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Yamaha Scorpio, Service Manual

The Yamaha Scorpio Service Manual is a comprehensive guide that provides detailed instructions and diagrams for maintaining and repairing your Yamaha Scorpio motorcycle. This invaluable manual is available for free download at manualshive.com, enabling you to access it conveniently and effortlessly.

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INSP

ADJ

WHEEL INSPECTION/SPOKE INSPECTION AND

TIGHTENING/CABLE INSPECTION

WHEEL INSPECTION
1.Inspect:

●

Wheels
Damage/Bends 

→

 Replace.

NOTE:

Always balance the wheel when a tire or wheel
has been changed or replaced.

WARNING

●

Never attempt even small repairs to the
wheel.

●

Ride conservatively after installing a tire
to allow it to seat itself properly on the
rim.

SPOKE INSPECTION AND TIGHTENING
1.Inspect:

●

Spokes 

1

 

Bend/Damage 

→

 Replace.

Loose spoke 

→

 Retighten.

2.Tighten:

●

Spokes

CABLE INSPECTION

WARNING

Damage cable sheath may cause corrosion
and interfere with the cable movement. An
unsafe condition may result so replace
such cable as soon as possible.

1.Inspect:

●

Cable sheath

●

Cables (throttle, clutch and starter)
Damage 

→

 Replace.

T

 

R

.

.

Nipple:

0.6 m • kg

Summary of Contents for Scorpio

Page 1: ...SCORPIO SX 4 SERVICEMANUAL a Winanda Fairyanto s collection nanda jogjalandrover org fairyanto gmail com yamaha_scorpio yahoogroups com 5BP F8197 B0 ...

Page 2: ...SERVICE MANUAL SCORPIO 2006 oleh Yamaha Motor Co Ltd Edisi kedua Agustus 2006 dialih bahasakan oleh Technical Publication Yamaha Indonesia Motor Manufacturing di cetak di Indonesia ...

Page 3: ...s berusaha meningkatkan mutu produksinya untuk itu jika ada perubahan yang mendasar dalam spesifikasi dan prosedur pengerjaan kami akan sampaikan ke seluruh jaringan Yamaha melalui buletin Servioce Information TECHNICAL PUBLICATION GROUP 1 SERVICE INFORMATION DIV YAMAHA MOTOR CO LTD INFORMASI PENTING YANG ADA DIDALAM BUKU PETUNJUK INI Informasi penting secara khusus ditandai dengan tanda tanda seb...

Page 4: ...erima dengan mudah oleh para mekanik Petunjuk yang ada meliputi berbagai hal antara lain tentang cara membongkar memperbaiki dan pemeriksaan jika ada prosedur yang penting dan perlu perhatian khusus 4 kami beri garis dengan tiap tiap prosedur kami beri tanda INFORMASI PENTING Data spesifikasi dan special tool diinformasikan dalam frame dengan gambar alat 5 Angka didalam lingkaran 6 menunjukkan nam...

Page 5: ...iran A Pelumasan B Alat khusus Special tool C Pengencangan D Bats keausan kelonggaran E Putaran mesin F Ω V A Illustrasi simbol G hingga N pada gambar menunjukkan tipe pelumas dan bagian yang perlu dilumasi G Lumasi dengan oli mesin H Lumasi dengan oli gear I Lumasi dengan molybdenum disulfide oil J Lumasi dengan gemuk bearing roda K Lumasi dengan gemuk lightweight lithium soap base L Lumasi denga...

Page 6: ...AR ISI INFORMASI UMUM GEN INFO 1 SPESIFIKASI SPEC 2 PERAWATAN BERKALA DAN PENYETELAN INSP ADJ 3 MEMBONGKAR MESIN ENG 4 CARBURATOR CARB 5 RANGKA CHASSIS CHAS 6 KELISTRIKAN ELEC 7 TROUBLESHOOTING TRBL SHTG 8 ...

Page 7: ...OR RANGKA 1 1 NOMOR MESIN 1 1 INFORMASI PENTING 1 2 PROSEDUR PERSIAPAN MEMBONGKAR 1 2 PART PENGGANTI 1 2 GASKETS OIL SEALS DAN O RINGS 1 2 LOCK WASHERS PLATES DAN COTTER PINS 1 3 BEARING DAN SEAL OIL 1 3 CIRCLIPS 1 3 MEMERIKSA SAMBUNGAN KABEL 1 4 SPECIAL TOOLS 1 5 ...

Page 8: ...GEN INFO ...

Page 9: ...0020 NOMOR RANGKA CHASIS Nomor rangka 1 tercetak pada rangka di bagian down tube EB100030 NOMOR MESIN Nomor mesin 2 tercetak pada crankcase mesin sebelah kanan CATATAN bentuk dan spesifikasi sewaktu waktu dapat berubah tanpa pemberitahuan IDENTIFIKASI SEPEDA MOTOR 1 2 ...

Page 10: ...omponen part dilepas bersihkan dari kotoran yang menempel pada komponen untuk mempermudah dan mem percepat pemasangan kembali 6 Jaga semua komponern dari pengaruh panas EB101010 PART PENGGANTI 1 Pergunakan hanya spare part asli Yamaha genuine part pergunakan juga oli dan gemuk yang disarankan Yamaha untuk pelumasan Komponen imitasi terlihat sama dengan yang asli tetapi kualitasnya jauh lebih buruk...

Page 11: ...ght lithium pada pada permukaan lidah seal dan pada saat mema sang bearings lumasi dengan oli dan pastikan bearing berputar lancar 1 Oil seal PERHATIAN Jangan menggunakan udara bertekanan untuk membersihkan bearing hal ini akan merusak permukaan bearing 1 Bearing EB101050 CIRCLIPS 1 Periksa dengan seksama circlip sebelum pemasangan Selalu ganti circlip pin piston dengan yang baru Ganti circlip jik...

Page 12: ...emeriksa agar kabel tidak tercabut terlepas 5 Jika mudah tercabut bengkokkan pin pengait 1 dan pasangkan kembali ke terminal connector 6 Pasang Connector CATATAN Kedua connectors harus click bersamaan 7 Periksa sistim penyambungan dengan tester CATATAN Jika tidak ada sambungan bersihkan terminal Lakukan langkah pemeriksaan 1 hingga 7 pada saat memeriksa kabel bodi Untuk pemeriksaan dapat menggunak...

Page 13: ... 90890 01135 Crankcase separating tool Alat ini digunakan untuk memisahkan crank case Pot 90890 01274 Bolt 90890 01275 Crankshaft installer pot Crankshaft installer bolt Alat ini digunakan untuk memasang poros engkol crankshaft Spacer 90890 01288 Adapter M10 90890 01383 Spacer Adapter M10 Alat ini digunakan untuk memasang poros engkol crankshaft 90890 01311 Tappet adjusting tool Alat ini digunakan...

Page 14: ...engencangkan dan mengendorkan baut kemudi steering 90890 01701 Sheave holder Alat ini digunakan untuk menahan magnet secondary sheave 90890 03081 Compression gauge Alat ini digunakan untuk mengukur tekanan kompresi mesin 90890 03112 Pocket tester Alat ini digunakan untuk memeriksa rangkaian kelistrikan 90890 03113 Engine tachometer Alat ini digunakan untuk menyetel putaran langsam mesin 90890 0401...

Page 15: ...ersal clutch holder Alat ini digunakan untuk menahan clutch boss pada saat memasang dan melepas baut clutch boss nut 90890 06754 Ignition checker Alat ini digunakan untuk memeriksa komponen sistim pengapian Nomor Tool Nama Tool Gambar Illustrasi ...

Page 16: ...IKASI UMUM 2 1 SPESIFIKASI PERAWATAN 2 4 MESIN 2 4 RANGKA CHASSIS 2 12 KELISTRIKAN 2 15 SPESIFIKASI TORSI UMUM 2 17 UNIT SATUAN 2 17 POIN PELUMASAN DAN TIPE PELUMAS YANG DIPAKAI 2 18 MESIN 2 18 RANGKA CHASSIS 2 19 JALUR KABEL 2 20 ...

Page 17: ...SPEC ...

Page 18: ...meter Langkah 70 58 mm Perbandingan kompresi 9 5 1 Tekanan kompresi 8 5 kg cm2 370 r min Sistim starter Motor starter dan kick starter Sistem pelumasan Pelumasan basah Tipe oli atau grade Oli mesin SAE 20W40 tipe SE motor oil YAMALUBE jika temperature dibawah 15 C SAE 10W30 tipe SE motor oil jika temperatur diatas 15 C Kapasitas oli Oli mesin Penggantian berkala 1 2 Liter Dengan melepas filter oli...

Page 19: ... 4th 26 25 1 040 5th 23 27 0 852 Chassis Frame type Double cradle Caster angle 25 3 Trail 85 mm Tire Type With tube Size F 80 100 18 M C 47P Size R 100 90 18 M C 56P Wear limit 0 8 mm Tire pressure cold tire Basic weight With oil and full fuel tank 131 kg Maximum load 180 kg Cold tire pressure FRONT REAR Rider 2 00 kg cm2 2 00 kg cm2 With passenger 2 00 kg cm2 2 25 kg cm2 Load is the total weight ...

Page 20: ...ectrical Ignition system CDI Generator system A C magneto generator Battery type or model GM7B 4B Battery capacity 12 V 7 AH Headlight type Bulb type Bulb wattage quantity Headlight 12 V 35 W 36 5 W 1 Auxiliary light 12 V 3 4 W 1 Tail brake light 12 V 5 W 21 W 1 Flasher light 12 V 10 W 4 Meter light 12 V 1 7 W 2 Indicator light NEUTRAL 12 V 3 4 W 1 HIGH BEAM 12 V 3 4 W 1 TURN 12 V 3 4 W 2 Model SX...

Page 21: ...ide dia 24 96 24 98 mm Cam dimensions Intake A 36 52 36 62 mm B 30 201 30 301 mm Exhaust A 36 564 36 664 mm B 30 216 30 316 mm Camshaft runout limit 0 03 mm Rocker arm and rocker arm shaft Rocker arm inside diameter 14 992 15 000 mm Shaft outside diameter 14 960 14 981 mm Arm to shaft clearance 0 009 0 037 mm Cam chain Cam chain type no of links DID SCR 0404SDH Cam chain adjustment method Automati...

Page 22: ...990 mm EX 5 960 5 975 mm Guide inside dia IN 6 000 6 012 mm EX 6 000 6 012 mm Stem to guide clearance IN 0 010 0 037 mm EX 0 025 0 052 mm Stem runout limit 0 03 mm Valve spring Free length lnner IN 36 17 mm EX 36 17 mm Outer IN 36 63 mm EX 36 63 mm Set length valve closed lnner IN 30 5 mm EX 30 5 mm Outer IN 32 mm EX 32 mm Compressed pressure installed Inner IN 7 65 9 35 kg EX 7 65 9 35 kg Outer I...

Page 23: ...ce 0 020 0 025 mm Limit 0 05 mm Piston size D 69 977 69 996 mm Measuring point H 4 mm Piston ring Top ring Type Barrel Dimensions B T 1 2 2 8 mm End gap installed 0 15 0 30 mm Side clearance installed 0 03 0 07 mm 2nd ring Type Taper Dimensions B T 1 2 2 8 mm End gap installed 0 15 0 30 mm Side clearance 0 02 0 06 mm Oil ring Dimensions B T 2 5 2 8 mm End gap installed 0 3 0 9 mm Model SX 4 H D T ...

Page 24: ...nimum length 33 2 mm Push rod bending limit 0 5 mm Transmission Main axle deflection limit 0 08 mm Drive axle deflection limit 0 08 mm Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 025 mm Carburetor I D mark 5BP1 00 Main jet M J 110 Main air jet M A J 120 Jet needle J N 4EL10 2 Needle jet N J O 2 Pilot jet P J 17 5 Pilot air jet P A J 1 65 P A J 2 1 2 Pilot screw P S 3 Pilo...

Page 25: ...Fuel level 2 7 4 7 mm below the float chamber line Engine idling speed 1 350 1 450 r min Lubrication system Oil filter type Paper and wire mesh type Oil pump type Trochoid type Tip clearance 0 15 mm Side clearance 0 04 0 09 mm Model SX 4 ...

Page 26: ...2 9 SPEC MAINTENANCE SPECIFICATIONS Lubrication chart Model SX 4 OIL CLEANER PIN WITH HOLE CRANKSHAFT CYLINDER HEAD CAMSHAFT OIL PUMP MAIN AXLE DRIVE AXLE OIL STRAINER OIL PAN ...

Page 27: ... 1 0 Oil delivery pipe crankcase cover Union bolt M10 1 20 2 0 cylinder Union bolt M8 1 18 1 8 Carburetor joint Bolt M6 2 10 1 0 Air filter case lower Bolt M6 2 6 0 6 upper Bolt M6 2 10 1 0 Exhaust pipe joint lower Flange bolt M8 2 20 2 0 Exhaust pipe Nut M8 2 18 1 8 Muffler Flange bolt M8 2 30 3 0 Crankcase Flange bolt M6 12 10 1 0 Crankcase cover left Flange bolt M6 9 10 1 0 Crankcase cover righ...

Page 28: ...ATIONS Pickup coil Bolt M6 2 7 0 7 Starter motor Bolt M6 2 10 1 0 Kick crank Bolt M8 1 20 2 0 Kick racket wheel guide Bolt M6 2 10 1 0 Use lock washer Part to be tightened Part name Thread size Q ty Tightening torque Remarks Nm m kg ...

Page 29: ...thout fork spring Oil grade Yamaha fork oil 10W or equivalent Rear suspension Shock absorber travel 32 mm Spring rate K1 16 01 kg mm Stroke K1 0 32 mm Optional spring No Swingarm Swingarm free play limit End 1 mm Swingarm free play limit Side 1 mm Front wheel Type Spoke wheel Rim size 1 85 1 60 Rim material Steel Rim runout limit Vertical 2 mm Lateral 2 mm Rear wheel Type Spoke wheel Rim size 1 85...

Page 30: ...inside diameter 11 mm Caliper cylinder inside diameter 26 99 mm 22 22 mm Recommended fluid DOT 3 or 4 Rear drum brake Type Leading and trailing Drum inside diameter 130 mm Limit 131 mm Lining thickness 4 mm Limit 1 mm Shoe spring free length 50 5 mm Brake lever and brake pedal Brake lever free play 2 5 mm Brake pedal free play 20 30 mm Clutch lever Clutch lever free play 10 15 mm Item SX 4 ...

Page 31: ...bar and swingarm M8 1 25 16 1 6 Kick starter and frame M10 1 25 52 5 2 Front wheel axle M14 1 5 58 5 8 Front brake disc M6 1 0 23 2 3 Front brake caliper M10 1 25 30 3 0 Brake hose union bolt M10 1 25 26 2 6 Brake caliper bleed screw M7 1 0 6 0 6 Rear wheel axle M14 1 5 85 8 5 Sprocket and wheel hub M8 1 25 30 3 0 Tension bar and rear brake shoe plate M8 1 25 16 1 6 Brake lever camshaft M6 1 0 10 ...

Page 32: ...esistance 10 kΩ Charging system type A C magneto generator CDI magneto Model manufacturer F5BP YAMAHA Nominal output 14 V 100 W at 5 000 r min Lighting coil resistance 0 24 0 36 Ω at 20 C Yellow Red Black Charging coil resistance 0 32 0 48 Ω at 20 C White Black Rectifier regulator Model manufacturer SH656 12 SHINDENGEN No load regulated voltage DC 14 1 14 9 V Capacity 8 A Battery Capacity 12 V 7AH...

Page 33: ...sher relay Type Condenser type Model manufacturer 3RS DENSO Self cancelling device No Flasher frequency 75 95 cycle min Wattage 10 W 2 3 4 W Starting circuit cut off relay Model manufacturer ACA12115 3 MATSUSHITA Diode Yes Circuit breaker Type Fuse Amperage for individual circuit quantity Main 15 A 1 Reserve 15 A 1 Item SX 4 ...

Page 34: ...ture A Distance across flats B Outside thread diameter DEFINITION OF UNITS A B A Nut B Bolt General torque specifications Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 Unit Read Definition Measure mm cm millimeter centimeter 10 3 meter 10 2 meter Length Length kg kilogram 103 gram Weight N Newton 1 ...

Page 35: ...e oil Valve stem IN EX M Molybdeum disulfide oil Valve stem end IN EX M Molybdeum disulfide oil Cam chain cam sprocket E Engine oil Oil pump shaft rotor IN OUT housing E Engine oil Kick shaft E Engine oil Kick idle sprocket inside E Engine oil Kick crank shaft LS Lithium soap base grease Kick idle gear kick gear E Engine oil Starter clutch E Engine oil Primary driven gear E Engine oil Push lever a...

Page 36: ...LS Lithium soap base grease Change pedal LS Lithium soap base grease Side main stand sliding surface LS Lithium soap base grease Tube guide throttle grip inner surface LS Lithium soap base grease Brake lever bolt sliding surface LS Lithium soap base grease Clutch lever collar sliding surface LS Lithium soap base grease Swingarm pivot bearing LS Lithium soap base grease Rear shock absorber bolt LS ...

Page 37: ...ad B Breather hose C Air vent hose D Throttle cable E Clutch cable F Magneto lead G Pick up coil lead H Wire harness È Clamp the wire harness É Pass the cable holder through the tachometer cable Ê Install the horn lead short side to the right side of the horn Ë Clamp the taillight lead Ì Clamp the wire harness Í Clamp the wire harness at the white tape portion F G H 0 A B C D E 1 2 3 4 5 6 7 8 9 Ë...

Page 38: ...e Ð Clamp the throttle cable and clutch cable Ñ Insert the air vent hose into the frame Ò Clamp the wire harness and turn the clamp end to inside of motorcycle Ó Clamp the magneto lead and pick up coil lead and push the leads into holder F G H 0 A B C D E 1 2 3 4 5 6 7 8 9 Ë Ì Í Î Ð Ï Ò Ó Ñ È É Ê CABLE ROUTING ...

Page 39: ...Pick up coil lead A Magneto lead B Fuel tank over flow hose È Install the horn lead long side to the left side of the horn É Clamp the battery breather hose carburetor over flow hose and fuel tank over flow hose Ê Pass the speedometer cable through the holder Ë Clamp the magneto lead and pick up coil lead Ì Clamp the battery breather hose A A 0 A B E D C 1 2 3 4 5 6 7 8 9 È É Ê Ë Ë Ì CABLE ROUTING...

Page 40: ...2 23 ...

Page 41: ... 12 AIR FILTER CLEANING 3 13 CARBURETOR JOINT INSPECTION 3 15 FUEL LINE INSPECTION 3 15 EXHAUST SYSTEM INSPECTION 3 16 CHASSIS 3 17 FRONT BRAKE ADJUSTMENT 3 17 BRAKE PAD INSPECTION 3 17 BRAKE FLUID LEVEL INSPECTION 3 18 AIR BLEEDING HYDRAULIC BRAKE SYSTEM 3 18 BRAKE HOSE INSPECTION 3 19 REAR BRAKE ADJUSTMENT 3 20 BRAKE SHOE INSPECTION 3 21 BRAKE LIGHT SWITCH ADJUSTMENT 3 21 DRIVE CHAIN SLACK ADJUS...

Page 42: ...INSP ADJ ELECTRICAL 3 28 BATTERY INSPECTION 3 28 FUSE INSPECTION 3 31 HEADLIGHT BEAM ADJUSTMENT 3 32 HEADLIGHT BULB REPLACEMENT 3 32 ...

Page 43: ...reather hose is properly routed 7 Clutch Check operation Adjust 8 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads if necessary 9 Rear brake Check operation and adjust brake pedal free play Replace brake shoes if necessary 10 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 11 Wheel bearings Check bearing for looseness damage 12...

Page 44: ... levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every two years Replace the brake hose every four years or if cracked or damaged 20 Carburetor Check starter choke operation Adjust engine idling speed 21 Engine oil Change 22 Engine oil filter ele ment Clean 23 Engine oil strainer Clean 24 Front and rear brake swi...

Page 45: ...holder b as shown SIDE COVER 1 Remove Seat 2 Remove Side covers left and right NOTE Remove screws a and knob b and then pull the side cover off as shown FUEL TANK 1 Remove Air scoop left and right Bolt Washer Fuel sender coupler Breather hose Fuel hose Fuel tank 1 NOTE Turn the fuel cock to OFF position before removing fuel hose ...

Page 46: ... Remove Air scoop left and right 1 2 Remove Spark plug Tappet cover intake side 1 Tappet cover exhaust side 2 3 Remove Timing mark accessing screw with O ring 1 Camshaft end cover with O ring 2 4 Measure Valve clearance Out of specification Adjust Measurement steps Rotate the crankshaft counterclockwise to align the slit a on the rotor with the slit b on the crankcase cover when the piston is Top ...

Page 47: ...djuster to prevent it from moving and tighten the locknut Measure the vale clearance If the clearance is incorrect repeat above steps until specified clearance is obtained 6 Install O ring Tappet cover intake side Turning in Valve clearance is decreased Turning out Valve clearance is increased Tappet adjusting tool 90890 01311 T R 14 Nm 1 4 m kg T R 18 Nm 1 8 m kg IDLING SPEED ADJUSTMENT 1 Start t...

Page 48: ... out until the specified idling speed is obtained 5 Adjust Throttle cable free play Refer to the THROTTLE CABLE ADJUST MENT section Engine idling speed 1 350 1 450 r min Pilot screw 3 turns out Turning in Idling speed is increased Turning out Idling speed is decreased THROTTLE CABLE ADJUSTMENT NOTE Prior to adjusting the throttle cable free play the engine idling speed should be adjusted 1 Check T...

Page 49: ...djusting nut on the handlebar side Handlebar side Loosen the locknut 1 Turn the adjusting nut 2 in or out until the specified throttle cable free play is obtained Tighten the locknut WARNING After adjusting the throttle cable free play start the engine and turn the handlebar to the right or left to ensure that this does not cause the engine idling speed to change Turn in Throttle cable free play i...

Page 50: ...rmal color is a medium to light tan color 3 Clean Spark plug with spark plug cleaner or wire brush 4 Measure Spark plug gap a with a wire gauge Out of specification Adjust gap Spark plug gap 0 6 0 7 mm COMPRESSION PRESSURE MEASUREMENT NOTE Insufficient compression pressure will result in performance loss 1 Start the engine and let it warm up for sev eral minutes 2 Turn off the engine 3 Remove Spar...

Page 51: ...ding on the compression gauge stabilizes WARNING Before cranking the engine ground all spark plug leads to prevent sparking Compression pressure With oil applied into cylinder Reading Diagnosis Higher than without oil Worn or damaged pistons Same as without oil Possible defective ring s valves cylinder head gas ket or piston Repair Compression pressure at sea level Standard 1 200 kPa 12 0 Kg cm2 1...

Page 52: ...ankcase NOTE Before checking the engine oil level wait a few minutes until the oil has settled Recommended oil Refer to the chart for the engine oil grade API standard SE or higher grade ENGINE OIL REPLACEMENT 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler bolt Engine oil drain bolt 1 along with...

Page 53: ...nt cover È Outside É Inside 6 Check Engine oil drain bolt gasket Oil filter element drain bolt gasket Damage Replace 7 Install Engine oil drain bolt along with the gasket Oil filter element drain bolt along with he gasket T R Oil filter element cover bolt 10 Nm 1 0 m kg T R 20 Nm 2 0 m kg T R 10 Nm 1 0 m kg 8 Fill Crankcase With the specified amount of the recom mended engine oil 9 Install Engine ...

Page 54: ...il engine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize Check the engine oil passages and the oil pump for damage or leakage Refer to the OIL PUMP section in CHAPTER 4 Start the engine after solving the problem s and check the engine oil pressure again Tighten the oil gallery bolt to specification T R Oil gall...

Page 55: ...ngine side Loosen the locknuts 1 Turn the adjusting bolt 2 in or out until the specified clutch cable free play is obtained Tighten the locknuts AIR FILTER CLEANING 1 Check Air filter check hoses 1 NOTE On the bottom of the air filter case is a check hoses 1 If dust or water or both collects in this hoses clean the air filter element and air filter case 2 Remove Side cover left Refer to the SIDE C...

Page 56: ...h solvents may cause a fire or an explo sion NOTE After cleaning gently squeeze the air filter ele ment to remove the excess solvent CAUTION Do not twist the air filter element when squeezing it 5 Check Air filter element Damage Replace 6 Apply the recommended oil to the entire sur face of the air filter element and squeeze out the excess oil The air filter element should be wet but not dripping R...

Page 57: ... element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning leading to poor engine performance and possible overheat ing CARBURETOR JOINT INSPECTION 1 Inspect Carburetor joint 1 Cracks Damage Replace FUEL LINE INSPECTION 1 Inspect Fuse hose Cracks Damage Replace ...

Page 58: ...t Exhaust pipe 1 Muffler 2 Cracks Damage Leak Repair or replace Exhaust pipe Joint 3 gasket 4 Damage Leak Repair or replace 2 Tighten Muffler and exhaust pipe T R Nuts exhaust pipe joint 5 18 Nm 1 8 m kg Bolt exhaust pipe joint 6 20 Nm 2 0 m kg Bolts muffler 7 30 Nm 3 0 m kg ...

Page 59: ...TION After adjusting the front brake lever free play make sure that there is no brake drag Free play brake lever 2 5 mm at brake lever end Turning in brake lever free play is decreased Turning out brake lever free play is increased BRAKE PAD INSPECTION 1 Operate the brake lever 2 Inspect Brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as set Refer to the BRAKE PAD PE...

Page 60: ...r The system is disassembled A brake hose is loosened or removed The brake fluid level is very low Brake operation is faulty If the brake system is not properly bled a loss of braking performance may occur 1 Bleed Brake system Air bleeding steps a Fill the reservoir with the proper brake fluid b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect a ...

Page 61: ...cult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the brake system have disappeared k Fill the brake fluid reservoir to the proper level Refer to the BRAKE FLUID LEVEL INSPECTION section WARNING After bleeding the brake system check the brake operation T R Bleed screw 6 Nm 0 6 m kg BRAKE HOSE INSPECTION 1 Inspect Brake hos...

Page 62: ...edal position Adjustment steps Loosen the locknut 1 Turn the adjusting bolt 2 in or out until the specified brake pedal position is obtained Tighten the locknut to specification Brake pedal position below the top of the rider footrest 30 mm Turn in Brake pedal is raised Turn out Brake pedal is lowered T R Locknut 10 Nm 1 0 m kg 3 Check Brake pedal free play a Out of specification Adjust Free play ...

Page 63: ...ee play is increased BRAKE SHOE INSPECTION 1 Operate the brake pedal 2 Inspect Brake shoes Wear indicator 1 reaches the wear limit line 2 Replace the brake shoes as a set Refer to the REAR WHEEL AND REAR BRAKE section in CHAPTER 6 BRAKE LIGHT SWITCH ADJUSTMENT 1 Check Brake light operation timing Incorrect Adjust 2 Adjust Brake light operation timing Adjustment steps Hold the main body 1 of the sw...

Page 64: ... drive chain slack is obtained NOTE Turn each chain adjuster nuts exactly the same amount to maintain correct axle align ment There are marks a on each chain adjuster nuts Use them when adjusting the slack for proper alignment Before tightening the axle nut and locknuts to specification make sure that there is no clearance at the adjuster nuts or the swin garm end on both sides by pushing the whee...

Page 65: ...load 200 kPa 2 0 kg cm2 200 kPa 2 0 kg cm2 100 kg maximum Load 200 kPa 2 0 kg cm2 225 kPa 2 25 kg cm2 2 Inspect Tire surfaces Wear Damage Replace 1 Tread depth 2 Side wall 3 Wear indicator Minimum tire tread depth front and rear 0 8 mm 3 After a tire repair or replacement be sure to tighten the valve stem locknut 1 to specifi cation STEERING HEAD INSPECTION 1 Stand the motorcycle on a level surfac...

Page 66: ...tem nut Handle crown 6 Adjust Steering head Adjustment steps Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 NOTE Set the torque wrench at a right angle to the ring nut wrench Loosen the lower ring nut 4 completely then tighten it to specification WARNING Do not overtighten the lower rin...

Page 67: ...slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned Install the lock washer 1 NOTE Make sure that the lock washer tabs a sit cor rectly in the ring nut slots b 7 Install Handle crown Steering stem nut Pinch bolt T R 110 Nm 11 0 m kg T R 23 Nm 2 3 m kg REAR SHOCK ABSORBER INSPECTION 1 Remove Seat Side cover right Refer to the SID...

Page 68: ... Ride conservatively after installing a tire to allow it to seat itself properly on the rim SPOKE INSPECTION AND TIGHTENING 1 Inspect Spokes 1 Bend Damage Replace Loose spoke Retighten 2 Tighten Spokes CABLE INSPECTION WARNING Damage cable sheath may cause corrosion and interfere with the cable movement An unsafe condition may result so replace such cable as soon as possible 1 Inspect Cable sheath...

Page 69: ...cable end and cable guide groove at inside of throttle housing 1 Level pedal 1 Lubricate the pivoting parts of the each lever and pedal Sidestand centerstand 1 Lubricate the pivoting parts Rear suspension 1 Lubricate the pivoting parts Recommended lubricant Engine oil Lithium soap base grease Recommended lubricant Engine oil Recommended lubricant Engine oil Recommended lubricant Lithium soap base ...

Page 70: ...ote INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive measures Change batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes etc DO NOT SMOKE when charging or han...

Page 71: ... sure that the breather hose is routed correctly If the breather hose is positioned in such a way as to allow battery electrolyte or gas to come into contact with the frame this could damage the motorcycle and ruin its finish 6 Check Specific gravity Less than 1 280 Recharge the battery Replace the battery if Battery voltage will not rise to a specific value or bubbles fail to rise during charging...

Page 72: ...s routed correctly If the breather pipe touches the frame or exits in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmetic damage to the motorcycle can occur 8 Inspect Battery terminals Dirty Clean with a wire brush Poor connection Correct NOTE After cleaning the terminals apply a light coat of grease 9 Install Battery 10 Connect Battery leads CAUTION Fi...

Page 73: ...ce Blown fuse Blown fuse replacement steps Turn off ignition and the circuit Install a new fuse of proper amperage Turn on switches to verify operation of elec trical device If fuse blows immediately again check circuit in question WARNING Do not use fuse of higher amperage rating than recommended Extensive electrical system damage and fire could result from substitution of a fuse of improper ampe...

Page 74: ...olt headlight body Position the headlight body up or down to adjust the headlight beam 3 Install Headlight unit HEADLIGHT BULB REPLACEMENT 1 Remove Holding screw 1 Headlight unit 2 2 Remove Cover 1 Bulb defective NOTE Turn the bulb holder 2 counterclockwise to remove the bulb WARNING Keep flammable products and your hands away from the bulb while it is on it will be hot Do not touch the bulb until...

Page 75: ...b holder CAUTION Avoid touching glass part of bulb Also keep it free from oil otherwise transpar ency of glass bulb life and illuminous flux will be adversely affected If oil gets on bulb clean it with a cloth moistened thor oughly with alcohol or lacquer thinner 4 Install Cover Headlight unit ...

Page 76: ...EAD INSPECTION 4 12 TIMING CHAIN TENSIONER INSPECTION 4 13 CYLINDER HEAD INSTALATION 4 14 CAMSHAFT AND ROCKER ARMS 4 16 ROCKER ARM AND CAMSHAFT REMOVAL 4 17 CAMSHAFT INSPECTION 4 18 ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 4 18 CAMSHAFT AND ROCKER ARM INSTALLATION 4 19 VALVES AND VALVE SPRINGS 4 21 VALVE AND VALVE SPRINGS REMOVAL 4 22 VALVES AND VALVE SPRINGS INSPECTION 4 24 VALVE SEATS INSPEC...

Page 77: ... 4 51 SHIFT SHAFT INSPECTION 4 52 KICK SHAFT ASSEMBLING 4 53 SHIFT SHAFT AND KICK STARTER INSTALLATION 4 53 OIL PUMP 4 54 OIL PUMP REMOVAL 4 55 OIL PUMP INSPECTION 4 55 OIL PUMP INSTALLATION 4 56 CRANKCASE AND CRANKSHAFT 4 57 CRANKCASE SEPARATING 4 58 CRANKSHAFT INSPECTION 4 59 BEARINGS AND OIL SEALS INSPECTION 4 60 TIMING CHAIN TIMING CHAIN DRIVE SPROCKET AND TIMING CHAIN GUIDES INSPECTION 4 60 C...

Page 78: ...h Kickstarter shaft and shift shaft Oil pump Generator 1 Remove Seat Fuel tank Refer to the SEAT FUEL TANK section in CHAPTER 3 WARNING Securely support the motorcycle so there is no danger of it falling over ENGINE OIL 1 Remove Drain plug Refer to the ENGINE OIL REPLACEMENT section in CHAPTER 3 EXHAUST PIPE ASSEMBLY 1 Remove Bolts right footrest bracket Right footrest bracket 1 ...

Page 79: ...e 4 Remove Exhaust pipe assembly 5 Remove Bolts muffler Nut muffler Muffler 1 LEFT FOOTREST BRACKET 1 Remove Bolt shift pedal Bolts left footrest bracket Left footrest bracket 1 NOTE When removing shift pedal shift the transmis sion into 1st gear DRIVE CHAIN 1 Remove Drive chain case 1 ...

Page 80: ...heel axle nut Locknuts Drive chain adjuster nuts CARBURETOR 1 Remove Carburetor Refer to the CARBURETOR section in CHAPTER 5 WIRE CABLE AND TUBE 1 Remove Spark plug lead cap 1 Ignition coil 2 2 Straighten Stopper 3 Remove Clutch cable 1 4 Remove Breather hose 1 Tachometer cable 2 ...

Page 81: ...enerator lead coupler 2 Generator leads 3 STARTER MOTOR 1 Remove Starter motor Refer to the ELECTRIC STARTING SYS TEM in CHAPTER 7 ENGINE 1 Remove Engine mounting bracket 1 2 Remove Rear upper mounting bolt 1 Front mounting bolt 2 Rear lower mounting bolt 3 ...

Page 82: ...ounting bracket Bolt engine mounting bracket frame Bolt engine mounting bracket engine STARTER MOTOR 1 Install Starter motor Refer to the ELECTRIC STARTING SYS TEM in CHAPTER 7 T R Rear lower mounting bolt 79 Nm 7 9 m kg Rear upper mounting bolt 58 Nm 5 8 m kg T R Front mounting bolt 58 Nm 5 8 m kg T R Bolt engine mounting bracket frame 30 Nm 3 0 m kg Bolt engine mounting bracket engine 58 Nm 5 8 ...

Page 83: ...d cap CARBURETOR 1 Install Carburetor Refer to the CARBURETOR section in CHAPTER 5 DRIVE CHAIN 1 Install Drive chain Drive sprocket Lock washer T R Nut drive chain 110 Nm 11 0 m kg 2 Install Drive chain case LEFT FOOTREST BRACKET 1 Install Left footrest bracket T R Bolt shift arm 10 Nm 1 0 m kg Bolt footrest bracket 30 Nm 3 0 m kg ...

Page 84: ...8 Nm 1 8 m kg Bolt exhaust pipe joint 20 Nm 2 0 m kg Bolts muffler 30 Nm 3 0 m kg 5 Install Right footrest bracket Bolts right footrest bracket FUEL TANK AND SEAT 1 Install Fuel tank Seat Refer to the SEAT FUEL TANK REMOVAL AND INSTALLATION section in CHAPTER 3 2 Fill Engine oil Into crankcase Refer to the ENGINE OIL REPLACEMENT section in CHAPTER 3 ENGINE INSTALLATION ...

Page 85: ...ver free play Refer to the THROTTLE CABLE ADJUST MENT CLUTCH ADJUSTMENT section in CHAPTER 3 4 Adjust Drive chain slack Refer to the DRIVE CHAIN SLACK ADJUSTMENT section in CHAPTER 3 Throttle cable free play 3 5 mm Clutch lever free play 10 15 mm Drive chain slack 20 30 mm ...

Page 86: ...EAD CYLINDER HEAD 1 O ring 2 Tappet cover 3 O ring 4 Camshaft sprocket cover 5 Plate 6 Cam chain tensioner 7 Gasket 8 Camshaft sprocket 9 Gasket 0 Dowel pin A Cylinder head B Spark plug C Timing chain guide exhaust side ...

Page 87: ...tor joint 1 Spark plug 2 4 Remove Tappet cover 1 Tachometer cable 2 Camshaft sprocket cover 3 5 Remove Timing mark accessing screw with O ring 1 Camshaft end cover with O ring 2 6 Align Camshaft sprocket I mark With the stationary pointer on the cylinder head TDC alignment steps Turn the crankshaft counter clockwise with a wrench Align the camshaft sprocket I mark 1 with the stationary pointer 2 o...

Page 88: ...ne counter clock wise turn to meet above condition 7 Loosen Bolt camshaft sprocket 1 NOTE Hold the crankshaft end with a wrench 2 8 Remove Cam chain tensioner 1 9 Remove Camshaft sprocket NOTE Fasten a safety wire to the cam chain 10 Remove Engine mounting bracket Refer to the ENGINE REMOVAL section 11 Remove Cylinder head 1 NOTE Loosen the bolts in this stage using a criss cross pattern CYLINDER ...

Page 89: ...r head Scratches damage Replace 3 Measure Cylinder head warpage Out of specification Resurface Warpage measurement and resurfacement steps Place a straightedge and feeler gauge across the cylinder head Measure the warpage If the warpage is out of specification resur face the cylinder head Place a 400 600 grit wet abrasive paper on the surface plate and resurface the head using a figure eight sandi...

Page 90: ...he timing chain tensioner housing by hand NOTE While pressing the timing chain tensioner rod wind it clockwise with stopper 1 until it stops b Remove your finger and slowly release the timing chain tensioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner ...

Page 91: ...cing outward Force the camshaft counter clockwise to remove the cam chain slack Insert your finger into the cam chain ten sioner hole and push the cam chain damper inward While pushing the cam chain damper be sure the camshaft sprocket I mark 1 aligns with the stationary pointer 2 on the cylinder head at TDC If marks are aligned tighten the camshaft sprocket bolt temporary If marks do not align ch...

Page 92: ...lign Adjust 6 Adjust Valve clearance Refer to the VALVE CLEARANCE ADJUST MENT section in CHAPTER 3 7 Install Tappet cover Camshaft sprocket cover 8 Install Spark plug Carburetor joint T R Bolt tensioner cylinder 10 Nm 1 0 m kg Bolt camshaft sprocket 60 Nm 6 0 m kg Intake valve cold 0 05 0 10 mm Exhaust valve cold 0 10 0 15 mm T R Tappet cover 18 Nm 1 8 m kg Camshaft sprocket cover 10 Nm 1 0 m kg T...

Page 93: ...4 16 ENG CAMSHAFT AND ROCKER ARMS CAMSHAFT AND ROCKER ARMS 1 Locknut 2 Valve adjuster 3 Rocker arm 4 Rocker arm shaft exhaust 5 Rocker arm shaft intake 6 O ring 7 Bearing 8 Camshaft 9 Plate ...

Page 94: ...mshaft remove the cylinder head 1 Loosen Locknut 1 Valve adjuster 2 2 Remove Stopper plate 3 3 Remove Camshaft 1 Bearing 2 NOTE Remove the camshaft and collar by using 10 mm bolt 3 4 Attach Slide hammer set 1 5 Remove Rocker arm shaft Rocker arm intake exhaust Slide hammer bolt 90890 01085 Weight 90890 01084 ...

Page 95: ...Exhaust a 36 564 36 664 mm Limit 36 46 mm b 30 216 30 316 mm Limit 30 12 mm 3 Inspect Camshaft oil passage Stuffed Blow out oil passage with com pressed the air YP402060 ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 1 Inspect Cam lobe contact surface 1 Adjuster surface 2 Wear Pitting Scratches Blue discoloration Replace Inspection steps Inspect the two contact areas on the rocker arms for signs of ...

Page 96: ...ter of the rocker arm shafts Out of specification Replace Inside diameter rocker arm 14 992 15 000 mm Limit 15 02 mm Outside diameter rocker arm shaft 14 960 14 981 mm Limit 14 94 mm YP CAMSHAFT AND ROCKER ARM INSTALLATION 1 Lubricate Rocker arm shaft Rocker arm inner surface 2 Install Rocker arm 1 Rocker arm shaft 2 NOTE Install the rocker arm shaft exhaust com pletely pushed in Rocker arm shaft ...

Page 97: ...4 20 ENG CAMSHAFT AND ROCKER ARMS 3 Lubricate Camshaft 1 Camshaft Molybdenum disulfide grease Camshaft bearing Engine oil 4 Install Plate 1 Bolts 2 T R 8 Nm 0 8 m kg ...

Page 98: ...4 21 ENG VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS 1 Valve cotter 2 Upper spring seat 3 Lower spring seat 4 Oil seal 5 Inner valve spring 6 Outer valve spring 7 Valve ...

Page 99: ...alve valve spring valve seat etc of the cylinder head the valve sealing should be checked 1 Check Valve sealing Leakage at valve seat Inspect the valve face valve seat and valve seat width Refer to the VALVE SEATS INSPECTION section Valve seat checking steps Pour a clean solvent 1 into the intake and exhaust ports Check the valve seating There should be no leakage at the valve seat 2 ...

Page 100: ... spring seat 6 Valve 7 NOTE Identify each part position very carefully so that it can be reinstalled in its original place Deburr any deformed valve stem end Use an oil stone to smooth the stem end 1 Deburr 2 Valve stem 4 Eliminate Carbon deposit From the combustion chamber Use a rounded scraper NOTE Do not use a sharp instrument and avoid dam aging or scratching Spark plug threads Valve seat Cyli...

Page 101: ... Compressed valve spring force a Out of specification Replace b Installed length YP402030 5 Measure Valve spring tilt a Out of specification Replace Valve stem diameter Intake 5 975 5 990 mm Limit 5 95 mm Exhaust 5 960 5 975 mm Limit 5 935 mm Runout limit 0 03 mm Valve spring free length Inner valve spring 36 17 mm Limit 34 47 mm Outer valve spring 36 63 mm Limit 34 63 mm Inner valve spring 30 5 m...

Page 102: ...ace the valve guide Valve guide inside diameter Intake 6 000 6 012 mm Limit 6 042 mm Exhaust 6 000 6 012 mm Limit 6 042 mm Stem to guide clearance Valve guide inside diameter a Valve stem diameter Stem to guide clearance limit Intake 0 08 mm Exhaust 0 1 mm EB402020 VALVE SEATS INSPECTION 1 Eliminate Carbon deposits from the valve face and valve seat 2 Inspect Valve seats Pitting wear Reface the va...

Page 103: ...e face made contact blueing will have been removed If the valve seat is too wide too narrow or the seat is not centered the valve seat must be replaced Valve seat width Intake 0 9 1 1 mm Limit 1 6 mm Exhaust 0 9 1 1 mm Limit 1 6 mm EB402020 4 Lap Valve face Valve seat NOTE After replacing the valve seat valve and valve guide the valve seat and valve face should be lapped Lapping steps Apply a coar...

Page 104: ...ng operation Apply Mechanic s blueing dye Dykem b to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clean pattern Measure the valve seat width c again EB404032 VALVES AND VALVE SPRINGS INSTALLATION 1 Deburr Valve stem end Use an oil stone to smooth the stem end 2 Apply Molybdenum disulfide oil onto the valve stem 3 ...

Page 105: ...Install the valve cotters while compressing the valve spring with a valve spring compressor 2 5 Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood CAUTION Do not hit so much as to damage the valve Valve spring compressor 90890 04019 ...

Page 106: ...4 29 ENG CYLINDER AND PISTON CYLINDER AND PISTON 1 Oil delivery pipe 2 Cylinder 3 O ring 4 Gasket 5 O ring 6 Dowel pin 7 Piston 8 Piston rings 9 Piston pin clip 0 Piston pin ...

Page 107: ...Remove Piston pin clip 1 NOTE Before removing the piston pin clip cover the crankcase with a clean rag 2 so you will not accidentally drop the clip into the crankcase 4 Remove Piston pin 1 Piston 2 NOTE Before removing the piston pin deburr the clip grooved and pin hole area If the piston pin groove is deburred and piston pin is still diffi cult to remove use the piston pin puller CAUTION Do not u...

Page 108: ...N 1 Measure Cylinder bore Out of specification Rebore or replace NOTE Measure the cylinder bore with a cylinder bore gauge Measure the cylinder bore in parallel to and at right angles to the crankshaft Then find the average of the measurements Cylinder bore 70 000 70 018 mm Limit 70 1 mm Difference limit between A B and C 0 03 mm 2 Measure Warpage Out of specification Replace Cylinder warpage limi...

Page 109: ...as a set Piston skirt diameter 69 977 69 996 mm Oversize 2 70 50 mm Oversize 4 71 00 mm Piston to cylinder clearance Cylinder bore Piston skirt diameter Piston to cylinder clearance 0 020 0 025 mm Limit 0 05 mm 3 Measure Piston pin bore diameter Out of specification Replace 4 Measure Piston pin outside diameter Out of specification Replace 5 Inspect Piston pin Blue discoloration groove Clean or re...

Page 110: ...ring 0 03 0 07 mm Limit 0 1 mm 2 nd ring 0 02 0 06 mm Limit 0 1 mm 2 Position Piston rings into the cylinder NOTE Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore 3 Measure End gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of the oil ring If the oil ring rails show excessive gap replace all three rings ...

Page 111: ...iston pin 2 Piston pin clip 3 NOTE Apply engine oil onto the piston pins The mark a on the piston must face the exhaust side of the cylinder Before installing the piston pin clip cover the crankcase opening with a clean rag to pre vent the piston pin clip from falling into the crankcase Make sure to install each piston in its respec tive cylinder 3 Install O ring Gasket cylinder Dowel pins New New...

Page 112: ...face Engine oil 6 Install Cylinder 1 NOTE Install the cylinder with one hand while com pressing the piston rings with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cav ity 7 Install Oil delivery pipe 1 CYLINDER AND PISTON ...

Page 113: ...ve sprocket cover 2 Cover 3 O ring 4 Crankcase cover left 5 Gasket 6 Dowel pin 7 Stator assembly 8 Pickup coil 9 Generator rotor 0 Starter clutch A Starter clutch gear B Bearing C Starter clutch idle gear 2 D Starter clutch idle gear 1 ...

Page 114: ...n in CHAP TER 3 2 Remove Left footrest bracket Refer to the LEFT FOOTREST BRACKET section 3 Remove Drive sprocket cover 1 Cover 2 4 Remove Starter idle gear 1 1 Bearing 2 Shaft 3 5 Remove Neutral switch leads 1 Crankcase cover left NOTE Working in a crisscross loosen the bolts 1 4 turn each Remove them after all are loos ened M6 40 mm bolts 1 6 M6 30 mm bolts 7 9 6 Remove Gasket Dowel pin ...

Page 115: ...the sheave holder Loosen the nut while holding the generator rotor with sheave holder 2 2 Remove Generator rotor 1 Use a flywheel puller 2 Sheave holder 90890 01701 Flywheel puller 90890 01362 3 Remove Woodruff key 1 4 Remove Washer 1 Starter clutch idle gear 2 2 Washer 3 Starter clutch gear 4 Bearing 5 Washer 6 ...

Page 116: ...to the starter clutch 2 and hold the starter clutch b When turning the starter clutch gear clock wise È the starter clutch and the starter clutch gear should engage If the starter clutch gear and starter clutch do not engage the starter clutch is faulty and must be replaced c When turning the starter clutch gear coun terclockwise É it should turn freely If the starter clutch gear does not turn fre...

Page 117: ...installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft NOTE Do not allow the special tool to touch the pro jection a on the generator rotor Sheave holder 90890 01701 T R Nut rotor 60 Nm 6 0 m kg CRANKCASE COVER LEFT INSTALLATION 1 Install Stator coil 1 Pickup coil 2 2 Install Dowel pin Gasket T R Bolts starter coil 7 Nm 0 7 m kg Screws pickup ...

Page 118: ...lts 1 6 M6 30 mm bolts 7 9 T R Bolts crankcase cover left 7 Nm 0 7 m kg 4 Install Neutral switch lead 1 5 Install Starter clutch idle gear 1 Cover 1 Drive sprocket cover 2 6 Install Left footrest bracket Refer to the LEFT FOOTREST BRACKET section 7 Install Fuel tank Refer to the FUEL TANK section in CHAP TER 3 GENERATOR ...

Page 119: ... 4 Compression spring 5 Pressure plate 6 Push plate 7 Push rod 1 8 Clutch plate 9 Friction plate 1 0 Cushion spring A Friction plate 2 B Clutch boss C Thrust washer D Clutch housing E Ball F Push rod 2 G Push lever assembly H Primary drive gear I Collar J Straight key ...

Page 120: ... ring 3 filter cover O ring 4 2 Remove Oil delivery pipe 1 3 Remove Kick starter 1 4 Remove Crankcase cover right NOTE Working in a crisscross pattern loosen screw 1 4 turn each Remove them after all are loosened Be sure not to give damages to the mating surface M6 55 mm bolt 1 M6 50 mm bolts 2 4 M6 35 mm bolt 5 M6 25 mm bolts 6 C 5 Remove Gasket Dowel pin ...

Page 121: ...utch plate 4 5 pcs Cushion spring 5 Push plate 6 Push rod 1 7 Ball 8 Push rod 2 9 3 Straighten Lock washer tab NOTE Slide the right side of crankcase to remove ball and push rod 1 4 Loosen Nut clutch boss Nut primary drive gear NOTE Loosen the nut clutch boss while holding the clutch boss with universal clutch holder 1 Universal clutch holder 90890 04086 ...

Page 122: ...ate 1 2 Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set Measure at four places 3 Inspect Clutch plates Damage Replace the clutch plates as a set 4 Measure Clutch plate warpage Out of specification Replace the clutch plates as a set Use a surface plate and a feeler gauge 1 Thickness friction plate 1 2 2 9 ...

Page 123: ...fication Replace the clutch springs as a set Free length clutch spring 34 9 mm Limit 33 2 mm 7 Inspect Push rod 2 Wear crack damage Replace 8 Measure Push rod 2 Out of specification Replace Bending limit push rod 2 0 5 mm 9 Inspect Dogs on the housing Cracks wear damage Deburr or replace 10 Inspect Clutch housing bearing 1 Cracks wear damage Replace ...

Page 124: ...y drive gear 2 Crow washer 3 Lock washer 4 Nut primary drive gear 5 New T R 80 Nm 8 0 m kg 2 Install Clutch housing Thrust washer Clutch bass Lock washer 1 Nut 2 clutch boss NOTE Install the primary drive gear and clutch boss nut 2 while holding the clutch boss with a clutch holding tool 3 3 Bend Lock washer tab 1 primary drive gear and clutch boss along a flat side of the end Universal clutch hol...

Page 125: ...tall Pressure plate 1 Compression springs Bolts 2 compression springs NOTE Tighten the bolts in a crisscross pattern T R 6 Nm 0 6 m kg 6 Adjust Clutch mechanism free play Clutch mechanism free play adjustment steps Loosen the locknut 1 Push the push lever toward the front of the engine with your finger to align the push lever tab with the alignment mark on the crankcase With the push lever in this...

Page 126: ...all Dowel pins 1 Gasket 2 New 9 Install Crankcase cover right M6 55 mm bolt 1 M6 50 mm bolts 2 4 M6 35 mm bolt 5 M6 25 mm bolts 6 C T R Bolts crankcase cover right 10 Nm 1 0 m kg 10 Install Kick crank 1 NOTE Align the lip a of kick crank boss with the bolt b as shown CLUTCH ...

Page 127: ...4 50 ENG KICK STARTER AND SHIFT SHAFT KICK STARTER AND SHIFT SHAFT 1 Kick shaft 2 Kick segment gear 3 Kick pinion gear 4 Kick spring 5 Kick crank 6 Shift shaft assembly 7 Stopper lever ...

Page 128: ...using Refer to the CLUTCH REMOVAL section 2 Remove Shift pedal Refer to the LEFT FOOTREST BRACKET section 3 Remove Circlip 1 Washer 2 Kick pinion gear 3 Washer 4 Circlip 5 4 Remove Kick shaft assembly 1 Shift shaft assembly 2 5 Remove Stopper lever assembly 1 T KICK STARTER INSPECTION 1 Inspect Kick segment gear 1 Ratchet gear teeth 2 Wear damage Replace ...

Page 129: ...pring Wear crack Replace T402200 SHIFT SHAFT INSPECTION 1 Inspect Stopper lever Roller turns roughly Replace Bends damage Replace 2 Inspect Stopper lever spring Wear damage Replace 3 Inspect Shift shaft assembly Shift shaft spring Bends wear damage Replace ...

Page 130: ...ick shaft a to the kick segment gear b SHIFT SHAFT AND KICK STARTER INSTALLATION 1 Install Stopper lever assembly 1 T R Bolt stopper 10 Nm 1 0 m kg LOCTITE 2 Install Shift shaft assembly 1 Kick shaft assembly 2 NOTE Hook the kick spring onto the crankcase stop per 3 Install Circlip 1 Washer 2 Kick pinion gear 3 Washer 4 Circlip 5 4 Bend Lock washer ...

Page 131: ...4 54 ENG OIL PUMP OIL PUMP 1 Oil pump assembly 2 Oil pump gear 3 Circlip 4 Gasket 5 Oil strainer ...

Page 132: ...TION 1 Measure Tip clearance È between the inner rotor 1 and the outer rotor 2 Side clearance É between the outer rotor 2 and the pump housing 3 Out of specification Replace the oil pump assembly Housing and rotor clearance Ê between the pump housing 3 and the rotors 1 2 Out of specification Replace the oil pump assembly Tip clearance È 0 15 mm Limit 0 20 mm Side clearance É 0 04 0 09 mm Limit 0 1...

Page 133: ...MP 2 Inspect Oil stainer Cracks damage Replace Contamination Clean the flushing oil OIL PUMP INSTALLATION 1 Install Gasket 1 Oil pump assembly 2 Oil pump gear 3 Circlip 4 Oil strainer 5 T R Bolt oil pump 6 Nm 0 6 m kg ...

Page 134: ... AND CRANKSHAFT CRANKCASE AND CRANKSHAFT 1 Crankcase left 2 Crankcase right 3 Dowel pin 4 Crank shaft assembly 5 Bearing 6 Timing chain drive sprocket 7 Timing chain 8 Timing chain guide intake side 9 Drain bolt 0 Gasket ...

Page 135: ...n at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them M6 70 mm bolts 2 4 M6 60 mm bolts 5 6 M6 55 mm bolts 7 9 M6 45 mm bolts 0 C 3 Remove Circlip 1 Crankcase right NOTE Align the shift drum 2 projections with the slots on the right crankcase before removing right crankcase CAUTION Use soft hammer to tap on the case half tap only on reinforced port...

Page 136: ...shaft and or bearing NOTE Measure the crankshaft runout with the crank shaft assembly turning slowly 2 Measure Big end side clearance 2 Out of specification Replace big end bear ing crank pin and or connecting rod 3 Measure Crank width 3 Out of specification Replace crankshaft Runout limit 0 03 mm Big end side clearance 0 35 0 85 mm Crank width 69 25 69 30 mm 4 Inspect Bearing 1 Wear crack damage ...

Page 137: ... finger Rough movement Replace 2 Check Oil seals Damage wear Replace EAS00207 TIMING CHAIN TIMING CHAIN DRIVE SPROCKET AND TIMING CHAIN GUIDES INSPECTION 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check Timing chain drive sprocket More than 1 4 tooth a wear Replace the camshaft sprocket and the timing chain as a set a 1 4 tooth b Correct 1 Timin...

Page 138: ... the crankshaft bottoms against the bearing Crankshaft installer pot 2 90890 01274 Crankshaft installer bolt 3 90890 01275 Adaptor M10 4 90890 01383 spacer 5 90890 01288 CRANKCASE ASSEMBLING 1 Apply Sealant To the mating surface of both case halves 1 2 Install Dowel pins 2 3 Fit the right crankcase onto the left case Tap lightly on the case with a soft hammer CAUTION Before installing and torquing...

Page 139: ...n a crisscross pattern Install a copper washer on bolts 1 2 3 M6 70 mm bolts 1 3 M6 60 mm bolts 4 5 M6 55 mm bolts 6 8 M6 45 mm bolts 9 B 5 Install Neutral switch C T R Bolt left crankcase 10 Nm 1 0 m kg 6 Install Push lever clutch Timing chain drive sprocket 1 Timing chain guide intake side 2 Timing chain 3 ...

Page 140: ... pinion gear 2 3rd 4th pinion gear 3 5th pinion gear 4 2nd pinion gear 5 Drive axle 6 1st wheel gear 7 3rd wheel gear 8 4th wheel gear 9 5th wheel gear 0 2nd wheel gear A Drive sprocket B Shift drum assembly C Shift fork L D Shift fork C E Shift fork R ...

Page 141: ...um assembly 4 NOTE Note the position of each part Pay particular attention to the location and direction of shift forks 2 Remove Transmission gear assembly 1 T402190 SHIFT FORK SHIFT CAM INSPECTION 1 Inspect Shift fork cam follower 1 Shift fork pawl 2 Scoring bends wear damage Replace 2 Inspect Shift drum grooves 1 Wear damage scratches Replace Shift drum segment 2 Damage wear Replace ...

Page 142: ...hift fork guide bar Unsmooth operation Replace the shift fork and the shift fork guide bar NOTE When damaged the shift fork and mission gear replace the facing each gear as set EAS00424 TRANSMISSION INSPECTION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure Drive axle runout with a centering device and dial gauge 1 Out of spe...

Page 143: ... the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies NOTE When reassembling the main axle press the 2nd pinion gear 1 onto it 2 as shown 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Damage bends looseness Replace ...

Page 144: ...ork L 3 Shift fork C Shift fork R 4 Into the crankcase right Guide bar 5 NOTE Facing the mark on shift fork down ward 2 Check Shifter operation Unsmooth operation Repair NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely ...

Page 145: ...CARB CHAPTER 5 CARBURETION CARBURETOR 5 1 REMOVAL 5 2 DISASSEMBLY 5 3 INSPECTION 5 5 ASSEMBLY 5 7 INSTALLATION 5 9 FUEL LEVEL ADJUSTMENT 5 10 ...

Page 146: ...CARB ...

Page 147: ...le set 4 Pilot screw set 5 Piston valve 6 Starter plunger assembly 7 Needle jet 8 Pilot jet 9 Throttle stop screw set 0 Gasket A Main jet B Needle valve assembly C Needle valve holder D Drain hose E Float pivot pin F Float G Drain screw H Pilot air jet I Coasting enricher J Coasting enricher spring ...

Page 148: ...Avoid spilling fuel on the hot engine 1 Remove Fuel tank Refer to the FUEL TANK section in CHAPTER 3 2 Remove Battery Refer to the BATTERY INSPECTION sec tion in CHAPTER 3 3 Remove Drive chain guard 1 4 Remove Battery case 1 5 Remove CDI unit 1 Starter relay 2 Fuse 3 ...

Page 149: ...drain screw 1 and drain the gas oline 8 Loosen Lock nut 2 throttle cable 9 Remove Throttle cable 3 10 Loosen Screw 1 carburetor joint 11 Remove Carburetor 1 DISASSEMBLY 1 Remove Vacuum chamber cover 1 2 Remove Piston valve spring 2 Piston valve 3 CARBURETOR ...

Page 150: ...5 4 CARB CARBURETOR 3 Remove Jet needle set 1 4 Remove Pilot screw set 1 5 Remove Float chamber cover 1 Gasket 6 Remove Float pivot pin 1 Float 2 Needle valve 3 7 Remove Needle valve holder 1 ...

Page 151: ...etor body Fuel passage Contamination Clean as indicated Carburetor cleaning steps Wash carburetor in petroleum based solvent Do not use any caustic carburetor cleaning solution Blow out all passages and jets with a com pressed air 2 Inspect Float Damage Replace 3 Inspect Needle valve assembly 1 Damage wear contamination Replace as a set ...

Page 152: ... for cracks by pouring gasoline into the valve If it leaks replace with a new piston valve 5 Check Free movement Insert the throttle valve into the carburetor body and check for free movement Stick Replace 6 Inspect Main jet 1 Needle jet 2 Pilot jet 3 Pilot screw 4 Pilot air jet 5 Bends wear damage Replace Contamination Blow out jets with a com pressed air 7 Inspect Starter plunger assembly 1 ...

Page 153: ...ways use a new gasket 1 Install Jet needle set To piston valve assembly NOTE Be sure to install the jet needle plate so that the projection a is located toward the hole b in the piston valve 2 Install Pilot screw set 1 Note the following installation points Screw in the pilot screw 4 until it is lightly seated Back out by the specified number of turns Pilot screw turn out 2 1 2 ...

Page 154: ...lder T R Screw float valve holder 2 Nm 0 2 m kg 5 Install Float chamber cover 1 T R Screw float chamber cover 5 Nm 0 5 m kg 6 Install Piston valve assembly 1 Piston valve spring 2 Vacuum chamber cover 3 NOTE Match the tab a on the rubber diaphragm to the matching recess b in the piston valve T R Screw vacuum chamber cover 4 Nm 0 4 m kg ...

Page 155: ...o insert the projection a into the slot b of carburetor joint 2 Adjust Engine idle speed Refer to the IDLING SPEED ADJUST MENT section in CHAPTER 3 Engine idle speed 1 350 1 450 r min 3 Adjust Throttle cable free play a throttle grip Refer to the THROTTLE CABLE ADJUST MENT section in CHAPTER 3 Throttle cable free play 3 5 mm ...

Page 156: ...t the fuel level gauge 1 to the drain pipe 2 using a level gauge adapter Loosen the drain screw 3 Measure the fuel level a with the gauge If the fuel level in incorrect adjust the fuel level Remove the carburetor Inspect the needle valve If it is worn replace it If it is fine adjust float level by bending the float tang b slightly Install the carburetor Recheck the fuel level Fuel level 2 7 4 7 mm...

Page 157: ...2 FRONT BRAKE CALIPER 6 12 MASTER CYLINDER 6 13 BRAKE PAD REPLACEMENT 6 14 FRONT BRAKE CALIPER REMOVAL 6 16 FRONT BRAKE CALIPER INSPECTION 6 17 FRONT BRAKE CALIPER INSTALLATION 6 17 MASTER CYLINDER REMOVAL 6 20 MASTER CYLINDER INSPECTION 6 20 MASTER CYLINDER INSTALLATION 6 21 FRONT FORK 6 24 FRONT FORK REMOVAL 6 25 FRONT FORK DISASSEMBLY 6 25 FRONT FORK INSPECTION 6 27 FRONT FORK ASSEMBLY 6 27 FRO...

Page 158: ...REMOVAL 6 42 REAR SHOCK ABSORBER INSPECTION 6 43 SWINGARM INSPECTION 6 43 RELAY ARM INSPECTION 6 44 CONNECTING ARM INSPECTION 6 44 DRIVE CHAIN INSPECTION 6 44 REAR WHEEL CLUTCH HUB INSPECTION 6 46 DRIVEN SPROCKET ASSEMBLY 6 46 REAR SHOCK ABSORBER AND SWINGARM INSTALLATION 6 46 ...

Page 159: ...6 1 CHAS FRONT WHEEL AND BRAKE DISC CHASSIS FRONT WHEEL AND BRAKE DISC 1 Front wheel axle 2 Collar 3 Oil seal 4 Bearing 5 Spacer 6 Meter clutch 7 Speedometer gear unit 8 Brake disc ...

Page 160: ... is no danger of it falling over 1 Place the motorcycle on level place 2 Remove Speedometer cable 1 Front wheel axle nut 2 3 Remove Front wheel axle 1 Collar 2 Speedometer gear unit 3 Front wheel 4 T FRONT WHEEL DISASSEMBLY 1 Remove Bearings 1 Spacer 2 Remove the bearings using a general bear ing puller 3 ...

Page 161: ... Refer to the TIRE INSPECTION section in CHAPTER 3 Front wheel Refer to the WHEEL INSPECTION section in CHAPTER 3 3 Check Spokes Bends damage Replace Loose spokes Retighten Turn the wheel and tap the spokes with a screwdriver NOTE A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Tighten Loose spokes Nipple NOTE Check the front wheel runout after tightening the spokes Wh...

Page 162: ...Grooved wear Replace the collar and the oil seal as a set Front wheel runout limits Radial 2 0 mm Lateral 2 0 mm BRAKE DISC INSPECTION 1 Inspect Brake disc Galling damage Replace 2 Measure Brake disc deflection a Out of specification Inspect the wheel runout If wheel runout is within the limits replace the brake disc Measuring point 2 mm Brake disc thickness b Out of specification Replace Brake di...

Page 163: ...e oil seal with its manufacturer s marks or numbers facing outward CAUTION Do not strike the inner race of balls of the bearing Contact should be made only with the outer race FRONT WHEEL INSTALLATION 1 Install Brake disc 1 NOTE Apply LOCTITE to the threads of the brake disc bolts Tighten the brake disc bolts in stages using a crisscross pattern T R 23 Nm 2 3 m kg 2 Install Speedometer gear unit 1...

Page 164: ...HAS FRONT WHEEL AND BRAKE DISC 3 Tighten Front wheel axle nut NOTE Be sure that the projection torque stopper a of the gear unit housing is positioned correctly T R 58 Nm 5 8 m kg 4 Connect Speedometer cable ...

Page 165: ...E 1 Drive chain puller 2 Brake camshaft lever 3 Brake shoe wear indicator 4 Spacer 5 Brake shoe plate 6 Brake camshaft 7 Brake shoe 8 Oil seal 9 Bearing 0 Spacer A Rear wheel clutch hub damper B Rear wheel clutch hub C Driven sprocket D Collar E Rear wheel axle ...

Page 166: ... wheel axle 2 Washers Spacer 3 Rear wheel 4 4 Remove Brake shoe plate T REAR WHEEL DISASSEMBLY 1 Remove Bearings 1 Spacer 2 Refer to the FRONT WHEEL AND BRAKE DISC section T701020 REAR WHEEL INSPECTION 1 Inspect Rear wheel axle Rear wheel Rear wheel bearings Oil seals Refer to the FRONT WHEEL AND BRAKE DISC section 2 Check Spokes Refer to the FRONT WHEEL AND BRAKE DISC section 3 Measure Rear wheel...

Page 167: ...les with a cloth 2 Measure Brake shoe thickness a Out of specification Replace b Measure point Brake shoe thickness limit 1 0 mm 3 Inspect Brake shoe spring Wear damage Replace 4 Inspect Brake drum inner surface Oil scratches Remove 5 Measure Brake drum inside diameter a Out of specification Replace Oil Use a rag soaked in lacquer thinner or solvent Scratch Use an emery cloth lightly and evenly po...

Page 168: ...ator 2 Installation steps Set the camshaft with its punched mark a facing the direction as shown Align the projection b on the indicator with the camshaft notch and install Check the proper position of the brake shoe 2 Install Brake camshaft lever 1 Install the camshaft lever with its slit and the indicator at right angle as shown T REAR WHEEL ASSEMBLY 1 Install Bearing 1 Spacer 2 Refer to the FRO...

Page 169: ...he slot in the rear wheel clutch hub damper fits over the tab on the rear wheel clutch hub assembly 2 Install Rear wheel Spacer Rear wheel axle Rear wheel axle nut 3 Install Tension bar T R 85 Nm 8 5 m kg T R 16 Nm 1 6 m kg 4 Adjust Brake pedal free play 5 Adjust Drive chain slack Refer to the DRIVE CHAIN SLACK ADJUSTMENT section in CHAPTER 3 Brake pedal free play 20 30 mm Drive chain slack 20 30 ...

Page 170: ...2 CHAS FRONT BRAKE FRONT BRAKE FRONT BRAKE CALIPER 1 Brake caliper 2 Brake pad 3 Brake pad spring 4 Retaining bolt 5 Brake caliper piston 6 Brake caliper piston seal 7 Bleed screw kit 8 Brake caliper bolt ...

Page 171: ...6 13 CHAS FRONT BRAKE MASTER CYLINDER 1 Brake master cylinder 2 Brake master cylinder kit 3 Reservoir diaphragm 4 Reservoir cap 5 Master cylinder holder 6 Brake hose 7 Union bolt 8 Copper washer ...

Page 172: ... connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Loosen Retaining bolts 2 Remove Brake caliper bolts Brake caliper 3 Remove Retaining bolts 1 Brake pads 2 NOTE Install new brake pad springs ...

Page 173: ...he brake caliper bleed screw Install new brake pad springs and a new brake pads Install the brake caliper 3 and retaining bolts 4 brake caliper bolts 5 T R Brake caliper bleed screw 6 Nm 0 6 m kg T R Retaining bolt 27 Nm 2 7m kg Brake caliper bolt 30 Nm 3 0 m kg 6 Inspect Brake fluid level Refer to the BRAKE FLUID LEVEL INSPECTION section in CHAPTER 3 a LOWER level line 7 Check Brake lever operati...

Page 174: ...mp out the brake fluid carefully 2 Remove Retaining bolts 1 Brake caliper 2 3 Remove Brake caliper pistons 1 Brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper WARNING Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out th...

Page 175: ...led replace the brake caliper piston seals Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Replace when brakes are disas sembled FRONT BRAKE CALIPER INSTALLATION WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on...

Page 176: ... T R 26 Nm 2 6 m kg 2 Install Brake pad springs Brake pads Brake caliper Brake caliper retaining bolt T R 27 Nm 2 7 m kg 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake...

Page 177: ...e always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to the AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 3 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to the BRAKE FLUID LEVEL INSPECTION section in CHAPTER 3 6 Check Brake level operation Soft or spongy feeling Bleed the brake system Refer to ...

Page 178: ...remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove Master cylinder holder Brake master cylinder EAS00592 MASTER CYLINDER INSPECTION The following procedure applies to the both of the brake master cylinders 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow ou...

Page 179: ...brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components 1 Install Brake master cylinder 1 Master cylinder holder Brake lever compression spring NOTE Install the master cylinder bracket with the UP mark facing up Adjust the brake master cylinder to the proper angle as shown First tighten the upper bolt then the lower bolt Reco...

Page 180: ...e specified amount of the recom mended brake fluid WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that wat...

Page 181: ... Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to the BRAKE FLUID LEVEL INSPECTION section in CHAPTER 3 6 Check Brake lever operation Soft of spongy feeling Bleed the brake system Refer to the AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 3 ...

Page 182: ...6 24 CHAS FRONT FORK FRONT FORK 1 Cap bolt 2 O ring 3 Spacer 4 Spring seat 5 Fork spring 6 Rebound spring 7 Damper rod 8 Oil lock piece 9 Inner tube 0 Dust seal A Oil seal clip B Oil seal C Outer tube ...

Page 183: ...ve Front wheel Refer to the FRONT WHEEL AND BRAKE DISC section 3 Remove Bolts 1 front fender Collars 2 Front fender 3 4 Loosen Cap bolt 1 Handle crown pinch bolt 2 Lower bracket pinch bolt 3 WARNING Before loosening the upper and lower bracket pinch bolts support the front fork leg 5 Remove Front fork leg FRONT FORK DISASSEMBLY The following procedure applies to both of the front fork legs 1 Remov...

Page 184: ... tube 4 Remove Damper rob bolt Copper washer NOTE While holding the damper rod with the damper rod holder 1 and T handle 2 loosen the damper rod bolt 3 5 Remove Inner tube Damper rod Pull out the inner tube with damper rod Damper rod holder 19mm 90890 04084 T Handle 90890 01326 6 Remove Oil seal 1 CAUTION Never reuse the oil seal 2 Rag ...

Page 185: ...th limit 384 mm 3 Check Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Oil lock piece 2 Damage Replace CAUTION When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork 4 Check Cap bolt O ring Damage wear Replace EAS00659 FRONT FORK ASSEMBLY The following procedure applies to both of the front ...

Page 186: ...s from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface 3 Tighten Damper rod bolt 1 NOTE While holding the damper rod with the damper rod holder 2 and T handle 3 tighten the damper rod bolt 1 Recommended lubricant Fork oil 10 W or equivalent Damper rod holder 19 mm 90890 04084 T handle 90890 01326 T R 30 Nm 3 0 m kg 4 Install Oil seal 1 wi...

Page 187: ...front fork leg with a plastic bag 1 to pro tect the oil seal during installation 5 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 6 Install Dust seal 1 with the fork seal driver weight 7 Fill Front fork leg with the specified amount of the recommend fork oil Fork seal driver weight 90890 01367 Front fork seal driver attachment ø33 90890 01368 Qua...

Page 188: ...ler pitch facing up Before installing the cap bolt apply grease onto the O ring Temporarily tighten the cap bolt Front fork leg oil level a from the top of the inner tube with the inner tube fully compressed and without the fork spring 95 mm EAS00662 FRONT FORK INSTALLATION The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the handle crown ...

Page 189: ...nch bolt 2 Cap bolt 3 WARNING Make sure that the brake hoses are routed properly 3 Install Front fender Collars Bolts front fender 4 Install Front wheel Refer to the FRONT WHEEL AND BRAKE DISC section T R 30 Nm 3 0 m kg T R 23 Nm 2 3 m kg T R 23 Nm 2 3 m kg T R 7 Nm 0 7 m kg ...

Page 190: ...6 32 CHAS STEERING HEAD AND HANDLEBAR STEERING HEAD AND HANDLEBAR HANDLEBAR 1 Grip end 2 Throttle grip 3 Handlebar 4 Throttle cable 5 Clutch cable ...

Page 191: ...HAS STEERING HEAD AND HANDLEBAR STEERING HEAD 1 Handlebar holder 2 Bolt cap 3 Lock washer 4 Upper ring nut 5 Rubber washer 6 Lower ring nut 7 Ball race cover 8 Bearing 9 Bearing 0 Bearing race A Lower bracket ...

Page 192: ...ove Grip end 1 left Handlebar grip 2 left Clutch cable 3 Clutch lever holder 4 NOTE Before removing the clutch lever holder 4 remove the clutch switch leads and clutch cable 3 Remove Handlebar switch 1 right 4 Remove Throttle cable 1 5 Remove Grip end 1 right Throttle grip 2 Brake lever holder 3 ...

Page 193: ... Securely support the motorcycle so there is no danger of its falling over 1 Place the motorcycle on the centerstand and place a suitable stand under the engine to elevate the front wheel 2 Remove Handlebar Headlight unit 1 3 Remove Leads 1 Headlight body 2 Speedometer cable 3 Tachometer cable 4 Speedometer assembly 5 Holder 6 ...

Page 194: ... Upper ring nut 2 Rubber washer Lower ring nut 3 Use the steering nut wrench to remove the upper ring nut and lower ring nut Lower bracket WARNING Support the lower bracket so that it may not fall down Steering nut wrench 90890 01403 STEERING HEAD AND HANDLEBAR INSPECTION 1 Wash the bearing race and ball with solvent 2 Inspect Lower bracket 1 Bearings 2 Bearing races 3 Inner surface 4 handle crown...

Page 195: ...e on the lower bracket using the floor chisel 4 and the hammer as shown Install the new bearing races NOTE Always replace bearings and races as a set 4 Inspect Handlebar Bends damage Replace STEERING HEAD INSTALLATION Reverse the REMOVAL procedures Note the following points 1 Lubricate Bearing upper lower Bearing race Lithium soap base grease ...

Page 196: ... in CHAPTER 3 4 Install Holder Pass the brake cable and wire harness through the holder 5 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts 6 Install Handle crown 7 Install Front fork Refer to the FRONT FORK section 8 Install Front wheel Refer to the FRONT WHEEL AND BRAKE DISC section T R Nut steering stem 110 Nm 11 0 m kg T R Pinch bolt lower bracket 30 Nm 3 0 m k...

Page 197: ... m kg 2 Install Clutch lever 1 Grip 2 left Grip end 3 left Handlebar switch 4 left NOTE Align the handlebar switch projection with the hole on the handlebar Apply lithium soap base grease to clutch cable end when installing left handlebar switch 3 Install Brake lever holder 1 Throttle grip 2 right Throttle grip end 3 Handlebar switch 4 right Throttle cable 5 NOTE Align the handlebar switch project...

Page 198: ... when installing throttle grip end 4 Adjust Throttle cable free play Refer to the THROTTLE CABLE FREE PLAY ADJUSTMENT section in CHAPTER 3 T R Bolt throttle grip end 23 Nm 2 3 m kg Throttle cable free play 3 5 mm STEERING HEAD AND HANDLEBAR ...

Page 199: ...SORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Bush 3 Swingarm 4 Bearing 5 Dust cover 6 Bush 7 Drive chain guide 8 Relay arm 9 Bush 0 Oil seal A Collar B Connecting arm C Bush D Oil seal E Collar ...

Page 200: ...ngarm so that it does not drop down 4 Remove Bolt rear shock absorber 1 Rear shock absorber 5 Check Swingarm side play È Swingarm vertical movement É a Check the tightening torque of the pivot shaft nut b Check the swingarm side play È by moving the swingarm from side to side c If the swingarm side play is large check the spacers bearings washers and dust cov ers d Check the swingarm vertical move...

Page 201: ...ing Damage wear Replace the rear shock absorber assembly Bushings Damage wear Replace Dust seals Damage wear Replace Bolts Bends damage wear Replace EAS00707 SWINGARM INSPECTION 1 Inspect Swingarm Bends cracks damage Replace 2 Inspect Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Dust covers Collars Washe...

Page 202: ...ollar as a set 2 Inspect Oil seals 3 Damage Replace EC574310 CONNECTING ARM INSPECTION 1 Inspect Bushs 1 Collars 2 Free play exists unsmooth revolution rust Replace bush and collar as a set 2 Inspect Oil seals 3 Damage Replace T701020 DRIVE CHAIN INSPECTION 1 Inspect Drive chain stiffness Stiffness Clean and lubricate or replace 2 Inspect Drive chain 1 Driven sprocket 2 More than 1 2 tooth a wear ...

Page 203: ...rt as possible Then remove the drive chain from the kerosene and dry it CAUTION This motorcycle has a drive chain with small rubber O rings 1 between the drive chain side plates Never use high pressure water or air steam gasoline certain sol vents e g benzene or a coarse brush to clean the drive chain Don t soak drive drain in kerosine for more than ten minutes O ring is damage by ker osine 5 Chec...

Page 204: ...ven sprocket 1 Lock washers 2 Bolts 3 NOTE Tighten the bolts in a crisscross pattern New T R 30 Nm 3 0 m kg 2 Bend Lock washer tab 1 along a flat side of the end EAS00711 REAR SHOCK ABSORBER AND SWINGARM INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Lubricate Bearings Collars Dust covers Pivot shaft Bushes Recommended lubricant Lithium soap base grease ...

Page 205: ...swingarm 3 Install Collar 1 Bushes 2 Oil seals 3 to the relay arm 4 Install Collars 1 Bushes 2 Oil seals 3 to the connecting arm 5 Install Connecting arm 1 Bolt connecting arm relay arm 2 Washer 3 Nut connecting arm relay arm 4 NOTE Apply the lithium soap base grease on the bolt Install the nut on the right side of the chassis T R 59 Nm 5 9 m kg ...

Page 206: ...pivot shaft from right side T R 59 Nm 5 9 m kg T R 59 Nm 5 9 m kg 8 Install Bolt relay arm frame 1 Washer 2 Nut relay arm frame 3 NOTE Apply the lithium soap base grease on the bolt T R 59 Nm 5 9 m kg 9 Install Bolt rear shock absorber frame 1 NOTE Apply the lithium soap base grease on the bolt 10 Install Bolt rear shock absorber relay arm 1 Washer 2 Nut rear shock absorber relay arm 3 NOTE Apply ...

Page 207: ... 7 8 CIRCUIT DIAGRAM 7 8 TROUBLESHOOTING 7 9 ELECTRIC STARTING SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 STARTING CIRCUIT OPERATION 7 14 TROUBLESHOOTING 7 15 STARTER MOTOR 7 19 CHARGING SYSTEM 7 25 CIRCUIT DIAGRAM 7 25 TROUBLESHOOTING 7 26 LIGHTING SYSTEM 7 28 CIRCUIT DIAGRAM 7 28 TROUBLESHOOTING 7 29 LIGHTING SYSTEM CHECK 7 31 SIGNALING SYSTEM 7 34 CIRCUIT DIAGRAM 7 34 TROUBLESHOOTING 7 36 SIGNAL SYSTEM C...

Page 208: ... ELEC ...

Page 209: ...7 1 ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1 Fuel sender 2 Starting circuit cut off relay 3 Rectifier regulator 4 Rear brake switch 5 Starter relay 6 Battery 7 Main switch ...

Page 210: ...7 2 ELEC ELECTRICAL COMPONENTS 1 Ignition coil 2 Flasher relay 3 CDI unit 4 Neutral switch 5 Horn ...

Page 211: ... for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE indicates a continuity of electricity between ...

Page 212: ...er to the CHECKING SWITCH CONTINUITY section Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch LOCK OFF ON 6 3 5 7 2 4 B R Br R B Br B W B W L W B W OFF ON OFF RUN 9 B 8 HI LO Y G B G Y Br 1 OFF ON P B R L N Br W Dg Ch OFF ON Y Br OFF ON PO L Br B Y L Y L Y P B Y Ch L Br Br W Dg B A 10A C Sb ...

Page 213: ... THE SWITCHES 1 Clutch switch 2 Pass switch 3 Horn switch 4 Dimmer switch 5 Turn switch 6 Main switch 7 Lights switch 8 Front brake switch 9 Engine stop switch 0 Start switch A Fuse B Rear brake switch C Neutral switch ...

Page 214: ... bulb NOTE Bulbs of the A and B type uses a bulb holder Remove the bulb holder before removing the bulb itself Most of the bulb holders for this type can be removed by turn ing counterclockwise Most of the bulbs of C and D type can be removed from the bulb sockets by pushing and turning them counterclockwise Bulbs of the E type can just be pulled out CAUTION Be sure to hold the socket firmly when ...

Page 215: ...ecting the tester lead to the terminal 1 and the tester lead to the terminal 2 Then check the continuity between the termi nals 1 and 3 by connecting the tester lead still to the terminal 1 and the tester lead to the terminal 3 If the tester shows in either case replace the bulb 3 Check the bulb socket by installing a proven bulb to it As in the checking of bulbs con nect the pocket tester leads t...

Page 216: ...L Y B Y BLACK L Y P B Y Ch L Br Br W Dg B I B B G Y Br BLACK BLACK A B L B B L N L L J O K M B Ch L Dg Y L Dg B Ch Y Br W Br R R L W R W Br R R R R B W Br Y R R B W W Br G R O O W W Y R W R Br G B Br P Br P Br Br W Q W V U T R S C 8 7 B R B B R B B B B B B B Sb R W L Y Ch Dg L Br G G B B Sb Sb Sb Sb Y B W L W B Br W L Y R P L Y Dg Ch B G Y Y G Y B L B B B B B Dg Ch Dg Ch B Y L Br Y Br G Y B Y R Ch...

Page 217: ...owing parts before troubleshooting 1 Headlight unit 2 Seat 3 Fuel tank Use the following special tools in this troubleshooting IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE NO SPARK OR INTERMITTENT SPARK Pocket tester 90890 03112 Ignition checker 90890 06754 CORRECT 1 Spark plug Check the spark plug type condition and gap Refer to the SPARK PLUG INSPECTION section in CHAPTER 3 Standard spark plug D...

Page 218: ...then apply clutch lever or shift the transmission into neutral Push the start switch or kick the kick crank Check the ignition spark condition Minimum spark gap 6 mm SPARK Ignition circuit is good 3 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester Ω 1k to the spark plug cap MEETS SPECIFICATION Checking the spark plug cap for the speci fied resistance Spark plug cap res...

Page 219: ...tion coil base 2 BOTH MEETS SPECIFICATIONS Measure the primary and secondary coil resistances Primary coil resistance È 0 32 0 48 Ω at 20 C Secondary coil resistance É 5 68 8 52 kΩ at 20 C OUT OF SPECIFICATIONS Replace ignition coil CORRECT 5 Main switch Check the main switch for continuity Refer to the CHECKING THE SWITCHES section INCORRECT Replace main switch CORRECT 6 Engine stop switch Check ...

Page 220: ...OF SPECIFICATION Replace source coil 8 Pickup coil resistance Disconnect the CDI magneto coupler from the wire harness Connect the pocket tester Ω 100 to the pickup coil Tester lead Red 1 terminal Tester lead White 2 terminal MEETS SPECIFICATION 3 CDI magneto Measure the pickup coil resistance Pickup coil resistance 248 372 Ω at 20 C OUT OF SPECIFICATION Replace pickup coil CORRECT 9 Wiring connec...

Page 221: ...CK L Y P B Y Ch L Br Br W Dg B I B B G Y Br BLACK BLACK A B L B B L N L L J O K M B Ch L Dg Y L Dg B Ch Y Br W Br R R L W R W Br R R R R B W Br Y R R B W W Br G R O O W W Y R W R Br G B Br P Br P Br Br W Q W V U T R S C 8 7 B R B B R B B B B B B B Sb R W L Y Ch Dg L Br G G B B Sb Sb Sb Sb Y B W L W B Br W L Y R P L Y Dg Ch B G Y Y G Y B L B B B B B Dg Ch Dg Ch B Y L Br Y Br G Y B Y R Ch L P B L Y ...

Page 222: ...tarting circuit cut off relay is open so current cannot reach the starter motor When one of both of the above conditions have been met however the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE CLUTCH LEVER IS PULLED IN 1 Battery 2 Starter relay 3 Starter motor 4 Main switch 5 Starting circuit cut o...

Page 223: ...fore troubleshooting 1 Side cover right 2 Headlight unit 3 Seat 4 Fuel tank Use the following special tool in this troubleshooting STARTER MOTOR DOES NOT OPERATE Pocket tester 90890 03112 CONTINUITY 1 Fuse Connect the pocket tester Ω 1 to the fuse Check the fuse for continuity INCORRECT Replace fuse CORRECT 2 Battery Check the battery condition Check the battery fluid level battery termi nals and ...

Page 224: ... or fluid is in the vicinity INOPERATIVE Repair or replace starter motor WARNING A wire for the jumper lead must have the equivalent capacity as that of the battery lead or more otherwise it may cause the jumper lead to be burned This check is likely to produce sparks so be sure that no flammable gas or fluid is the vicinity MOVES 4 Starter relay Disconnect the starter relay coupler from the wire ...

Page 225: ... lead Red White terminal 4 Step 2 Battery lead Brown terminal 1 Battery lead Blue Yellow terminal 3 Tester lead Brown terminal 1 Tester lead Red White terminal 4 Check the relay for continuity NO CONTINUITY Replace relay CORRECT 6 Main switch Check the main switch for continuity Refer to the CHECKING THE SWITCHES section INCORRECT Replace main switch CORRECT 7 Engine stop switch Check the engine s...

Page 226: ...ch switch Check the clutch switch for continuity Refer to the CHECKING THE SWITCHES section INCORRECT Replace clutch switch CORRECT 10 Start switch Check the start switch for continuity Refer to the CHECKING THE SWITCHES section INCORRECT Replace handlebar switch right 11 Wiring connection Check the entire ignition system for conti nections Refer to the WIRING DIAGRAM section POOR CONNECTION Corre...

Page 227: ...19 ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 1 Brush 2 Armature 3 O ring 4 O ring A BRUSH LENGTH LIMIT 3 5 mm B COMMUTATOR WEAR LIMIT 21 mm C MICA UNDER CUT 1 5 mm D ARMATURE COIL RESISTANCE 0 Ω at 20 C ...

Page 228: ...section in CHAPTER 4 3 Disconnect Starter motor lead 1 4 Remove Starter motor 2 5 Remove Bolts starter motor front cover 6 Remove Starter motor yoke 1 O ring 2 7 Remove Armature 1 Inspection and repair 1 Inspect Commutator Dirty Clean it with 600 grit sandpaper 2 Measure Commutator diameter a Out of specification Replace starter motor Commutator wear limit 21 mm ...

Page 229: ...mm 4 Inspect Armature coil continuity insulation Defects s Replace starter motor Inspecting steps Connect the pocket tester for continuity check 1 and insulation check 2 Measure the armature coil resistances If the resistance is incorrect replace the starter motor 5 Measure Brush length a Out of specification Replace Pocket tester 90890 03112 Armature coil resistance Continuity check 1 Ω 1 0 Ω at ...

Page 230: ...pressure Fatigue out of specification Replace as a set Brush spring pressure 560 840 g 7 Inspect Bearing Oil seal O ring Wear damage Replace Assembly Reverse the Removal procedure Note the following points 1 Install Brush Brush spring Using a thin screw driver ...

Page 231: ...tor yoke 2 4 Install Starter motor assembly NOTE Align the groove a on the starter motor assembly with the groove b on the housing 5 Install O ring 1 Screw WARNING Always use a new O ring 6 Install O ring 2 WARNING Always use a new O ring NOTE Apply a lightly grease to the O ring 2 New ...

Page 232: ...7 24 ELEC ELECTRIC STARTING SYSTEM Installation 1 Install Starter motor 1 Starter motor lead 2 T R Bolt starter motor 10 Nm 1 0 m kg ...

Page 233: ...FF ON PO 0 H G F E D BLACK B Y L Y L Y B Y BLACK L Y P B Y Ch L Br Br W Dg B I B B G Y Br BLACK BLACK A B L B B L N L L J O K M B Ch L Dg Y L Dg B Ch Y Br W Br R R L W R W Br R R R R B W Br Y R R B W W Br G R O O W W Y R W R Br G B Br P Br P Br Br W Q W V U T R S C 8 7 B R B B R B B B B B B B Sb R W L Y Ch Dg L Br G G B B Sb Sb Sb Sb Y B W L W B Br W L Y R P L Y Dg Ch B G Y Y G Y B L B B B B B Dg ...

Page 234: ...ubleshooting THE BATTERY IS NOT CHARGED Pocket tester 90890 03112 Inductive tachometer 90890 03113 CORRECT 1 Fuse Connect the pocket tester Ω 1 to the fuse Check the fuse for continuity NO CONTINUITY Replace fuse CORRECT 2 Battery Check the battery condition Check the battery fluid level battery termi nals and specific gravity Refer to the BATTERY INSPECTION section in CHAPTER 3 Specific gravity 1...

Page 235: ... r min MEETS SPECIFICATION Replace battery 4 Charging coil resistance Disconnect the CDI magneto coupler from the wire harness Connect the pocket tester Ω 1 to the stator coil Battery lead White 1 terminal Battery lead Black 2 terminal MEETS SPECIFICATION Measure the charging coil resistance Charging coil resistance 0 32 0 48 Ω at 20 C White Black OUT OF SPECIFICATION Replace stator assembly CORRE...

Page 236: ...L Y P B Y Ch L Br Br W Dg B I B B G Y Br BLACK BLACK A B L B B L N L L J O K M B Ch L Dg Y L Dg B Ch Y Br W Br R R L W R W Br R R R R B W Br Y R R B W W Br G R O O W W Y R W R Br G B Br P Br P Br Br W Q W V U T R S C 8 7 B R B B R B B B B B B B Sb R W L Y Ch Dg L Br G G B B Sb Sb Sb Sb Y B W L W B Br W L Y R P L Y Dg Ch B G Y Y G Y B L B B B B B Dg Ch Dg Ch B Y L Br Y Br G Y B Y R Ch L P B L Y Br ...

Page 237: ... OR METER LIGHT DO NOT COME ON Pocket tester 90890 03112 1 Lighting coil resistance Disconnect the CDI magneto coupler from the wire harness Connect the pocket tester Ω 1 to the stator coil Tester lead Yellow 1 terminal Tester lead Black 2 terminal MEETS SPECIFICATION Measure the lighting coil resistance Lighting coil resistance 0 24 0 36 Ω at 20 C Yellow Black OUT OF SPECIFICATION Replace stator ...

Page 238: ... left CORRECT 4 Pass switch Check the pass switch for continuity Refer to the CHECKING THE SWITCHES section INCORRECT Pass switch is faulty replace handlebar switch left CORRECT 5 Wiring connection Check the entire lighting system for con nections Refer to the WIRING DIAGRAM section Check condition of each circuit for lighting system Refer to the LIGHTING SYSTEM CHECK section POOR CONNECTION Corre...

Page 239: ...high beam indicator light leads Headlight Tester lead Yellow 2 or Green 1 lead Tester lead Black 3 lead High beam indicator light Tester lead Yellow 4 lead Tester lead Black 5 terminal È When dimmer switch is LO position É When dimmer switch is HI position Start the engine Turn the lights switch to ON Turn the dimmer switch to LO or HI posi tion Check for voltage 12 V on the Green and Yellow lead ...

Page 240: ...cket are faulty replace MEETS SPECIFI CATION 12 V 2 Voltage Connect the pocket tester DC 20 V to the bulb socket leads Tester lead Blue 1 terminal Tester lead Black 2 terminal Start the engine Turn the lights switch to ON or PO Check for voltage 12 V on the Blue lead at the bulb socket connector This circuit is good OUT OF SPECIFICATION Wiring circuit from main switch to bulb socket connector is f...

Page 241: ...ocket are faulty replace MEETS SPECIFI CATION 12 V 2 Voltage Connect the pocket tester DC 20 V to the bulb socket leads Tester lead Blue 1 terminal Tester lead Black 2 terminal Start the engine Turn the lights switch to ON or PO Check for voltage 12 V on the Blue lead at the bulb socket connector This circuit is good OUT OF SPECIFICATION Wiring circuit from main switch to bulb socket connector is ...

Page 242: ...R L N HI LO OFF ON OFF ON OFF ON PO 0 H G F E D BLACK B Y L Y L Y B Y BLACK L Y P B Y Ch L Br Br W Dg B I B B G Y Br BLACK BLACK A B L B B L N L L J O K M B Ch L Dg Y L Dg B Ch Y Br W Br R R L W R W Br R R R R B W Br Y R R B W W Br G R O O W W Y R W R Br G B Br P Br P Br Br W Q W V U T R S C 8 7 B R B B R B B B B B B B Sb R W L Y Ch Dg L Br G G B B Sb Sb Sb Sb Y B W L W B Br W L Y R P L Y Dg Ch B ...

Page 243: ...elay A Front brake switch B Rear brake switch D Horn switch H Turn signal switch J Tail black light K Rear turn signal light L Front turn signal light O Neutral switch P Fuel sender R Fuel gauge U Neutral indicator light V Turn indicator light X Battery Y Fuse ...

Page 244: ...T AND OR INDICATOR LIGHT DO NOT COME ON HORN DOES NOT SOUND FUEL GAUGE DOES NOT OPERATED Pocket tester 90890 03112 CONTINUITY 1 Fuse Remove the fuse Connect the pocket tester Ω 1 to the fuse Check the fuse for continuity Refer to the FUSE INSPECTION section in CHAPTER 3 NO CONTINUITY Fuse is faulty replace it CORRECT 2 Battery Check the battery condition Refer to the BATTERY INSPECTION section in ...

Page 245: ...o the CHECKING THE SWITCHES section INCORRECT Main switch is faulty replace it CORRECT 4 Wiring connection Check the entire signal system for connec tions Refer to the WIRING DIAGRAM section Check condition of each circuit for signal sys tem Refer to the SIGNAL SYSTEM CHECK section POOR CONNECTION Correct ...

Page 246: ...NCORRECT Horn switch is faulty replace handlebar switch left MEETS SPECIFI CATION 12 V 2 Voltage Connect the pocket tester DC 20 V to the horn lead Tester lead Brown 1 lead Tester lead Frame ground Turn the main switch to ON Check for voltage 12 V on the Brown lead at the horn terminal OUT OF SPECIFICATION Wiring circuit from main switch to horn termi nal is faulty repair ...

Page 247: ...umper lead Turn the main switch to ON HORN IS SOUNDED Horn is good MEETS SPECIFI CATION 12 V 4 Voltage Connect the pocket tester DC 20 V to the horn at the Pink terminal Tester lead Pink 1 lead Tester lead Frame ground Turn the main switch to ON Check for voltage 12 V on the Pink lead at the horn terminal Adjust or replace horn OUT OF SPECIFICATION Horn is faulty replace it ...

Page 248: ...the CHECKING THE SWITCHES section INCORRECT Brake switch is faulty replace it MEETS SPECIFI CATION 12 V 3 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Yellow 1 terminal Tester lead Black 2 terminal Turn the main switch to ON The brake level is pulled in or brake pedal is stopped down Check for voltage 12 V on the Yellow lead at the bulb socket connector This c...

Page 249: ...eck the turn signal switch for continuity Refer to the CHECKING THE SWITCHES section INCORRECT Turn signal switch is faulty replace handle bar switch left MEETS SPECIFI CATION 12 V 3 Voltage Connect the pocket tester DC 20 V to the flasher relay Tester lead Brown 1 terminal Tester lead Frame ground Turn the main switch to ON Check for voltage 12 V on the Brown lead at the flasher relay terminal OU...

Page 250: ...place it MEETS SPECIFI CATION 12 V 5 Voltage Connect the pocket tester DC 20 V to the bulb socket connector At flasher light left Tester lead Chocolate 1 lead Tester lead Frame ground At flasher light right Tester lead Dark green 2 lead Tester lead Frame ground Turn the main switch to ON Turn the turn signal switch to L or R Check for voltage 12 V on the Chocolate lead or Dark green lead at the bu...

Page 251: ...e neutral switch for continuity Refer to the CHECKING THE SWITCHES section INCORRECT Neutral switch is faulty replace it MEETS SPECIFI CATION 12 V 3 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Brown 1 terminal Tester lead Frame ground Turn the main switch to ON Check for voltage 12 V on the Brown lead at bulb socket connector This circuit is good OUT OF SPECI...

Page 252: ...e specified resistance Fuel sender resistance Up 4 Ω 1 4 10 Ω at 20 C Fuel sender resistance Down 5 Ω 10 90 100 Ω at 20 C OUT OF SPECIFICATION Replace fuel sender 2 Voltage Connect the pocket tester DC 20 V to the fuel meter coupler Tester lead Brown 1 terminal Tester lead Black 2 terminal MEETS SPECIFI CATION 12 V Turn the main switch to ON Check for voltage 12 V on the Brown lead at the fuel met...

Page 253: ...in switch to ON Check the fuel meter needle moves FULL or EMPTY NOTE Before reading the meter stay put the float for more than three minutes respectively at UP or DOWN DOES NOT MOVE Replace fuel meter 4 Wiring connection Check the entire signal system for connec tion Refer to the WIRING DIAGRAM section ...

Page 254: ...TRBL SHTG CHAPTER 8 TROUBLESHOOTING TROUBLESHOOTING 8 1 ELECTRICAL SYSTEM 8 1 COMPRESSION SYSTEM 8 2 INTAKE AND EXHAUST SYSTEM 8 3 ...

Page 255: ...TRBL SHTG ...

Page 256: ...8 1 TRBL SHTG TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM ...

Page 257: ...8 2 TRBL SHTG TROUBLESHOOTING COMPRESSION SYSTEM ...

Page 258: ...8 3 TRBL SHTG TROUBLESHOOTING INTAKE AND EXHAUST SYSTEM ...

Page 259: ... R Ch L P B L Y Br W Dg B 1 Main switch 2 Rectifier regulator 3 CDI magneto 4 CDI unit 5 Ignition coil 6 Spark plug 7 Start switch 8 Engine stop switch 9 Horn 0 Flasher relay A Front brake switch B Rear brake switch C Handlebar switch left D Horn switch E Lights switch F Pass switch G Dimmer switch H Turn signal switch I Clutch switch J Tail brake light K Rear flasher light L Front flasher light M...

Page 260: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 261: ...Scorpio new SUPPLEMENTARY SERVICE MANUAL 5BP F8197 B1 ...

Page 262: ...h Technical Publication PT Yamaha Indonesia Motor Manufacturing di cetak di Indonesia SERVICE MANUAL SCORPIO 5BP F8197 B0 EAS00000 PENDAHULUAN Buku Service Manual tambahan ini dibuat untuk melengkapi Service Manual Scorpio yang sudah ada Untuk mendapatkan petunjuk cara cara perbaikan Sepeda Motor Scorpio dengan sempurna sebaiknya buku ini dipadu dengan Buku Service Manual dibawah ini ...

Page 263: ...erus menerus berusaha meningkatkan mutu produksinya untuk itu jika ada perubahan yang mendasar dalam spesifikasi dan prosedur pengerjaan kami akan sampaikan keseluruh jaringan Yamaha melalui buletin Service Information CATATAN Bentuk dan spesifikasi sewaktu waktu dapat berubah mengikuti perkembangan model EAS00004 INFORMASI PENTING YANG ADA DIDALAM BUKU PETUNJUK INI Informasi penting secara khusus...

Page 264: ...iterima dengan mudah oleh para mekanik Petunjuk yang ada meliputi berbagai hal antara lain tentang cara membongkar memperbaiki dan pemeriksaan jika ada prosedur yang penting dan perlu perhatian khusus 4kami tambahkan gambar segi tiga hitam dengan tanda seru didalamnya INFORMASI PENTING 8Data spesifikasi dan special tool diinformasikan dalam frame dengan gambar alat 5 8Angka didalam lingkaran 6 men...

Page 265: ... w Alat spesial special tool e Torsi pengencangan r Batas keausan kelonggaran t Putaran mesin y Data kelistrikan Simbol uhingga spada gambar diagram menun jukkan tipe pelumas dan bagian yang perlu dilu masi u Oli mesin i Oli gear o Oli Molybdenum disulfide p Gemuk bearing roda wheel bearing grease a Gemuk Lithium soap based s Gemuk Molybdenum disulfide Simbol dhingga fpada gambar diagram menun juk...

Page 266: ... KEPALA CYLINDER CYLINDER HEAD 9 KARBURATOR AIR INDUCTION SYSTEM 10 AIR INJECTION 10 AIR CUT OFF VALVE 10 RANGKA CHASSIS KEMUDI STEERING HEAD DAN TANGKAI KEMUDI 12 TANGKAI KEMUDI 12 SHOCK ABSORBER BELAKANG DAN LENGAN AYUN 13 MEMERIKSA RANTAI 13 KELISTRIKAN ELECTRICAL SISTIM PENERANGAN 15 RANGKAIAN DIAGRAM 15 MEMERIKSA SISTIM PENERANGAN 18 SISTIM SINYAL 21 RANGKAIANDIAGRAM 21 MEMERIKSA SISTIM SINYA...

Page 267: ...Tipe Pabrik pembuat D8EA 9 NGK Kerenggangan 0 8 0 9 mm 0 0315 0 0354 in Tekanan angin ban kondisi dingin Berat Dengan oli dan bensin penuh 136 kg 300 lb Beban maksimum 180 kg 396 lb Berat total barang bawaan pengendara penumpang dan aksesoris SPEC 1 SPESIFIKASI UMUM SPESIFIKASI SPESIFIKASI UMUM ...

Page 268: ... keluar Pilot outlet P O Ø0 8 Bypass B P 1 Ø0 9 B P 2 Ø0 8 B P 3 Ø0 8 Valve seat size V S Ø2 0 Starter jet G S 1 25 G S 2 0 7 Ketinggian bahan bakar 3 8 5 8 mm 0 15 0 23 in dibawah sambungan rumah pelampung Putaran langsam mesin 1 350 1 450 r min Pipa Air induction system Baut M6 2 10 1 0 7 2 Unit Air cut off valve Baut M6 2 10 1 0 7 2 komponen yang dikencangkan nama ukuran ulir Q ty Torsi pengenc...

Page 269: ...SIS Keterangan Scorpio Tromol rem belakang Tipe Leading dan trailing Diameter dalam tromol 130 mm 5 12 in Limit 131 mm 5 16 in Ketebalan kampas rem 4 mm 0 16 in Limit 1 mm 0 04 in Panjang per kampas rem Per 1 52 mm 2 05 in Per 2 48 mm 1 89 in ...

Page 270: ...ang 0 Kabel sinyal belok belakang sebelah kanan q Kabel Fuel sender w Selang pernafasan e Selang pernafasan r Kabel gas Throttle cable t Kabel kopling y Kabel magnet u Kabel switch netral i Kabel bodi o Kabel sinyal belok belakang sebelah kiri p Battery a Kabel kuning s Kabel biru d Kabel hitam f Karet pengikat Battery å Klem kabel bodi Masukkan kabel tachometer kedalam guide ç Tempatkan terminal ...

Page 271: ...ernafasan mesin kedalam rangka Ikat kabel bodi dan dan arahkan ujung klem mengha dap kedalam Ikat kabel magnet dan kabel switch netral dan tekan kabel kearah dalam dari holder Masukkan kabel sein kedalam lubang yang terdapat pada fender belakang sebelah kanan µ Masukkan kabel lampu sinyal kedalam special washer kanan dan kiri Arahkan ke arah depan ø Bungkus kabel seperti pada gambar π Jangan mengi...

Page 272: ...neto 7 Selang pernafasan Battery 8 selang over flow karburator 9 Kabel speedometer 0 Kabel bodi q kabel Magneto w Selang Bend å Clamp selang pernafasan Battery dan selang karburator over flow Tepatkan kabel speedometer kedalam holder ç Clamp kabel magneto dan kabel switch netral Clamp kabel switch netral terlebih dahulu dan selanjutnya clamp kabel magneto Clamp selang pernafasan Battery ...

Page 273: ...gunci handel crown ç Masukkan kabel kopling kedalam guide penuntun Masukkan kabel bodi kedalam guide penuntun Clamp selang rem ƒ Masukkan selang rem kabel gas kedalam guide penuntun Tepatkan kabel gas diluar baut pengunci handle crown Clamp kabel saklar tangkai kemudi dan kabel switch rem ˆ Kabel main switch jangan tertarik dan tepatkan dengan kabel meter Clamp selang rem dan kabel gas Ke head lam...

Page 274: ...sa 9 Pipa Exhaust 1 9 Knalpot Muffler 2 Retal rusak bocor perbaiki 9 Joint pipa pembuangan 3 9 Gasket 4 Rusak bocor perbaiki 2 Kencangkan 9 Pipa Muffler dan exhaust 2 3 7 7 6 1 4 5 4 Mur pipa pembuangan 5 18 Nm 1 8 m kg 13 ft lb Baut joint pipa exhaust 6 20 Nm 2 0 m kg 15 ft lb Baut muffler 7 30 Nm 3 0 m kg 22 ft lb ...

Page 275: ... q w 7 Nm 7 0 m kg 5 0 ft lb 18 Nm 1 8 m kg 13 ft lb 10 Nm 1 0 m kg 7 2 ft lb 0 0 4 3 8 9 t r 0 y MEMBONGKAR MESIN CYLINDER HEAD 1 O ring 2 Tappet cover 3 O ring 4 Camshaft sprocket cover 5 Plate 6 Cam chain tensioner 7 Gasket 8 Camshaft sprocket 9 Gasket 0 Dowel pin q Cylinder head w Busi Spark plug e Timing chain guide sisi exhaust side r Gasket t Air induction system pipe y O ring ...

Page 276: ...buang diperlukan 600 to 700 C AIR CUT OFF VALVE Air cutoff valve bekerja karena tekanan gas pemasukan melalui diaphragma piston valve Dalam kondisi normal Air Cut Valve terbuka sehingga udara mengalir ke lubang pembua ngan åke Pada saat deceleration kondisi handel gas tiba tiba tertutup terjadi hisapan negative presure ç sehingga Air Cut Off Valve tertutup untuk mencegah tekanan balik atau after b...

Page 277: ... Selang Air induction system unit air cut off valve ke cylinder head 4 Selang vacuum Air induction system 5 Unit Air cut off valve 6 Selang Air induction system unti air cut off valve ke rumah saringan udara 5 1 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 4 3 2 6 ...

Page 278: ...kg 13 3 ft lb LS 3 7 Nm 0 7 m kg 5 2 ft lb 4 5 6 7 8 0 19 Nm 1 9 m kg 14 ft lb 110 Nm 11 0 m kg 81 1 ft lb 7 Nm 0 7 m kg 5 2 ft lb LS 2 9 1 q 23 Nm 2 3 m kg 17 ft lb 1 Holder tangkai kemudi 2 Baut cap 3 Washer pengunci 4 Mur ring atas 5 Washer karet 6 Mur ring bawah 7 Penutup ball race 8 Bearing 9 Bearing 0 Bearing race q Bracket bawah ...

Page 279: ... mlahkan panjang keduanya 9 Panjang cdiantara titik tengah pin panjang bagian dalam a panjang bagian luar b 2 9 Ukur 15 mata c dari rantai 9 Diluar spesifikasi ganti rantai penggerak gear sprocket depan dan belakang satu set CATATAN 9Pada saat mengukur 15 mata rantai tekan rantai kedalam untuk menghindari gaya tarik 9Lakukan pengukuran pada dua tempat yang berbeda 2 Periksa 9 Rantai penggerak Driv...

Page 280: ...rantai pada bagian dalam dan cairan pembersih akan merusak O rings begitu juga ujung sikat akan merusakkan O rings Untuk itu hanya minyak tanah yang diijinkan jangan merendam dalam minyak tanah lebih dari 10 menit hal ini akan merusakkan O ring pada rantai 4 Periksa 9 O rings 1 Rusak Ganti rantai penggerak 9 Roller rantai 2 Rusak Aus Ganti rantai 9 Plat rantai 3 Retak Aus karat Ganti rantai pengge...

Page 281: ... BLACK L B B L Br R R L W R W Br R R R R B W Br Y R R B W W Br G R O O W W Y R W R Br G B Br P Br P Br B R B B R B B B B B B B B Sb R W L Y Ch Dg L Br G G B B Sb Sb Sb Sb Y B W L W B L Y R P L Y B G Y Y G Y B L B B B B B Dg B Dg B B Ch Ch Y L Br Y Br G Y B Y R Ch L P B L Y Br W Dg B Dg Ch Br W Br W Br W 9 1 v b n c m 2 3 4 6 5 g 9 0 i u y t r o f a a d j x x z k l e 8 7 q w p s s h 3 CDI magneto t...

Page 282: ...3 Saklar dimmer LAMPU DEPAN LAMPU INDIKATOR LAMPU JAUH LAMPU BELAKANG LAMPU METER TIDAK MENYALA CATATAN 9Buka komponen dibawah ini sebelum melakukan perbaikan 1 Penutup samping kanan 2 Lampu depan 3 Tempat duduk 9Pergunakan alat spesial tool ini untuk perbaikan Pocket tester 90890 03112 SESUAI SPESIFIKASI Kabel Tester terminal kuning 1 1 Kabel Tester terminal hitam 2 2 Ganti unit stator DILUAR SPE...

Page 283: ...r Pass 9Periksa sistim penyambungan saklar Pass lihat bagian PEMERIKSAAN SAKLAR SWITCH BAGUS Saklar Pass rusak perbaiki atau ganti saklar kemudi sebelah kiri TIDAK BAGUS 5 Sistim penyambungan kabel 9Periksa sistim penyambungan kabel pada sistim penerangan Lihat bagian DIAGRAM KELISTRIKAN BAGUS Perbaiki SAMBUNGAN BERMASALAH Periksa kondisi kabel kabel pada sistim penerangan lihat bagian PEMERIKSAAN...

Page 284: ...ter DC 20 V pada lampu depan dan kabel lampu indikator lampu jauh 9Hidupkan mesin 9geser saklar lampu pada posisi ON 9Geser saklar dimmer pada posisi LO atau posisi HI 9Periksa voltase 12 V pada kabel hijau atau kabel kuning pada socket connector Lampu depan Kabel Tester Kabel Kuning 2 2 atau Hijau 1 1 Kabel Tester Kabel hitam 3 3 Lampu indikator lampu jauh Kabel Tester Kabel kuning 4 4 Kabel Test...

Page 285: ...PENERANGAN 1 Bohlam dan socket bohlam 9periksa kondisi bohlam dan socket bohlam lihat bagian PEMERIKSAAN BOHLAM TERSAMBUNG Bohlam Socket bohlam rusak perbaiki ganti TIDAK TERSAMBUNG 2 Lampu meter tidak meyala Kabel Tester terminal biru 1 1 Kabel Tester terminal hitam 2 2 SESUAI SPESIFIKASI 12V Rangkaian kabel dari kunci kontak ke connector rusak perbaiki TIDAK TERSAMBUNG rangkaian dalam kondisi ba...

Page 286: ...20 1 Bohlam dan socket bohlam 9Periksa kondisi bohlam dan socket bohlam lihat bagian PEMERIKSAAN SAKLAR ADA HUBUNGAN Bohlam dan socket bohlam rusak perbaiki TIDAK TERSAMBUNG 3 lampu belakang tidak menyala L Y B 1 2 Kabel Tester terminal biru 1 1 Kabel Tester terminal hitam 2 2 SESUAI SPESIFIKASI 12V Rangkaian kabel dari kunci kontak ke socket bohlam rusak perbaiki TIDAK SESUAI Rangkaian kabel dala...

Page 287: ... ON OFF ON PO B Y L Y L Y B Y L Y P B Y Ch L Br Br W Dg B B B G Y Br BLACK BLACK BLACK BLACK L B B L Br R R L W R W Br R R R R B W Br Y R R B W W Br G R O O W W Y R W R Br G B Br P Br P Br B R B B R B B B B B B B B Sb R W L Y Ch Dg L Br G G B B Sb Sb Sb Sb Y B W L W B L Y R P L Y B G Y Y G Y B L B B B B B Dg B Dg B B Ch Ch Y L L Br Y Br G Y B Y R Ch L P B L Y Br W Dg B Dg Ch Br W Br W Br W 9 1 v b...

Page 288: ...witch rem depan w Switch rem belakang r Tombol klakson i Saklar sinyal belok p Lampu belakang rem a Lampu sinyal belok belakang s Lampu sinyal belok depan g Switch Netral h Sender bahan bakar k Meter bahan bakar z Lampu Indikator netral x Lampu indikator belok v Battery b Sekring ...

Page 289: ...LAKSON TIDAK BERFUNGSI 9 9 METER BAHAN BAKAR TIDAK BEKERJA CATATAN 9Lepaskan komponen komponen dibawah ini sebelum bekerja 1 Penutup samping kanan 2 Lampu depan 3 Tempat duduk 4 Tangki bensin 9Pergunakan alat dibawah ini untuk perbaikan Pocket tester 90890 03112 sekring putus ganti sekring TIDAK TERSAMBUNG SESUAI TERHUBUNG 2 Battery 9Periksa kondisi Battery lihat bagian PEMERIKSAAN BATTERY BAB 3 B...

Page 290: ...EMERIKSAAN SAKLAR Kunci kontak rusak perbaiki atau ganti TIDAK BAGUS BAGUS 4 Sambungan kabel 9Periksa sistim penyambungan kabel pada sistim sinyal lihat bagian DIAGRAM KELISTRIKAN BAGUS Perbaiki SAMBUNGAN TIDAK BAGUS Periksa kondisi kabel pada sistim sinyal lihat bagian PEMERIKSAAN SISTIM SINYAL ...

Page 291: ...lakson Horm 9Periksa sistim penyambungan tombol lihat bagian PEMERIKSAAN SAKLAR BAGUS tombol klakson rusak perbaiki atau ganti saklar kemudi TIDAK BAGUS PEMERIKSAAN SISTIM SINYAL 1 Horn Klakson tidak berfungsi P Br 1 DC20V Kabel Tester kabel coklat 1 1 KLabel Tester Masa ground SESUAI SPESIFIKASI 12V Rangkaian kabel dari kunci kontakl ke ter minal horn rusak perbaiki DILUAR SPESIFIKASI ...

Page 292: ...LAKSON BERBUNYI Klakson dalam kondisi baik KLAKSON TIDAK BERBUNYI 4 Voltase 9Pasangkan pocket tester DC 20 V pada terminal klakson 9Putar kunci kontak pada posisi ON 9Periksa voltase 12 V pada terminal kabel Pink merah jambu P Br 1 DC20V Kabel Tester kabel Pink 1 1 Kabel Tester Masa ground SESUAI SPESIFIKASI 12V Klakson dalam kondisi rusak ganti perbaiki DILUAR SPESIFIKASI Setel atau Ganti Horn ...

Page 293: ...ster terminalkabelkuning 1 KabelTester terminalkabelhitam2 SESUAI SPESIFIKASI 12V Rangkaian kabel dari kunci kontak ke socket bohlam rusak perbaiki DILUAR SPESIFIKASI 1 Bohlam dan socket bohlam 9Periksa kondisi Bohlam dan Socket bohlam lihat bagian PEMERIKSAAN BOHLAM ADA HUBUNGAN Bohlam dan Socket putus ganti TIDAK TERHUBUNG PUTUS 2 Saklar Switch rem 9Periksa kondisi switch rem lihat bagian PEMERI...

Page 294: ...bel Tester Masa ground SESUAI SSPESIFIKASI 12V Rangkaian kabel dari kunci kontak ke relay rusak perbaiki DILUAR SPESIFIKASI 1 Bohlam dan socket bohlam 9Periksa kondisi bohlam dan socket bohlam lihat bagian PEMERIKSAAN BOHLAM TERHUBUNG Bohlam dan socket bohlam rusak ganti TIDAK TERHUBUNG 2 Geser saklar pada posisi berbelok 9Periksa sistim penyambungan pada saklar lihat bagian PEMERIKSAAN SAKLAR BAG...

Page 295: ...OK DILUAR SPESIFIKASI 5 Voltase 9Pasangkan pocket tester DC 20 V pada connector socket bohlam 9Putar kunci kontak pada posisi ON 9Geser saklar sein ke arah L atau R 9Periksa voltase 12 V pada kabel coklat atau kabel hijau tua pada connector sock et bohlam Geser saklar sinyal kiri Kabel Tester kabel coklat 1 1 kabel Tester Masa ground Geser saklar sinyal kanan Kabel Tester kabel hijau tua 2 2 Kabel...

Page 296: ...netral lihat bagian PEMERIKSAAN SAKLAR BAIK Switch netral rusak perbaiki TIDAK SESUAI 3 Voltase 9Pasangkan pocket tester DC 20 V pada connector socket bohlam 9Putar kunci kontak pada posisi ON 9Periksa voltase 12 V pada kabel coklat yang berada pada connector 1 Sb Br G L B G L Sb Br B Kabel Tester terminal coklat 1 1 Kabel Tester Masa ground SESUAI SPESIFIKASI 12V Rangkaian kabel dari kunci kontak...

Page 297: ...sender keatas 4 4 Ω 1 4 10 Ω pada 20 C 68 F Tahanan sender kebawah 5 5 Ω 1 90 100 Ω pada 20 C 68 F SESUAI SPESIFIKASI Ganti sender bahan bakar DILUAR SPESIFIKASI 2 Voltase 9Pasangkan pocket tester DC 20 V pada coupler meter bahan bakar 9Putar kunci kontak pada posisi ON 9periksa voltase 12 V pada kabel coklat pada coupler meter bahan bakar 1 2 Kabel Tester terminal coklat 1 Kabel Tester terminal h...

Page 298: ...rum ke FULL atau EMPTY ELEC SISTIM SINYAL 32 4 jalur kabel 9Periksa jalur kabel pada bagian sistim sinyal lihat bagian DIAGRAM KELISTRIKAN BERGERAK ganti meter bahan bakar JARUM TIDAK BERGERAK CATATAN sebelum membaca tahanan pada posisi atas maupun bawah biarkan terlebih dahulu pada posisinya selama 10 detik ...

Page 299: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 300: ...ngit Sky blue W Putih White Y Kuning Yellow B W Hitam Putih Black White B Y Hitam Kuning Black Yellow Br W Coklat Putih Brown White Ch Coklat tua Chocolate Dg Hijau tua Dark green G Y Hijau Kuning Green Yellow L W Biru Putih Blue White L Y Biru Kuning Blue Yellow R W Merah Putih Red White Y R Kuning Merah Yellow Red WARNA KABEL LOCK OFF ON G B R Br B R B Br B W B W 15A Y R B L W R W GREEN W B R Y ...

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