacer Bearing Amount Observations 1 2 3 4 1 1 1 1 For assembly reverse the procedure disassembly 4 7 ...

Page 87: ... the wheel axle on a flat surface Replace warping WARNING Do not attempt to straighten a wheel axle a Clean the outside of the wheel hub front b Remove the oil seal 1 with a flathead screwdriver NOTE To avoid damaging the wheel place a cloth 2 between the screwdriver and the surface of the wheel 2 Check Rim delanteraRueda Damage wear Replace Refer to CHECKING TIRES on page 3 19 Refer to CHECKING W...

Page 88: ...il NewSeal 2 Check Brake delanteroDisco Refer to CHECKING THE DISCO FRONT BRAKE on page 4 19 3 Lubricate ruedaEje of Seal aceiteBordes velocidadBordes sensor Recommended lubricant Based grease lithium soap T R a Assemble the bearings and oil seal new in the reverse order of disassembly CAUTION 4 Assembly delanteraRueda NOTE Do not touch the inside track 1 or areas 2 of wheel bearings The contact u...

Page 89: ...ly 6 Assembly delanteraRueda NOTE Make sure the slot a enters the tube foreign and fits over the top b in the unit Speed sensor b to 7 Press ruedaEje of Wheel axle 60 Nm 6 0 m kg 43 ft lb WARNING Make sure the brake hose is properly guided CAUTION Before tightening the wheel axle nut push hard on the handlebar several times and check if the front fork bounces smoothly T R 4 10 ...

Page 90: ...FRONT WHEEL 4 11 ...

Page 91: ...0 14 8 9 LS Order Procedure Parts to remove Adjusting nut brake rod Brake rod Spring Pin Tension bar Nut Washer Rear wheel axle Washer Chain tensioner Spacer Spacer Rear Wheel Porta bands Amount Observations 1 1 2 3 4 5 1 1 1 1 6 7 8 9 10 11 12 13 14 1 1 1 1 2 1 1 1 1 For assembly reverse the procedure disassembly 4 12 ...

Page 92: ...rder Procedure Parts to remove Rear wheel sprocket Necklace Oil Seal Bearing Rear wheel hub Shock rear drive hub Bearing Spacer Oil Seal Amount Observations 1 2 3 4 5 6 7 8 9 1 1 1 1 1 4 2 1 1 For assembly reverse the procedure disassembly 4 13 ...

Page 93: ...vehicle on a suitable support so that the front wheel is lifted 2 Remove Adjusting nut brake rod 1 Brake rod 2 Spring 3 Pin 4 NOTE Press down the brake pedal to remove the pin from the brake rod 3 Remove Rear Wheel NOTE Push the rear wheel forward and remove the transmission chain wheel sprocket rear VERIFICATION REAR WHEEL 1 Check Wheel axle Rear Wheel Wheel bearings Oil Seals Refer to CHECKING F...

Page 94: ... page 3 14 T R Free pedal brake 15 0 20 0 mm REAR WHEEL ASSEMBLY DRUM 1 Lubricate Oil seal edges Recommended lubricant Based grease lithium soap 2 Assembly Rear sprocket Refer to CHECKING AND CHANGE GEAR OF THE REAR WHEEL on page 4 14 3 Lubricate Wheel axle Wheel bearings Recommended lubricant Based grease lithium soap 4 Fit Clearance of the drive chain Refer to ADJUSTING THE CLEARANCE CHAIN OF TR...

Page 95: ...s Order Procedure Parts to remove Bra brake hose Screw the front brake caliper Front brake callipers Brake Pad Clip Pin pads Front brake pads Spring brake pads Amount Observations 1 2 3 4 5 6 7 1 2 1 2 1 2 1 For assembly reverse the procedure disassembly 4 16 ...

Page 96: ...fer to BLEEDING THE SYSTEM HYDRAULIC BRAKE on page 3 15 1 2 3 4 5 6 7 8 9 Right mirror Lid of the brake master cylinder Diaphragm retainer cylinder reservoir Brake Master Diaphragm tank brake master cylinder Brake light switch Screw connection brake hose Copper washer Front brake hose Brake lever Clamp the front brake master cylinder Front brake master cylinder 1 1 1 1 1 1 2 1 1 1 1 For assembly r...

Page 97: ...nt brake master cylinder 2 4 1 5 3 7 6 Order Procedure Parts to remove Smock Pushrod Spring Pin lock Full Piston Spring Cylinder body Amount Observations 1 2 3 4 5 6 7 1 1 1 1 1 1 1 For assembly reverse the procedure disassembly 4 18 ...

Page 98: ...NT WHEEL on page 4 6 2 Check Brake disc Damaged Replace scratched 3 Measure Deformation of the brake disc Out of specification Correct deformation Brake disc or replace the brake disc a Place the vehicle on a suitable support so that the front wheel is lifted b Before measuring the deformation of the disc front brake turn the handlebars to the left or right to ensure that the wheel front is fixed ...

Page 99: ...fingers c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg 4 3 ft lb T When replacing the brake pads is not disconnect the brake hose or disassemble the brake caliper d Assemble the brake pads and springs new brake pads 3 Check Brake fluid level Below the level mark minimum on add brake fluid recommended to the proper level Refer to CHECKING BRAKE FLUID LEVEL on page 3 14 Max Min R 1 Measure Desg...

Page 100: ...als piston caliper 2 Dust Seals Caliper 3 1 2 3 1 2 a Apply compressed air through the opening a the union of the brake hose to force the output of the pistons of the brake caliper WARNING 1 Check Piston brake caliper 1 Roughness scratches wear Replace the pistons of the brake caliper Cylinders of the brake caliper 2 Scratches wear Replace the gripper Brake Body of the caliper 3 Cracks damage Repl...

Page 101: ... BRAKE PADS 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 2 Disassembly Caliper 1 Use only recommended brake fluid other fluids can cause damage brake in the rubber seals causing leaks and loss braking efficiency Refill with the same type of brake fluid and is in the system the fluid mixture can cau...

Page 102: ... 2 Check Kit brake master cylinder Damage scratches wear Replace 3 Check Deposit brake master cylinder Damage scratches wear Replace Diaphragm brake master cylinder Damage wear Replace 4 Check Brake Hose Cracks damage wear Replace MASTER CYLINDER ASSEMBLY FRONT BRAKE WARNING Before assembly all components internal brake must be cleaned and lubricated with a cleaner or new brake fluid Never use sol...

Page 103: ...ntly decreases the point boiling of the fluid and may cause in vapor CAUTION A correct guidance is essential for safe vehicle operation NOTE Brake hose assembly to the front the master cylinder at the angle shown in Figure While holding the brake hose tighten the connecting screw of the brake hose as shown Turn the handlebar to the left and right to ensure that the brake hose does not touch other ...

Page 104: ...FRONT BRAKE See PURGING SYSTEM HYDRAULIC BRAKE on page 3 15 4 25 ...

Page 105: ... 3 m lkg 31 ft lIb Order Procedure Parts to remove LS Amount Observations Porta full bands Refer to REAR WHEEL on page 4 12 1 2 3 4 5 6 Brake bands Spring full bands Lever brake camshaft Wear indicator brake bands Brake camshaft Plate holder strips 2 2 1 1 1 1 For assembly reverse the procedure disassembly 4 26 ...

Page 106: ... the scratches with emery cloth 5 Check Brake camshaft Damage wear Replace HOLDER ASSY BANDS REAR BRAKE 1 Assembly Tree Brake cam 1 Indicator wear of the brake band 2 Lever the brake camshaft 3 Screw shaft lever Brake cam 10 Nm 1 0 m kg 7 2 ft lb WARNING T R Do not allow oil or grease gets on contact with the brake bands NOTE a Assemble the brake camshaft so that its punch mark a remains as shown ...

Page 107: ...prings during assembly Install the spring brake bands as shown WARNING After joining new brake bands the inner diameter of the brake drum can check is within the wear limit a through the wear indicator on the slide brake bands to Do not apply grease to the lining of the brake bands 1 Check Position where the lever must be installed the brake camshaft the brake camshaft Reinstall the cam lever brak...

Page 108: ...dal to down to the end push the lever brake camshaft completely the direction of the arrow and check the wear indicator strips does not reach the brake wear indicator of the brake drum Not enough can still be used Reach Replace the wheel 4 29 ...

Page 109: ...arts to remove Amount Observations 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Rearview mirror Plug the handlebar Right handlebar switch Throttle cable Throttle grip Switch front brake light Clamp the front brake master cylinder Front brake master cylinder Clutch cable Coupling clutch switch Starter cable Left handlebar switch Handlebar grip Clutch lever 2 2 1 1 1 1 1 1 1 1 1 1 1 1 Disconnect 4 30 ...

Page 110: ... Ib LS T R 1 2 5 LS LS T R 7 16 3 1 10 13 17 8 6 4 9 15 12 January 141 LS 2 7 Nm 0 7 m kg 5ft Ib T R Order Procedure Parts to remove Amount Observations 15 16 17 Support of the clutch Handlebar top clamp Handlebar 1 2 1 For assembly reverse the procedure disassembly 4 31 ...

Page 111: ...st tighten the screws on the front of the handlebar clamp and then the rear Turn the handlebars to the left and right If no contact fuel tank to adjust the position of the handlebar NOTE T R 3 Remove Handlebar grip 1 NOTE Align the marks a of the handlebar with the upper surface of the clamp bracket the handlebar Blow compressed air between the left handlebar and the handlebar grip and gradually p...

Page 112: ...aster cylinder See the BRAKE FRONT on page 4 23 8 Assembly l Throttle grip 1 The throttle cable 2 The right handlebar switch 3 Plug the handlebar NOTE Lubricate the throttle cable end and Inside the throttle grip with a thin layer of soap based grease lithium and then install the handlebar grip Guide the throttle cable through the slot on the right handlebar switch then install the cable Align the...

Page 113: ...of clutch cable See SETTING THE GAME CLUTCH CABLE FREE on page 3 10 Free play of the lever clutch 10 0 15 0 mm 10 Fit Set throttle cable free See SETTING THE GAME THROTTLE CABLE FREE in page 3 6 Cable free play accelerator 3 0 5 0 mm 4 34 ...

Page 114: ...0 6 m kg 4ft Ib T R Order Procedure Parts to remove Amount Observations Front Wheel The following procedure applies to both front fork legs Refer to REAR WHEEL in page 4 6 1 2 3 4 Front fender Screw top bracket Screw bottom bracket Front fork bars 1 1 1 1 For assembly reverse the procedure disassembly Loosen Loosen 4 35 ...

Page 115: ...rts to remove Amount Observations The following procedure applies to both front fork legs 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Screw cap O ring Spacer Washer The fork spring Smock Oil Seal Clip Screw the damper rod Copper washer Damper rod Oil flow obturator Tube Oil Seal Oil Seal Washer 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 36 ...

Page 116: ...RK Disassembly of the front fork legs New 1 2 3 12 4 New 7 13 New 14 New 6 5 10 15 11 9 8 Order Procedure Parts to remove Amount Observations 15 Outer tube 1 For assembly reverse the procedure disassembly 4 37 ...

Page 117: ...screws upper and lower rods hold the front fork NOTE To facilitate removal of stop screws first loosen the screw on top then loosen the cap slightly without loosening the bottom bracket screw while the fork front is installed in the vehicle 3 Remove Dust 1 Oil seal clip 2 With a flathead screwdriver CAUTION Do not scratch the inner tube 1 1 2 4 Remove Screw rod of the damper 1 Damper rod 2 3 Remov...

Page 118: ...ing procedure applies to both Front fork bars WARNING Make sure the oil levels in both front fork legs are equal Different levels of oil can be in little loss of maneuverability and stability NOTE Do not attempt to straighten a bent inner tube as dangerously weaken 2 Measure Spring free length a Replace out of specification Free length of spring 254 4 mm During assembly of the fork legs front be s...

Page 119: ...ng outer tube 1 New Washer 2 With the Seal assembly tool of Front fork oil Seal assembly tool of the front fork oil YSST 875 5 Assembly Oil Seal 1 New Assembly tool oil seal Front fork 2 T New R Before installing the oil seal lubricate edges based grease lithium soap Lubricate the outer surface of inner tube oil suspension Before installing the oil seal cover the top of the front fork leg with a p...

Page 120: ...ompressed without fork spring Correct out of specification Level 87 0 mm Recommended Oil Oil 10W or suspension equivalent Number 459 cm3 CAUTION Be sure to use oil suspension recommended Other oils may have an adverse effect on the performance of the front fork When disassembling and assembling the bars front fork not perrmita that foreign materials from entering the fork front 12 Assembly Rfork e...

Page 121: ...e fork front lubricate the O ring grease ASSEMBLY OF THE BARS FRONT FORK The following procedure applies to both Front fork bars 2 1 Assembly Delanter fork legs Temporarily tighten the screws upper and lower supports 2 Press Screw top bracket 1 Screw the top bracket 25 Nm 2 5 m kg 18 ft lb 1 Screw bottom bracket 2 Screw bottom bracket 25 Nm 2 5 m kg 18 ft lb NOTE To give the proper torque to the s...

Page 122: ...g 16 ft lb Observations Order T R Full Streetlight Front fork bars T R T R Procedure Parts to remove Amount Refer to section GENERAL CHASSIS on page 4 1 Refer to FRONT FORK on page 4 40 1 2 3 4 5 6 7 8 9 10 11 Screw of the steering column Upper Bracket Lockwasher Upper ring nut Rubber washer Lower ring nut Bottom Bracket Bearing cover Upper bearing inner race Upper bearing Lower bearing Upper bear...

Page 123: ...15 12 7 T R 2 3 4 5 6 8 9 10 7 Nm 0 7 m kg 5ft lb 22 Nm 2 2 m kg 16 ft lb 1st 33 Nm 3 3 m kg 24 ft lb 2nd 22 Nm 2 2 m kg 16 ft lb Order 13 14 15 T R Lower bearing outer race Lower bearing inner race Smock T R T R Procedure Parts to remove Amount Observations 1 1 1 For assembly reverse the procedure disassembly 4 44 ...

Page 124: ...ways replace bearings and tracks Bearing as a whole Each time you remove the column 1dirección replace the dust WARNING Secure the bottom bracket securely so there is no risk of falling 2 1 CHECKING THE COLUMN ADDRESS 1 Wash Bearings Bearing races Solvent for cleaning recommended Kerosene 4 Check Upper Bracket Bottom Bracket Together with the stem of the address Curves cracks damage Replace FITTIN...

Page 125: ...MN on page 3 18 3 Assemble Upper Bracket Nut of the steering column 4 Assemble Front fork bars See section FORK FRONT on page 4 35 NOTE Temporarily tighten the mounting bolts top and bottom 5 Press Nut of the steering column Nut of the steering column 110 Nm 11 0 m kg 80 ft lb T R 4 46 ...

Page 126: ... 29 ft lb Amount Observations T R Order Procedure Parts to remove Seat side covers 1 2 mud guard Refer to GENERAL CHASSIS on page 4 1 1 2 3 4 5 6 Nut bolt rear upper shock Washer Nut bolt Rear shock absorber lower Washer Spacer Rear Shock 1 1 1 1 1 1 1 1 For assembly reverse the procedure disassembly 4 47 ...

Page 127: ...od Deformation damage Replace rear shock Rear shock Replace oil leaks rear shock Spring Damage wear Replace the rear shock Hubs Damage wear Replace the rear shock Screws Curves damage wear Replace REAR SHOCK MOUNTING 1 Assembly Rear Shock 2 Press Rear shock absorber top nut Upper shock nut back 40 Nm 4 0 m kg 29 ft lb Rear shock absorber lower nut Lower shock nut back 60 Nm 6 0 m kg 43 ft lb 3 Fit...

Page 128: ...R Order Procedure Parts to remove Amount Rear Wheel Rear Shock Rear fender See SHOCK BACK on page 5 1 Refer to REAR WHEEL in page 4 12 1 2 3 4 5 6 7 8 9 10 Pivot axle nut Pivot axis Support of the right footrest Left footrest support Seal of the guard Tilt Oil Seal Dust Cover Bushing Bearing 1 1 1 1 1 1 2 2 2 2 For assembly reverse the procedure disassembly 4 49 ...

Page 129: ...m 6 0 m kg 43 ft lb 10 Nm 1 0 m T R kg 7 ft lb T R 1 3 5 4 10 Nm 1 0 m kg 7 ft lb T 2 R 30 Nm 3 0 m kg 22 ft lb Observations T R Order Procedure Parts to remove Amount 11 Bearing 2 For assembly reverse the procedure disassembly 4 50 ...

Page 130: ... Spacers Bearings Solvent for cleaning recommended Kerosene b Measure the rocker side a moving the swing from side to side c If you look at the swingarm side play check the spacers bearings and overall VERIFICATION OF OVERHEAD 1 Check Tilt Curves damage wear Replace 2 Check Pivot axis Rotating the pivot shaft in a flat surface Replace curves T R 4 Check Dust Spacers Oil Seals Damage wear Replace B...

Page 131: ... B Right side to 4 Assembly Rear Shock Tension bar Rear Wheel Refer to SHOCK BACK on page 4 47 and WHEEL BACK on page 4 12 5 Fit backlash of the drive chain See section CLEARANCE CHAIN on page 3 16 Chain slack transmission 30 40 mm 4 52 ...

Page 132: ...Nm 1 0 m T R Order Procedure Parts to remove Amount Rear Wheel Footrest bracket right bracket left footrest Rear fender Refer to REAR WHEEL on page 4 12 See TILT on page 4 49 1 2 3 4 Chain cover Retaining the drive sprocket Gear Transmission chain 1 1 1 1 For assembly reverse the procedure disassembly 4 53 ...

Page 133: ...ength c of section 15 links of the drive chain using the following formula c length A between the inner faces of the rollers Length b between the outer faces of the rolls 2 NOTE 4 Check roller chain transmission 1 Damage wear Replace chain transmission Side plates of the chain of transmission 2 Damage wear Replace chain transmission Cracks Replace the drive chain When measuring the segment links 1...

Page 134: ... sprocket 10 Nm 1 0 m kg 7 2 ft lb 3 Assemble Tilt See TILT on page 4 49 Rear wheel Refer to REAR WHEEL in page 4 12 4 Fit Clearance of the drive chain See CLEARANCE CHAIN on page 3 16 Chain slack transmission 30 40 mm CAUTION A chain tensioned excessively overloaded engine and other vital parts and chain You can get loose and damage the swingarm or cause an accident Therefore keep the tension of ...

Page 135: ...CKING THE VALVES AND VALVE GU IAS CHECKING THE VALVE SEATS CHECKING THE VALVE SPRINGS VALVE ASSEMBLY CYLINDER AND PISTON REMOVING THE PISTON INSPECTION OF CYLINDER AND PISTON D CHECKING THE PISTON RINGS PISTON WRIST PIN INSPECTION ASSEMBLY PISTON AND CYLINDER STARTING AND MAGNETO GEAR MAGNET REMOVAL ARR GEAR REMOVAL ANQUE STARTING GEAR INSPECTION STARTING GEAR ASSEMBLY MOUNT MAGNET ELECTRIC START ...

Page 136: ...E LEVER POSITION INSTALLING THE SHIFT SHAFT PINION BALANCER PRIMARY DRIVE GEAR REMOVAL AND SPROCKETS THE BALANCER PRIMARY DRIVE GEAR INSPECTION AND SPROCKETS THE BALANCER ASSEMBLY OF THE BALANCER DRIVEN GEAR PRIMARY DRIVE GEAR REMOVAL AND SPROCKETS THE BALANCER ENCLOSURE SEPARATION OF COVERS INSPECTION COVERS INSPECTION AND CHAIN GUIDE TO THE SUPPLY CHAIN CHECKING THE OIL STRAINER INSPECTION OF BE...

Page 137: ...N CRANKSHAFT ASSEMBLY TRANSMISSION CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM INSPECTION OF TRANSMISSION FITTING THE PUSH RODS MAIN SHAFT ASSEMBLY AND DRIVE AXLE ASSEMBLY OF FORKS AND CHANGE DRUM 5 58 5 59 5 59 5 59 5 61 5 64 5 64 5 64 5 65 5 65 5 65 ...

Page 138: ... Nm 1 2 m kg 9 ft Ib T Order R 4 3 15 Nm 1 5 m kg 11 ft Ib 20 Nm 2 0 m kg 14 ft Ib Observations T R T R Procedure Parts to remove Amount 1 2 3 4 Air Duct Air guide Silencer Gasket exhaust pipe 2 1 1 1 For assembly reverse the procedure disassembly 5 1 ...

Page 139: ...CHECKING AND CHARGING BATTERY on page 7 34 Drain See OIL CHANGE MOTOR on page 3 9 See TANK FUEL on page 4 2 Engine Oil 1 2 3 4 5 6 7 8 9 10 Fuel tank Spark plug cap Starter Cable Throttle cable TPS Connector stator coils connector Crankshaft Sensor Neutral switch connector Clutch cable Negative battery cable Changes arm 1 1 1 1 1 1 1 1 1 1 1 Disconnect Disconnect Disconnect Disconnect Disconnect D...

Page 140: ...s to remove Silencer Fuel tank Refer to REMOVAL MOTOR on page 5 1 Refer to GENERAL CHASSIS on page 4 2 1 2 3 4 5 Screw nut assembly of the motor Front Side Screw nut assembly of the motor Bottom side rear Screw nut assembly of the motor Top side rear Screw nut assembly of the motor Upper side Engine 4 4 1 1 1 1 3 3 1 For assembly reverse the procedure disassembly 5 3 ...

Page 141: ...rm changes 1 Screw the arm of the changes 10 Nm 1 0 m kg 7 2 ft lb T R Do not completely tighten the screws and nuts 1 3 4 1 2 5 2 Press Motor mounting nut upper side Engine Mounting Nut Top side rear 30 Nm 3 0 m kg 22 ft lb Motor mounting nut Bottom side rear Engine Mounting Nut Bottom side rear 55 Nm 5 5 m kg 40 ft lb Nut Engine Mounting Front Side Engine Mounting Nut Front Side 55 Nm 5 5 m kg 4...

Page 142: ...1 M E 12 13 14 4 LS 15 14 7 Nm 7 0 m kg 5 ft Ib Procedure Parts to remove Amount Observations R 10 Nm 1 7 m kg 7 ft Ib T R 3 Seat cap 1 cap 2 Fuel tank Throttle cable starter cable clutch cable Carburetor intake manifold Silencer Refer to GENERAL CHASSIS on page 4 1 Disconnect Refer to REMOVAL MOTOR on page 5 2 Refer to CARBURETOR in the page 6 1 Refer to REMOVAL MOTOR on page 5 1 Disconnect 1 2 3...

Page 143: ...rts to remove Amount Observations T 10 Nm 1 7 m kg 7 ft Ib T R 3 Order R 4 5 6 7 8 9 10 11 12 13 14 15 Access screw end of the crankshaft Cylinder head cover Packing the cylinder head cover Dowel pin Tensor of the distribution chain Tensor packaging supply chain Camshaft sprocket Decompression cam Head Head gasket Dowel pin Guide the distribution chain side exhaust 1 1 1 1 1 1 1 1 1 1 2 1 For asse...

Page 144: ...ent the falling timing chain into the crankcase hold it with a cable b 4 Remove Stock NOTE to Loosen the screws in the correct sequence as shown Loosen each bolt 1 2 turn each time After all screws are fully loose remove them 2 2 d 6 4 c 3 1 5 d INSPECTION OF THE HEAD 1 Delete Carbon deposits from the chamber combustion with a scraper round NOTE c Do not use sharp instruments to prevent damage or ...

Page 145: ...the hand NOTE While pressing the rod chain tensioner distribution turn to the right with a thin screwdriver 1 until it stops b Measure the deformation c If the limit is exceeded correct butt as follows d Place a wet 400 600 sandpaper on surface plate and adjust the head with a sanding pattern in a figure eight NOTE 1 To ensure a level surface turn the cylinder several times INSPECTION OF GEAR TREE...

Page 146: ...ify that the decompression cam is not projects from the camshaft cams Exhaust as shown in Figure B HEAD ASSEMBLY 1 Assembly Stock NOTE Pass the chain through the cavity of the chain 1 2 Press Head bolts 1 Cylinder head bolts 22 Nm 2 2 m kg 16 ft lb Head bolts 2 Cylinder head bolts 10 Nm 1 0 m kg 7 2 ft lb NOTE A 2 Lubricate the threads of the cylinder head bolts with engine oil Tighten the cylinde...

Page 147: ... the butt Outside the correct alignment See the previous assembly steps When installing the camshaft sprocket make sure to maintain the chain on the side Exhaust so tensioned as possible CAUTION Do not rotate the crankshaft when installing the tree Cam to prevent damage or performance Improper valve e While holding the camshaft tighten temporarily screw shaft pinion Camshaft f Remove the cable fro...

Page 148: ... 14 ft lb PRCAUCIÓN Be sure to tighten the screw on the pinion camshaft to the specified torque avoid the possibility that the screw is loosened and damaging the motor 8 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 3 T R 5 11 ...

Page 149: ...5 ft Ib R T R 7 2 M 6 3 1 13 Nm 1 3 m kg 9 ft Ib T R 1 2 M 5 E 4 E M Order Procedure Parts to remove Amount Observations Head See the HEAD on page 5 5 1 2 3 4 5 6 7 Locknut Adjusting screw Retainer camshaft bearing Camshaft Rocker Intake rocker Exhaust rocker 2 2 1 1 2 1 1 For assembly reverse the procedure disassembly 5 12 ...

Page 150: ...ew 2 on the threaded end of camshaft and then remove the camshaft Escape B 25096 25196 mm Limit 25 066 mm b 1 2 to CAMSHAFT INSPECTION 1 Check Camshaft lobes Blue discoloration pitting Replace scratched the camshaft 2 Measure Dimension of the lobes Camshaft A and b Out of specification Replace camshaft 3 Check passage of the camshaft oil Blow compressed air obstructed CHECKING THE ROCKER AND AXLES...

Page 151: ...ockers Rocker shafts Recommended lubricant Inner surface of the rocker Molybdenum disulfide oil Rocker arm shaft Motor oil 2 Lubricate Camshaft Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearings Motor oil 4 Measure Outer diameter of the beam A Replace out of specification Outer diameter of the beam 9966 9976 mm Limit 9 950 mm 3 Install Intake and exhaust rocker Rocker shaft ...

Page 152: ... Procedure Parts to remove Amount Observations Head Rocker Camshaft See the HEAD on page 5 5 Refer to CAMSHAFT in page 5 12 1 2 3 4 5 6 7 8 Valve Pin Upper spring seat valve Valve spring Intake valve Exhaust valve Seal valve stem Lower spring seat valve Valve guide 4 2 2 1 1 2 2 2 For assembly reverse the procedure disassembly 5 15 ...

Page 153: ... VALVE GUIDES The following procedure applies to all valves and valve guides 1 Measure clearance between the valve stem and the Valve guides Out of specification Replace the stock clearance between the valve stem and the Valve guides Inner diameter valve guide a shank diameter Valve b Clearance between the stem valve and the valve guide Admission 0010 0037 mm Limit 0 080 mm Clearance between the s...

Page 154: ...nd valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure width valve seat C a Replace out of specification stock Width of the valve seat C Admission 0 90 1 10 mm Width of the valve seat C Escape 0 90 1 10 mm 5 Measure Deformation of the valve stem Out of specification valve Replace the NOTE a Instale the valve in the cylinder head When installing a new valve always replace...

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

Page 156: ...ssion 160 184 Compression strength installed Spring Escape 160 184 Installed length Admission 34 50 mm Installed length Escape 34 50 mm VALVE ASSEMBLY The following procedure applies to all valves and related components 1 Remove burrs End of the valve stem With a stone oil 2 Lubricate Valve stem 1 Stem seal valve 2 New With the recommended lubricant With the recommended lubricant Molybdenum disulf...

Page 157: ... To secure the valve pin in the valve stem lightly tap the tip of the valve with a hammer in the face soft CAUTION Hitting the valve tip with a force Excessive damage the valve b Short end 4 Install Valve pin 1 NOTE Install the valve pin compressing the valve spring with the spring compressor valve and the adapter compressor Valve spring 2 Valve spring compressor YSST 603 Spring compressor adapter...

Page 158: ...ew 4 1 E E 4New E 2New 3 3 Order Procedure Parts to remove Amount Observations Head See the HEAD on page 5 5 1 2 3 4 5 6 7 8 9 Cylinder Cylinder gasket Dowel pin Piston pin Piston pin Piston Top Ring Second ring Oil ring 1 1 2 2 1 1 1 1 1 For assembly reverse the procedure disassembly 5 21 ...

Page 159: ...ON OF CYLINDER AND PISTON 1 Check Wall of the piston Cylinder wall Replace cylinder vertical scratches piston and piston rings as a whole 2 Measure Piston cylinder clearance 2 1 a As the cylinder diameter C with the cylinder with the meter diameter drum 3 2 Remove Top Ring Second ring Oil ring NOTE Measure cylinder bore C verifying measures side by side and forward measures rearwardly of the cylin...

Page 160: ... piston and rings Piston ring 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 piston Piston Diameter D 53970 53985 mm d If out of specification replace the piston and piston rings as a whole e Calculate the piston cylinder clearance with the following formula Piston cylinder clearance Diameter...

Page 161: ...ween centers of ring Installed 0 20 to 0 70 mm CHECKING THE PISTON PIN 1 Check Piston pin Blue discoloration grooves Replace piston pin and then check the system Lubrication 2 Measure Outside diameter of piston pin a Out of specification Replace piston pin Pin Outside Diameter piston 14995 15000 mm Limit 14 975 mm 4 Calculate Clearance piston pin bore the piston pin hole EspecificaciónReemplace ou...

Page 162: ...from falling into the crankcase Top Ring Oil ring expander Oil ring upper guide Lower guide ring oil Second ring Exhaust side 5 Install Pin plug Cylinder Head Gasket New Cylinder 1 NOTE 1 to 2 While compressing piston rings one hand install the cylinder with the other hand Pass the timing chain and guide distribution chain intake side to through the cavity of the chain 3New 3 Lubricate Piston Pist...

Page 163: ... Nm 1 0 m l kg 7ft Ib l T R Procedure Parts to remove R Amount Observations Motor oil Cover drive chain 1 2 3 4 5 6 7 8 9 10 11 Connector on the stator coil Connector crankshaft position sensor Cable connector Neutral switch Screw access to mark time Access screw end of the crankshaft Magneto cover Gasket magneto cover Dowel pin Crankshaft position sensor Stator coil Magneto Rotor 1 1 1 1 1 1 1 2 ...

Page 164: ... Nm 1 4 m l T New kg 10 ft lb l 5 New LS Order R E T 20 11 l 70 Nm 7 0 m kg 51 ft lb l 10 Nm 1 0 m l kg 7ft Ib l T R Procedure Parts to remove R Amount Observations 12 13 14 15 16 17 18 19 20 Woodruff key Starter clutch sprocket Bearing Washer Axis of the freewheel clutch starter Washer Pin lock Freewheel clutch starter Starter clutch 1 1 1 1 1 1 1 1 1 For assembly reverse the procedure disassembl...

Page 165: ...the screws starter clutch 1 1 Magnet holder YSST 601B 2 Remove Magnet rotor 1 With the extractor magnet 2 Woodruff key CAUTION To protect the end of the crankshaft place a key of suitable size between the extractor magnet and the crankshaft NOTE CHECKING THE STARTER CLUTCH 1 Check The starter clutch rollers 1 Covers engine clutch spring boot 2 Spring clutch motor start 3 Damage wear Replace the cl...

Page 166: ...arter clutch and the starter clutch gear must be engage otherwise the starter clutch is defective and must be replaced c By turning the starter clutch gear counter clockwise B should turn freely otherwise the starter clutch is faulty and must be replaced to to to A 1 B MOUNTING MAGNETO 1 Install woodruff key Rotor magnet rotor Washer magneto rotor nut NOTE Clean the tapered crankshaft and the axis...

Page 167: ...6 8 1 4 9 3 2 10 2 3 Apply Sealant In the crankshaft position sensor in eyelet for mounting the stator wire Yamaha Adhesive No 1215 TG 1215 LS 4 Install Cover the magnet Magneto cover screw 10 Nm 1 0 m kg 7 2 ft lb NOTE Tighten the screws on the magneto cover proper tightening sequence as shown T R 5 30 ...

Page 168: ...T Removing the starter motor 2 Nm 0 2 m kg 1ft Ib 10 Nm 1 0 m T R kg 7ft Ib T R 2 2 1 Order Procedure Parts to remove Amount Observations 1 2 Starter Starter Cable 1 1 Disconnect For assembly reverse the procedure disassembly 5 31 ...

Page 169: ...arts to remove Amount Observations 1 2 3 4 5 6 7 8 9 10 11 Starter Cover Gasket Set of carbon brushes Support for carbon brushes Oil Seal Pin lock Stop washer Washer Bearing Front cover of the starter Starter 1 1 1 1 1 1 1 1 1 1 1 For assembly reverse the procedure disassembly 5 32 ...

Page 170: ...rmature with multimeter Multimeter to STARTER INSPECTION 1 Check Switch Dirty Clean with 600 grit 2 Measure Switch diameter a Out of specification Replace starter Limit 17 6 mm Armature coil Resistance of the switch 1 Ù 0 0315 to 0 0385 at 20 C 68 F b If the resistance is out of specification Replace the starter to 3 Measure Mica recess a Recess specification outside the mica appropriate measure w...

Page 171: ...k Bearing Oil Seal Damage wear Replace the cover starter frontal group brush holder STARTER ASSEMBLY 1 Install Front cover of the starter brush support assembly 1 Cover starter 2 NOTE Align the marks a in the hood starter and engine front cover start support assembly 1 2 to 5 34 ...

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

Page 173: ... 7 8 9 7 13 14 E Procedure Parts to remove Amount Observations Locknut Clutch spring Pressure Plate Short rod Clutch thrust Holder of the clutch pushrod Ball Friction disc 1 Clutch disc Friction Disc 2 Nut disc holder Lockwasher Disc holder Thrust Washer Clutch Conical spring washer 1 4 1 1 1 1 2 3 2 1 1 1 1 1 1 For assembly reverse the procedure disassembly 5 36 ...

Page 174: ...E LS 4New 5 Order Procedure Parts to remove Amount Observations Clutch 1 2 3 4 5 Refer to CLUTCH on page 5 35 1 1 1 1 1 Push the clutch lever Spring clutch push lever Pin lock Oil Seal Bearing For assembly reverse the procedure disassembly 5 37 ...

Page 175: ...ecification Replace friction discs as a whole NOTE X The space between the coating material friction in the friction disc 1 Y The space between the coating material friction in the friction disc 2 NOTE The space X must be less than the space Y Friction disk 1 and the friction disc 2 respectively INSPECTION OF CLUTCH DISCS The following procedure applies to all clutch discs 1 Check Clutch disc Dama...

Page 176: ...tside the clutch springs as a whole Free length of the springs clutch 41 60 mm Minimum length 40 60 mm Pitting in the lace of the disc holder will cause erratic clutch operation clutch INSPECTION OF PRESSURE PLATE 1 Check Pressure Plate Cracks damage Replace the plate pressure INSPECTION OF GEAR DRIVE PRIMARY 1 Check Pressure Plate Cracks damage Replace the plate pressure INSPECTION OF GEAR DRIVE ...

Page 177: ...s thrust washer a is placed opposite the clutch disc carrier 1 to 3 Install Clutch cutterbar 1 Lock washer 2 New Nut caddy NOTE 1 Lubricate the threads of the nut caddy clutch and the contacting surfaces of lock washer with motor oil Align the notch a in the washer security with a lower rib b in the Clutch cutterbar New 2 b CLUTCH ASSEMBLY 1 Install Conical spring washer 1 NOTE 1 to 4 Press Clutch...

Page 178: ...utch and spring damper clutch as shown in the illustration First install a friction disc and then switch between a clutch plate and a friction disc 12 b If the projection a is not aligned with the brand name b align follows Loosen the lock nut 2 With the push lever clutch completely pushed in the direction c rotate the push rod clutch short 3 inward or outward until the projection a is aligned wit...

Page 179: ... cover Clutch cover screw 10 Nm 1 0 m kg 7 2 ft lb NOTE Tighten the the cover screws clutch in proper tightening sequence as shown 1 9 8 10 11 7 6 12 T R 13 5 4 3 15 2 14 13 Fit Set the clutch cable free Refer to ADJUSTING THE GAME CLUTCH CABLE FREE on page 3 10 5 42 ...

Page 180: ... 1 0 m kg 7ft Ib T 10 Nm 1 0 m kg 7ft Ib Observations Clutch Primary drive gear pinion balancer T R R Procedure Parts to remove Amount Refer to CLUTCH on page 5 35 See PINION BALANCER on page 5 49 1 2 3 Oil baffle plate Oil pump Primary drive gear oil pump 1 1 1 For assembly reverse the procedure disassembly 5 43 ...

Page 181: ...r Procedure Parts to remove Amount Observations 1 2 3 4 5 6 Housing cover of the oil pump Pin Primary driven gear oil pump Internal rotor of the oil pump External rotor oil pump Pump housing oil 1 1 1 1 1 1 For assembly reverse the procedure disassembly 5 44 ...

Page 182: ... and the housing of the oil pump 0 13 to 0 19 mm Limit 0 15 mm Clearance between the casing oil pump and rotors internal and external 0 06 to 0 11 mm Limit 0 15 mm 3 Check Running the pump Repeat steps roughly Movement 1 and 2 or replace the defective parts ASSEMBLING THE OIL PUMP 1 Lubricate Internal rotor of the oil pump External rotor oil pump Primary driven gear pump oil With the recommended l...

Page 183: ...ating the oil pump See INSPECTION OIL PUMP on page 5 45 ASSEMBLING THE OIL PUMP 1 Install Oil pump Screw oil bulges 4 Nm 0 4 m kg 2 4 ft lb CAUTION After tightening the screws make sure that the oil pump rotates smoothly T R 5 46 ...

Page 184: ...3 LT 4 5 1 9 Nm 0 9 m kg 7ft Ib T R Order Procedure Parts to remove Amount Observations Clutch Shift arm Refer to CLUTCH on page 5 35 1 2 3 4 5 6 Axis changes Pin lock Shift shaft spring Lever cap Stop lever spring Oil Seal 1 1 1 1 1 1 For assembly reverse the procedure disassembly 5 47 ...

Page 185: ...the top of the lever Stop lever spring Damage wear Replace ASSEMBLY SHAFT CHANGES 1 Install Top of the lever 1 Spring stop lever 2 NOTE Hook the ends of the spring cap the lowest position of the lever and the protrusion of the cover 3 Engage the top of the lever with the segment drum changes 3 2 2 Install Axis of change 1 NOTE 1 Hook the end of the shaft spring on the spring changes the top of the...

Page 186: ... 4 5 m kg 33 ft Ib Observations Amount T R Clutch Refer to CLUTCH on page 5 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Primary drive gear nut Nut balancer drive gear Washer Primary drive gear Primary drive gear Balancer Straight key Lockwasher Plate 1 balancer driven gear Balancer driven gear Cup top Spring Dowel pin Straight key Plate 2 of the balancer driven gear 1 1 1 1 1 1 1 1 1 1 4 2 1 1 5 49 ...

Page 187: ...d balancer primary drive gear 6 5 13 4 3 1 60 Nm 6 0 m kg 43 ft Ib E 15 10 14 9 12 11 45 Nm 4 5 m kg 33 ft lb T R 8 T Order 15 R 7New 2 Procedure Parts to remove Amount Observations Spacer 1 For assembly reverse the procedure disassembly 5 50 ...

Page 188: ...on the gear primary driven balancer Align the punch mark a in the glass ceiling with the punch mark b in the gear primary driven balancer 2 to 1 1 3 INSPECTION PINION GEARS THE BALANCER AND GEAR PRIMARY DRIVER 1 Check Primary drive gear Balancer Primary driven gear Balancer Cup top Spring Dowel pin Cracks damage wear Replace 2 Check Primary drive gear See INSPECTION PRIMARY DRIVE GEAR In page 5 39...

Page 189: ...t lb Primary drive gear 60 Nm 6 0 m kg 43 ft lb NOTE Place an aluminum plate a between the primary drive gear Balancer 3 and the primary driven gear Balancer 4 and then tighten the nut on the gear primary driven balancer Place an aluminum plate b between the primary drive gear Balancer 3 and the primary driven gear Balancer 4 and then tighten the nut on the gear primary driven balancer 3 4 T R 1 t...

Page 190: ... Oil pump Axis changes Electric Start Balancer sprockets Magneto See the HEAD on page 5 5 Refer to CYLINDER AND PISTON on page 5 21 Refer to CLUTCH on page 5 35 Refer to OIL PUMP on page 5 43 Refer to SHIFT SHAFT on page 5 47 See ELECTRIC START on page 5 31 See PINION BALANCER on page 5 49 See MAGNETO AND CLUTCH THE START on page 5 26 1 2 3 4 Guide the distribution chain side inlet Chain cover Sup...

Page 191: ... ft Ib T Order R 4 5 6 10 Nm 1 0 m kg 7 ft Ib T R T 10 Nm 1 0 m kg 7 ft Ib R 3 1 5 7 2 10 Nm 1 0 m kg 7 ft Ib Amount Observations T R Procedure Parts to remove 5 6 7 Dowel pin Casing left Nozzle 2 1 1 For assembly reverse the procedure disassembly 5 54 ...

Page 192: ...R 3 2 3 3 3 3 LT 1 3 E LS Order Procedure Parts to remove Amount Observations Crankshaft Balancer Transmission Refer to CRANKSHAFT on page 5 58 Refer to TRANSMISSION on page 5 61 1 2 3 Oil Seal Bearing retainer Bearing 1 1 7 For assembly reverse the procedure disassembly 5 55 ...

Page 193: ... Blow out with compressed air INSPECTION OF THE SUPPLY CHAIN GUIDE AND CHAIN 2 1 B 10 15 9 8 7 6 5 11 12 3 13 4 14 A Housing right B Casing left 1 Check The distribution chain Damage stiffness Replace chain distribution and the camshaft sprocket as a whole 2 Spin Drum segment changes NOTE Rotate the drum segment changes 1 to the position shown in the illustration In this position the teeth of the ...

Page 194: ...ITE to screw threads of the retainer bearing Bearing retainer screw 7 Nm 0 7 m kg 5 1 ft lb LOCTITE 1 CRANKCASE ASSEMBLY 1 Thoroughly clean all surfaces contact seal and the crankcase 2 Apply Sealant On the contact surfaces of the housing Yamaha Adhesive No 1215 NOTE Do not allow product to come in contact with the oil passage T R to 4 Install Crankcase screws Crankcase screws 10 Nm 1 0 m kg 7 2 f...

Page 195: ...ving the crankshaft and the 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 2 Balancer Crankshaft 1 1 For assembly reverse the procedure disassembly 5 58 ...

Page 196: ... the crankshaft Replace Connecting rod side clearance D 0110 0410 mm 3 Measure Crankshaft width Out of specification the crankshaft Replace 2 Crankshaft width A 47 95 48 00 mm 1 CRANKSHAFT INSPECTION 1 Measure Deformation of the crankshaft Out of specification Replace crankshaft bearing or both NOTE 4 Check Crankshaft Sprocket Damage wear Replace the crankshaft Bearing Cracks damage wear Replace t...

Page 197: ...he edges of oil seals with soap based grease Lithium and each bearing with engine oil NOTE Keep the rod in the top dead PMS with one hand while turning the nut crankshaft mounting screw with the other Turn the mounting screw of the crankshaft until the bottom of the crankshaft is against the bearing 5 60 ...

Page 198: ...E 3 E Order Procedure Parts to remove Amount Observations Sump Refer to CRANKCASE on page 5 53 1 2 3 4 5 6 7 8 9 Guide bar claw changes Spring Shift drum Right shift fork Shift fork Center Left shift fork Drive shaft Main shaft Long pushrod clutch 2 4 1 1 1 1 1 1 1 For assembly reverse the procedure disassembly 5 61 ...

Page 199: ...6 5 4 3 2 1 M Order Procedure Parts to remove Amount Observations 1 2 3 4 5 6 7 Second pinion Fifth pinion Third pinion Pin lock Toothed washer Fourth pinion Main shaft pinion first 1 1 1 1 1 1 1 For assembly reverse the procedure disassembly 5 62 ...

Page 200: ... Order Procedure Parts to remove Amount Observations 1 2 3 4 5 6 7 8 9 10 11 12 13 Pin lock Washer Second Gear Fifth Gear Washer First gear Necklace Washer Fourth gear Pin lock Washer Third Gear Drive shaft 1 1 1 1 1 1 1 1 1 1 1 1 1 For assembly reverse the procedure disassembly 5 63 ...

Page 201: ... changes Guide bar Roll the shift fork on a flat surface Replace curves l WARNING Do not attempt to straighten a guide bar bent shift fork INSPECTION OF TRANSMISSION 1 Measure Deformation of the shaft main With a centering device and the indicator cover of 1 Replace specification outside the shaft principal l Shaft limit deformation main 0 03 mm 3 Check Fork movement changes Moving along the guide...

Page 202: ... in their respective Gear Reassembly incorrect axes of the transmission 5 Check Movement of transmission gears Replace parts coarse movement defective INSPECTION OF THE PUSH ROD CLUTCH 1 Check Long rod Clutch thrust Cracks damage wear Replace the long rod thrust of the clutch 2 Measure Deformation limit of the push rod Out of specification Replace the long rod clutch thrust l l l l Press the secon...

Page 203: ... right side of engine and be in the following sequence R C L 2 Check Transmission Rough motion l repair NOTE l l Apply engine oil to each gear and bearing Before assembling the engine crankcase make sure the transmission is in neutral and that the gears rotate freely 5 66 ...

Page 204: ... INSPECTION CARBURETOR ASSY CARBURETOR ASSEMBLY MEASURING AND ADJUSTING THE FUEL BLE INSPECTION OF THE FUEL WRENCH 6 1 6 2 6 4 6 6 6 7 6 7 6 8 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM REMOVING THE AIR INDUCTION SYSTEM INSPECTION SYSTEM AIR INDUCTION 6 9 6 10 6 11 ...

Page 205: ...side covers 1 2 hose Fuel Refer to GENERAL CHASSIS on page 4 1 1 2 3 4 5 6 7 8 Overflow fuel hose Fuel line Screw clamp connection carburetor Screw clamp Throttle cable Starter cable TPS connector Carburetor 1 1 1 1 1 1 1 1 Disconnect Loosen For assembly reverse the procedure disassembly 6 1 ...

Page 206: ...s Disassemble the carburetor Remove the parts in the order listed 1 2 3 4 5 6 7 8 9 10 11 12 13 Diaphragm cover Diaphragm spring Needle valve Piston valve Diaphragm Ring Drain screw Float chamber O ring Support sprayer Leading supplier O ring Main nozzle 1 1 1 1 1 1 1 1 1 1 1 1 1 6 2 ...

Page 207: ...e Parts to remove Amount Observations 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Float pin Float Set needle Throttle stop screw Washer Spring Jet pilot O ring Washer Spring O ring Filter mesh Cover plunger Support guide 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 3 ...

Page 208: ...ts to remove Amount Observations 28 29 30 31 32 33 34 35 36 37 38 39 O ring Spring plunger Plunger Spring washer Throttle stop Stop washer Spring TPS O ring Pin lock Washer Washer 1 1 1 1 1 1 1 1 1 1 1 1 For assembly reverse the procedure disassembly 6 4 ...

Page 209: ...ges Clogged Clean NOTE Always replace the gasket with a new one 6 Verificar Float 1 Damage Replace NOTE Wash the carburetor based solvent oil Do not use a caustic solution for carburetor cleaner Blow out all passages and jets with air compressed 3 Verificar Diaphragm Valve 1 Cracks damage Replace 7 Verificar Needle valve 1 Seating the needle valve 2 O ring 3 Damage obstruction wear Replace the nee...

Page 210: ...1 11 Check mixture screw 1 Damage wear Replace 1 CAUTION Before assembling the carburetor wash all parts with a solvent derived oil Always use new gaskets 1 Install Throttle screw 1 Jet pilot 2 Main nozzle 3 O ring 4 Main nozzle 5 Leading supplier 6 12 Check throttle screw 1 Damage wear Replace 1 1 2 13 Verificar YTPS 1 Damage faulty Replace Butterfly Butterfly axis 2 movement Obstruction damage w...

Page 211: ... Float chamber 5 1 3 2 2 1 5 4 5 Instalar Diaphragm Valve 1 3 Instalar Needle valve 1 CAUTION Do not overtighten any screws this can damage gaskets and O rings This can lead to fuel leakage 1 1 A B NOTE Make sure the raised A under the diaphragm must be aligned with the slot B in the body of carburetor 6 7 ...

Page 212: ... the level of bending the pin 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 the specifications MEASURING AND ADJUSTING THE FUEL 1 Medir Fuel level a Out of specification adjust 1 Fuel level below the contact surface of the chamber Float 6 0 7 0 mm a Place the vehicle on flat b Place the vehicle on the supporting de...

Page 213: ...SYSTEM AIR INDUCTION SYSTEM 5 1 2 3 4 3 2 5 1 4 1 2 3 4 5 Hose air induction system air filter Vacuum hose of the air induction system Through the air induction system to the motor Air filter Air induction system 6 9 ...

Page 214: ...ns Seat side cover side cover 1 2 Fuel tank Refer to GENERAL CHASSIS on page 4 1 Refer to GENERAL CHASSIS on page 4 2 1 2 3 4 Hose air induction system air filter Vacuum hose of the air induction system Air induction pipe To the head Air induction system 1 1 1 1 For assembly reverse the disassembly procedure 6 10 ...

Page 215: ... off valve closes automatically to protect from a performance loss due to self Exhaust Gas Recirculation EGR C Cracks damage Replace Union 3 way Cracks damage Replace 2 Check Reed valve Valve stop reed Valve seat sheet Cracks damage Replace valve plates 3 Check Air shutoff valve Cracks damage Replace 4 Check Operation of the air shutoff valve Replace does not work a Blowing air through the hose en...

Page 216: ...NDUCTION SYSTEM Air shutoff valve is opened Replace the air shutoff valve Air shutoff valve closed The air shutoff valve is OK 1 NOTE This test should be performed when the pressure is less than 50 kPa 6 12 ...

Page 217: ... CHECKING SWITCHES VERIFICATION OF BULBS AND SOCKETS OF BULBS CHECKING THE FUSE CHECKING AND CHARGING CHECKING THE RELAYS VERIFICATION OF RELAY TURN SIGNAL CHECKING THE SPARK PLUG HOOD CHECKING THE IGNITION COIL VERIFICATION OF THE DISTANCE FROM THE SPARK IGNITION CHECKING THE CRANKSHAFT POSITION SENSOR VERIFICATION OF PERFORMANCE STARTER CHECKING THE STATOR COIL VERIFICATION OF THE REGULATOR RECT...

Page 218: ... Black Br Sb Br Br B B 24 Br Br B ORW Br2 and GB Ch Dg BLACK Sb Bl L YW L g W TACHO 9 P Br RB 13 NEUTRAL 11 10 12 Br SPEED ILLMI TC VCC BL SGND L BRW YW W 28 B B1 RB B GY Br GND GY BRW And RED RED Br GB FUEL FUEL L And WB P BRW ORW GY BL L Br Dg B r Dg DIMMER 34 36 29 ILLUMI GBOrW Br HORN L NL N NR R 35 FLASHER BRW WB BRW WB Ch P P Ch 14PASSOFFON THREAD OFFON W 25 ORW W L BL And And 12V10W 12V21W ...

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

Page 220: ...HECKING THE HOOD SPARK PLUG on page 7 39 OK 5 Check the ignition coil See the section CHECKING THE COIL ON on page 7 39 OK 6 Check the position sensor crankshaft See the section CHECK SENSOR CRANKSHAFT POSITION in the page 7 40 OK 7 Check main switch See the section CHECKING THE SWITCH MAIN on page 7 30 OK 8 Check the TPS See the section TPS VERIFICATION on page 7 43 OK NG Replace the main switch ...

Page 221: ... the VERIFICATION SWITCH on page 7 30 OK 10 Verificar Wiring system full power See section CHART CIRCUIT on page 7 1 OK Replace the CDI NG The engine stop switch is damaged Replace the switch right handlebar NG Connect or repair wiring system Ignition 7 4 ...

Page 222: ...ack Br Br Br Sb B B 24 Br Br B ORW L Sb Bl YW Lg W Br2 and GB Ch Dg BLACK TACHO 9 P Br RB 13 NEUTRAL 11 10 12 Br SPEED ILLMI BRW TC VCC BL SGND L YW W GND 28 B B1 RB B GY GY BRW And RED RED Br GB FUEL FUEL L And WB P BRW ORW GY BL L Br Dg B r Dg 34 DIMMER HORN 35 29 ILLUMI Gbor W L Br FLASHER 36 NL N NR R BRW WB BRW WB Ch P P Ch 14PASSOFFON THREAD Or FFON W 25 ORW W L BL And 12V10W Y12V21W 35W G G...

Page 223: ...TARTING SYSTEM 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 7 6 ...

Page 224: ...n neutral the neutral switch is closed Pull the clutch lever to the handlebar the clutch switch is closed The cutting power prevents the starter motor running when one of the above conditions is not met In this case the starting circuit is open then the current fails to reach the starter motor When at least one of the above conditions is met the starting circuit is closed and can start the engine ...

Page 225: ...HEN THE TRANSMISSION IS IN NEUTRAL b WHEN IS CLUTCH LEVER SHOT TO THE HANDLEBARS 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 Start relay 10 Starter 7 8 ...

Page 226: ...heck the engine starts Refer to the VERIFICATION ENGINE START in the page 5 33 OK 5 Check the relay circuit court starting Refer to the VERIFICATION RELAYS on page 7 37 OK 6 Check the starter relay Refer to the VERIFICATION RELAYS on page 7 37 OK 7 Check main switch Refer to the VERIFICATION SWITCH on page 7 30 OK NG Replace the fuse NG Clean the battery terminals Recharge or replace battery OK Th...

Page 227: ... OK 11 Verificar the starter switch Refer to the VERIFICATION SWITCH on page 7 30 OK 12 Verificar Wiring system boot See the section CIRCUIT DIAGRAM on page 7 5 OK The circuit of the ignition system is OK NG The engine stop switch is damaged Replace i n t e r r u p t o r right handlebar NG Replace the neutral switch NG Replace the clutch switch NG The ignition switch is faulty Replace the switch r...

Page 228: ...lack Br Br Br Sb B B 24 Br Br B ORW L Sb Bl YW Lg W Br2 and GB Ch Dg BLACK TACHO 9 P Br RB 13 NEUTRAL 11 10 12 Br SPEED ILLMI BRW TC VCC BL SGND L YW W GND 28 B B1 RB B GY GY BRW And RED RED Br GB FUEL FU E L L And WB P BRW ORW GY BL L Br Dg Br Dg DIMMER 34 HORN 29 ILLUMI Gbor W L Br 35 NL N NR R FLASHER 36 BRW WB BRW WB Ch P P Ch 14PASSOFFON THREAD OFFON W 25 ORW W L BL And 12V10W Y12V21W 35W G G...

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

Page 230: ...n of the coil the stator See the section CHECKING THE COIL STATOR on page 7 41 OK 4 Check the regulator rectifier Refer to the VERIFICATION REGULATOR RECTIFIER in page 7 41 OK 5 Check the wiring system load See the section CIRCUIT DIAGRAM on page 7 11 OK The circuit of the charging system is OK NG Replace the fuse NG Clean the battery terminals Recharge or replace battery NG Change the position of...

Page 231: ...RW Black Br Br Br Sb B B 24 Br Br B ORW L Sb Bl YW Lg W Br2 and GB Ch Dg BLACK TACHO 9 P Br RB 13 NEUTRAL 11 10 12 Br SPEED ILLMI BRW TC VCC BL SGND L YW W GND 28 B B1 RB B GY Br GY BRW And RED RED Br GB FUEL FU E L L And WB P BRW ORW GY BL L Br Dg Br Dg DIMMER ILLUMI L Br 34 HORN 29 GBOrW 35 FLASHER NL N NR R 36 BRW WB BRW WB Ch P P Ch 14PASSOFFON THREAD Or FFON W 25 ORW W L BL And 12V10W Y12V21W...

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

Page 233: ...use Ok 3 Check the battery Refer to the VERIFICATION AND CHARGING THE BATTERY on page 7 34 NG Clean the battery terminals Recharge or replace battery Ok 4 Check main switch Refer to the VERIFICATION SWITCH on page 7 30 Ok 5 Check the light switch Refer to the VERIFICATION SWITCH on page 7 30 Ok 6 Check the switch step Refer to the VERIFICATION SWITCH on page 7 30 NG Replace the main switch NG The ...

Page 234: ...r Br Br Sb B 24 B Br2 and GB Ch Dg BLACK Sb Bl Br Br B ORW L YW Lg W TACHO 9 P Br RB 13 NEUTRAL 11 10 12 Br2 SPEED ILLMI BRW TC VCC BL SGND L YW W 28 B B1 RB B GY Br GND GY BRW And RED RED Br GB FUEL FUEL L And WB P BRW ORW GY BL L Br Dg Br Dg DIMMER ILLUMI L Br 34 HORN 29 GBOrW 35 36 NL N NR R FLASHER BRW WB BRW WB Ch P P Ch 14PASSOFFON THREAD OFFON W 25 ORW W L BL And And 12V21W 35W G G 18 B And...

Page 235: ...rn signal 11 Front brake switch 12 Rear brake switch 13 Meter 16 Headlight turn indicator LH 17 Headlight 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 The horn switch 36 Switch turn signal 7 18 ...

Page 236: ...n the battery terminals Recharge or replace battery 3 Check main switch Refer to the VERIFICATION SWITCH on page 7 30 Ok NG Replace the main switch 4 Check the circuit wiring signaling system Refer to the VERIFICATION SIGNAL SYSTEM Ok Check the status of each of the signaling system circuits See Verifying Signalling System Verification of the signaling system THE HORN DOES NOT SOUND NG Connect or ...

Page 237: ...eck the rear brake switch Refer to the VERIFICATION SWITCH on page 7 30 Ok NG Replace the rear brake switch 4 Check the wiring system signaling See the section CIRCUIT DIAGRAM on page 7 17 Ok The system circuit is OK NG Connect or repair wiring system signaling Shift indicator light indicator light turning both or no flash 1 Check the indicator light bulb of rotation and the socket Refer to sectio...

Page 238: ...eter The neutral indicator light does not light NG Connect or repair wiring system signaling 1 Check the light bulb neutral and the socket Refer to section VERIFICATION BULBS AND SOCKETS OF THE BULBS on page 7 33 Ok NG Replace the light bulb neutral socket or both 2 Check neutral switch Refer to the VERIFICATION SWITCH on page 7 30 Ok 3 Verificar wiring system signaling See the section CIRCUIT DIA...

Page 239: ...SIGNALLING SYSTEM 2 Check wiring system signaling See the section CIRCUIT DIAGRAM on page 7 17 NG Connect or repair wiring system signaling Ok Replace the meter 7 22 ...

Page 240: ...in the system by the auto diagnosis alerts the driver of evil detection operation illuminating the warning light engine failure After the engine has stopped the error code number appears in the light of engine failure warning Will be stored in system memory until it is deleted 1 1 Warning light engine failure Fault identification code of the warning light engine trouble 10 Digits Cycles of 1 secon...

Page 241: ...motor off METHOD OF SOLUTION OF PROBLEMS Engine operation is not normal and light warning lights engine failure 1 Check fault code number d Warning light engine failure on for 3 seconds Fault code No No fault code a Check the fault code that appears in the meter b Identify the flaw in the system with code fault See Table function self diagnosis c Identify the likely cause of the failure See Fault ...

Page 242: ...hort between the connector position sensor accelerator and the CDI connector Black blue black blue Yellow yellow Blue blue Check for open circuit and replace The throttle position sensor Circuit detail open Ground wire open circuit Output Cable open circuit Source feeding open circuit Output Voltage 5V 0V 0V Method reinstatement Turn the switch the main ON Order 1 Item components and cause likely ...

Page 243: ...ition coil Side of the primary coil IDC connector on the harness Verification or maintenance work Check the connector terminals and the coupler that may have gone Check the lock status connector and the coupler If a malfunction repair and connect the connector and the coupler securely Repair or replace if there is a circuit open or shorted Between coil connector on and the CDI coupler harness main...

Page 244: ...or pressed and activating motor Check the terminals of the coupler to the sensor speed may have left endo pony Check the lock status of the operation couplers the vehicle If a malfunction repair and connect the coupler securely Verification or maintenance work Repair or replace if there is a circuit open or shorted Between speed sensor coupler and coupling of the wiring harness Replace if defectiv...

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

Page 246: ...ENTS 1 Front brake switch 2 Fuel gauge 3 Starter cut relay 4 CDI 5 Main switch 6 Horn 7 Start relay 8 Neutral switch 9 Rear brake switch 10 Battery 11 Regulator rectifier 12 Fuse 13 Spark plug cap 14 Ignition coil 7 29 ...

Page 247: ...TS SWITCH INSPECTION 1 B R B B BLACK 2 R OFF ON B RED 3 Br GY 4 Br R Br BR Br and And 5 Sb 12 OFF PO ON 11 L W B 10 Br R W 9 Br PASS 8 And W B and G 7 Br P 6 Br Ch WDG Br Dg W Br B W Y P Ch Br R W L W W B B L And G B 7 30 ...

Page 248: ...1 Clutch switch 2 Main switch 3 Front brake switch 4 Rear brake switch 5 Neutral switch 6 Switch turn signal 7 The horn switch 8 Light switch 9 Light Switch step 10 Engine stop switch 11 Start switch 12 Headlight switch 7 31 ...

Page 249: ...ge 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 The a are shown in the left column and the switch lead colors B are shown in the top row Continuity ie a closed circuit between switch t...

Page 250: ...f from the terminal in 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 affected negatively If the bulb of the lamp is dirty wipe thoroughly with a cloth moistened with alcohol or lacquer thinner 2 Check Bulb for continuity With multimeter No continuity Replace Multimeter Bulbs c is ...

Page 251: ...malfunction in the lighting and ignition systems and could cause a fire 4 Install Seat and right cover Refer to GENERAL CHASSIS on page 4 1 CHECKING AND CHARGING WARNING To prevent a short circuit always place switch to OFF when revise or replace a fuse 1 Remove Seat and right side cover Refer to GENERAL CHASSIS on page 4 1 2 Check Fuse a Connect the multimeter and check the fuse continuity NOTE S...

Page 252: ...ry with temperature state of the battery plates and the level the electrolyte 3 Remove Battery 4 Check Battery voltage Level of electrolyte in the battery cell Charging the battery a Conecte a multimeter to the terminals battery Positive probe of the multimeter Positive battery terminal Negative probe of the multimeter Negative battery terminal NOTE A Open circuit voltage V B Loading condition of ...

Page 253: ...thod with a charger current voltage variable a Measuring open circuit voltage before to loading NOTE The voltage must be measured after 30 minutes without using the battery b Connect a charger and an ammeter to battery and start charging c Make sure the power is higher than the standard load current written in the battery NOTE If the load current is less than the charge level written in the batter...

Page 254: ...e battery charge this type of charger battery can not charge the MF battery It recommends a variable voltage charger d Charge the battery until the charging voltage battery is 15 V NOTE Adjust the charging time to 20 hours maximum e Measuring the charging voltage in open circuit battery after having been without use for more than 30 minutes 12 8 V or more Charging complete 12 7 V or less Rechargin...

Page 255: ...tive probe 4 Tester negative probe Result Continuity Between 1 and 3 VERIFICATION OF SIGNAL RELAY GIRO 1 Check Input voltage relay turn signal Off specification circuit from the switch to the relay coupler turn signal is defective and must be repaired Input voltage of the relay Turn signal 12 V DC Tester positive probe brown white 1 Tester negative probe land 1 Br W Br a Connect the multimeter to ...

Page 256: ...ark plug as shown Multimeter Tester positive probe orange 1 Tester negative probe land 2 c Measuring the resistance of the secondary coil c Measure the resistance of the spark plug cap CHECKING THE IGNITION COIL 1 Check Primary coil resistance Replace out of specification Primary coil resistance Ù 0 32 to 0 48 at 20 C 68 F 2 Check Resistance of the secondary coil Replace out of specification Secon...

Page 257: ... between electrodes from 0 8 to 0 9 mm plug NOTE a Connect the multimeter to the sensor coupler crankshaft position as shown Multimeter Tester positive probe blue yellow 1 Tester negative probe green 2 If the distance between electrodes of the spark plug is within specifications the circuit ignition system is working normally a Disconnect the spark plug cap from spark plug b Connect the dynamic sp...

Page 258: ...4 7 V at 5000 r min b Check the operation of motor boot CHECKING THE STATOR COIL 1 Desconectar CCoupling the stator coil From the wiring harness 2 Check Resistance of the stator coil Out of specification Replace the sensor crankshaft position stator assembly Resistance of the stator coil Ù 0464 0696 at 20 C 68 F a Connect the engine tachometer cable plug b Connect the multimeter to the coupler reg...

Page 259: ...erminals b Connect the multimeter Ù 1 to terminals of the horn Multimeter a Connect the multimeter Ù 100 in the coupler fuel gauge as shown Tester positive probe terminal of the horn 1 Tester negative probe terminal of the horn 2 Multimeter 1 Tester positive probe orange white 1 Tester negative probe green black 2 2 c Measure the resistance of the horn 2 Check Sound the horn Adjust or replace defe...

Page 260: ...imeter to the terminals of the body throttle sensor as shown Tester positive probe blue 1 Tester negative probe black blue terminal 2 Input voltage sensor throttle position 5V Azul negro azul Tester positive probe white 1 Tester negative probe blue black 2 1 W L BL 2 L W BL d Slowly open the throttle check that the voltage sensor output throttle position increase The voltage does not change or cha...

Page 261: ...UM AND HIGH SPEED FAILURE OF BIO MARCHASCAM SHIFT PEDAL DOES NOT MOVE SKIP GEARS CLUTCH FAILURE OVERHEATING Supercooling POOR PERFORMANCE ELFRENADO FAILURE OF THE FRONT FORK UNSTABLE HANDLING FAILURE OF SIGNALLING OR LIGHTING SYSTEM WIRING DIAGRAM 8 1 8 1 8 1 8 1 8 2 8 2 8 2 8 2 8 2 8 2 8 3 8 3 8 3 8 3 8 4 8 5 ...

Page 262: ...taminated fuel Clogged fuel pump Carburetor out of adjustment Electrical System 1 Battery Discharged battery Battery failure 2 Fuse Fuse damaged or incorrect Fuse improperly installed 3 Plug Incorrect spark plug cap Heat range spark plug incorrect Spark plug faulty Worn or damaged electrode Worn or damaged insulation Faulty spark plug cap 4 Ignition coil Body of the ignition coil with cracks or fr...

Page 263: ...ve changes Shift fork stuck Guide bar bent shift fork Transmission Transmission gear stuck Foreign objects between the wheels of transmission Incorrect assembly of the transmission SKIP GEARS Axis changes Pedal position error changes The top of the lever returns so incorrect Forks of changes Worn shift fork Shift drum Axial incorrect Treadwear drum changes Transmission Wear lace Gear CLUTCH FAILUR...

Page 264: ... Damage the brake hose Grease or oil on brake disc Grease or oil on brake pads Brake fluid level incorrect FAILURE OF THE FRONT FORK Oil leak Tube bent damaged or corroded Broken or damaged outer tube Improperly installed oil seal Edges of the damaged oil seal Incorrect oil level high Screw loose cushion rod Copper washer damper rod damaged O ring screw cap damaged Malfunction Bent or damaged inne...

Page 265: ...elay defective Light bulb turning molten Horn does not sound Horn maladjusted Damaged or defective horn Main switch defective Defective horn switch Battery failure Fuse broken damaged or incorrect Damaged or faulty wiring harness FAILURE OF LIGHTING SYSTEM O SIGNALING The front light is not lit Incorrect lamp bulb Many electrical accessories Hard to charge Bad connection Grounding the circuit Bad ...

Page 266: ... Br2 and GB Ch Dg BLACK Sb Bl Br Br B ORW L YW Lg W TACHO 9 P Br RB 13 NEUTRAL 11 10 12 Br2 SPEED ILLMI BRW TC VCC SGND L BL YW W 28 B B1 RB B GY BR GND GY BRW And RED RED Br GB FUEL FUEL L And WB P BRW ORW GY BL L Br Dg Br Dg DIMMER 34 36 29 GBOrW Br HORN L NL N NR R 35 FLASHER ILLUMI BRW WB BRW WB Ch P P Ch 14PASSOFFON THREAD OFFON W 25 ORW W L BL DIAG And And 12V21W 35W G G 18 B And G B Ch Dg B...

Page 267: ... 27 Starter cut relay 28 Clutch switch 29 Fuel gauge 30 Engine stop switch 31 Headlight switch 32 Backlight turn indicator L H 33 Backlight turn indicator R H 34 Light switch 35 The horn switch 36 Switch turn signal COLOR CODE B Black Coffee Br ChChocolate Dark green Dg G Green GyGris L Blue LgVerde clear Or Orange P Rosa Red R Blue sky Sb W White And Yellow B L Black Blue Br L Brown Blue Br W Bro...

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