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Yamaha Sirius T110LSE, Service Manual

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CHAS

CHAPTER 6

CHASSIS

FRONT WHEEL AND BRAKE DISC (T110LSE) ...................................................

6-1

REMOVING THE FRONT WHEEL .................................................................... 6-2
CHECKING THE FRONT WHEEL  .................................................................... 6-3
CHECKING THE BRAKE DISC ......................................................................... 6-5
CHECKING THE SPEEDOMETER GEAR UNIT............................................... 6-6
INSTALLING THE FRONT WHEEL ................................................................... 6-7

FRONT WHEEL AND DRUM BRAKE (T110LE) ...................................................

6-8

REMOVING THE FRONT WHEEL .................................................................... 6-9
DISASSEMBLING THE BRAKE SHOE PLATE ................................................. 6-9
CHECKING THE FRONT WHEEL ..................................................................... 6-10
CHECKING THE SPEEDOMETER GEAR UNIT .............................................. 6-11
CHECKING THE BRAKE................................................................................... 6-11
ASSEMBLING THE BRAKE SHOE PLATE ....................................................... 6-12
ASSEMBLING THE FRONT WHEEL................................................................. 6-13
INSTALLING THE FRONT WHEEL ................................................................... 6-13

REAR WHEEL AND BRAKE .................................................................................

6-14

REMOVING THE REAR WHEEL....................................................................... 6-15
DISASSEMBLING THE BRAKE SHOE PLATE ................................................. 6-17
CHECKING THE REAR WHEEL ....................................................................... 6-17
CHECKING THE REAR WHEEL DRIVE HUB................................................... 6-18
CHECKING THE REAR BRAKE........................................................................ 6-18
ASSEMBLING THE BRAKE SHOE PLATE ....................................................... 6-19
INSTALLING THE REAR WHEEL...................................................................... 6-19

FRONT BRAKE (T110LSE) ...................................................................................

6-21

FRONT BRAKE CALIPER ................................................................................. 6-21
REPLACING THE FRONT BRAKE PADS  ........................................................ 6-22
DISASSEMBLING THE FRONT BRAKE CALIPER........................................... 6-24
CHECKING THE FRONT BRAKE CALIPER ..................................................... 6-26
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER .................. 6-27
FRONT BRAKE MASTER CYLINDER .............................................................. 6-29
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER........................ 6-30
CHECKING THE FRONT BRAKE MASTER CYLINDER .................................. 6-31
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER......................................................................................... 6-32

FRONT FORK ........................................................................................................

6-35

REMOVING THE FRONT FORK LEGS............................................................. 6-36
DISASSEMBLING THE FRONT FORK LEGS................................................... 6-37
CHECKING THE FRONT FORK LEGS ............................................................. 6-39
ASSEMBLING THE FRONT FORK LEGS......................................................... 6-40
INSTALLING THE FRONT FORK LEGS ........................................................... 6-42

3S3-F8197-E0_6  05.11.2 17:25  Page A

Summary of Contents for Sirius T110LSE

Page 1: ...T110LE T110LSE SERVICE MANUAL 3S3 F8197 E0 ...

Page 2: ......

Page 3: ...E SERVICE MANUAL 2005 by Yamaha Motor Co Ltd First edition October 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited EAS00000 ...

Page 4: ...of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following Q The ...

Page 5: ...with a easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particularly important procedure 4 is placed between a line of mark or with each pro cedure preceded by 8 IMPORTANT FEATURES 8Data and a special tool are framed in a box preceded by a relevant symbol 5 8An encircled numeral 6 indicates a part name and an encircle...

Page 6: ......

Page 7: ... Lubricant w Special tool e Tightening torque r Wear limit clearance t Engine speed y Electrical data Symbols u to s in the exploded diagrams indi cate the types of lubricants and lubrication points u Engine oil i Gear oil o Molybdenum disulfide oil p Wheel bearing grease a Lithium soap based grease s Molybdenum disulfide grease Symbols d to f in the exploded diagrams indi cate the following d App...

Page 8: ......

Page 9: ...CIFICATIONS TROUBLESHOOTING ELECTRICALSYSTEM CHASSIS ENGINE PERIODIC CHECKSAND ADJUSTMENTS GENERALINFORMATION GEN INFO TRBL SHTG ELEC CHAS ENG CHK ADJ SPEC TABLE OF CONTENTS 4 6 7 8 3 2 1 CARBURETOR CARB 5 ...

Page 10: ......

Page 11: ... NUMBER 1 1 ENGINE SERIAL NUMBER 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 12: ...GEN INFO ...

Page 13: ...ION VEHICLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The number 1 is stamped into the frame as shown ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase NOTE Designs and specifications are subject to change without notice 1 ...

Page 14: ...ll of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire 1 2 EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance b...

Page 15: ...g EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives 4 Shaft GEN INFO IMPORTANT INFORMATION 1 300 000 OR 300 003 1 300 002 1 300 001 3 4 1 2 EAS00023 LOCK WASHERS PLATES AND...

Page 16: ...disconnect several times 3 Check 9all connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect 9lead 9coupler 9connector NOTE Make sure all connections are tight 5 Check 9continuity with the pocket tester NOTE 8If there is no continuity clean the terminals 8When checking the wire harness perform steps 1 to 3 8As a quick remedy use a contact ...

Page 17: ... This tool is necessary for separating the crankcase Weight Slide hammer bolt These tools are used when removing or installing the rocker arm shafts Weight 90890 01084 Slide hammer bolt 90890 01085 90890 01184 Fork seal driver weight This tool is used for to install the oil seal 90890 01186 Fork seal driver attachment This tool is used to install the oil seal 90890 01268 Ring nut wrencht This tool...

Page 18: ...312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber T handle This tool is used for holding the damper rod holder when removing or installing the damper rod holder 90890 01326 Flywheel puller This tool is used for removing the roter 90890 01362 90890 01403 Steering nut wrencht This tool is used to loosen and tighten the steering ring nut R20 90890 01701 Sheave hol...

Page 19: ...r This tool is needed for detecting engine rpm Valve spring compressor This tool is used when removing or installing the valve and valve spring 90890 04019 fl31 M6xP1 0 90890 04081 Spacer This tool is necessary for insatlling the crankshaft 90890 04086 Universal clutch holder This tool is needed to hold the clutch when removing or installing the clutch boss nut Tool No Tool name Usage Illustration...

Page 20: ... mm This tool is needed to install the valve guide 90890 04118 Valve guide reamer 4 5 mm This tool is needed rebore the new valve guide 90890 06754 Ignition checker This instrument is necessary for check ing the ignition system components Tool No Tool name Usage Illustration 90890 85505 Yamaha bond No 1215 This sealant bond is used for crankcase mating surface etc ...

Page 21: ... 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 TIGHTENING TORQUES 2 10 CHASSIS 2 12 TIGHTENING TORQUES 2 15 ELECTRICAL 2 17 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 CHASSIS 2 22 CABLE ROUTING 2 23 ...

Page 22: ...SPEC ...

Page 23: ...ngine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 110 3 cm3 6 73 cu in Bore stroke 51 0 54 0 mm 2 01 2 13 in Compression ratio 9 3 1 Compression pressure STD 1 300 kPa 13 kgf cm2 at 500 r min Starting system Kick and electric starter Lubrication system Wet sump Engine idling speed 1 400 1 600 r min Oil type or grade Engine oil SAE 20W40 A...

Page 24: ...on Left foot operation Gear ratio 1st 38 12 3 166 2nd 33 17 1 941 3rd 29 21 1 380 4th 23 21 1 095 Chassis Frame type Steel tube underbone Caster angle 27 Trail 77 mm 3 03 in Tire Type With tube Size front 60 100 17M C 33P rear 70 90 17M C 43P Model manufacturer front LOCAL MADE rear LOCAL MADE Min tire tread depth front 0 8 mm 0 03 in rear 0 8 mm 0 03 in Tire pressure cold tire Up to 90 kg load fr...

Page 25: ...heel travel Front wheel travel 95 mm 3 74 in Rear wheel travel 77 mm 3 03 in Electrical Ignition system DC C D I Generator system A C magneto Battery type manufacturer 12N5 3 B GS Battery capacity 12 V 5 AH Headlight type Incandescence Bulbs voltage wattage quantity Headlight 12 V 32 W 32 W 1 Tail brake light 12 V 5 W 21 W 1 Front turn signal light 12 V 10 W 2 Rear turn signal light 12 V 10 W 2 Me...

Page 26: ...0 8285 0 8325 in 21 015 mm 0 8274 in Exhaust A 25 775 25 875 mm 1 0148 1 0187 in 25 749 mm 1 0137 in B 20 950 21 050 mm 0 8248 0 8287 in 20 924 mm 0 8238 in Camshaft runout limit 0 03 mm 0 0012 in Timing chain Timing chain type No of links SILENT CHAIN 86 Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 10 000 10 015 mm 0 3937 0 3943 in 10 030 mm 0 3949 in Rocker ...

Page 27: ...ss IN 0 5 0 9 mm 0 0197 0 0354 in EX 0 8 1 2 mm 0 0315 0 0472 in Valve stem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 450 mm 0 1752 in EX 4 460 4 475 mm 0 1756 0 1762 in 4 435 mm 0 1746 in Valve guide inside diameter IN 4 500 4 512 mm 0 1772 0 1776 in 4 542 mm 0 1788 in EX 4 500 4 512 mm 0 1772 0 1776 in 4 542 mm 0 1788 in Valve stem to guide clearance IN 0 010 0 037 mm 0 0004 0 0015 i...

Page 28: ... Intake side Piston pin bore inside diameter 13 002 13 013 mm 0 5119 0 5123 in 13 043 mm 0 5135 in Piston pin outside diameter 12 996 13 000 mm 0 5117 0 5118 in 12 976 mm 0 5109 in Piston rings Top ring Ring type Barrel Dimensions B T 1 0 2 0 mm 0 04 0 08 in End gap installed 0 10 0 25 mm 0 0039 0 0098 in 0 40 mm 0 0157 in Ring side clearance installed 0 03 0 07 mm 0 0012 0 0028 in 0 12 mm 0 0047 ...

Page 29: ...te quantity 4pcs Max warpage 0 05 mm 0 0019 in Clutch springs Free length 30 3 mm 1 19 in 28 3 mm 1 11 in Spring quantity 4pcs Clutch release method Inner push cam push Clutch shoe thickness 2 20 mm 0 0866 in Clutch shoe groove depth 1 20 mm 0 0472 in 0 1 mm 0 0039 in Clutch housing inside diameter 105 mm 4 13 in 106 mm 4 17 in Weight outside diameter 105 mm 4 13 in 103 8 mm 4 09 in Clutch in revo...

Page 30: ...J 17 5 Pilot air screw turns out 1 1 8 Valve seat size ø1 5 Starter jet 1 32 5 Starter jet 2 ø0 6 Throttle valve size 3 5 Fuel level 3 0 mm 0 12 in Oil pump Oil pump type Trochoid type Inner rotor to outer rotor tip clear 0 15 mm 0 0059 in 0 20 mm ance 0 0079 in Outer rotor to oil pump housing 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm clearance 0 0059 in Oil pump housing to inner rotor and 0 06 0 10 m...

Page 31: ...2 9 OIL PUMP OIL STRAINER OIL PAN CYLINDERHEAD CONNECTING ROD BIG END PISTON CRANKSHAFT CAMSHAFT OIL RING TRANSMISSION CLUTCH Model T110LE T110LSE Lubrication chart SPEC MAINTENANCE SPECIFICATIONS ...

Page 32: ...ust pipe Nut M6 2 7 0 7 5 0 Exhaust pipe joint bolt Bolt M8 1 12 1 2 8 6 Muffler and muffler bracket Bolt M8 1 16 1 6 12 Muffler and passenger footrest Bolt M10 1 38 3 8 28 Air cut off valve assembly Bolt M6 2 7 0 7 5 0 Air induction system pipe Bolt M6 2 10 1 0 7 2 Air filter Air induction system Screw M6 2 12 1 2 8 6 Air filter case Screw M6 4 2 0 2 1 4 Crankcase Bolt M6 9 10 1 0 7 2 Crankcase c...

Page 33: ...1 0 7 2 Pickup coil Bolt M6 2 10 1 0 7 2 Stator coil Bolt M6 3 10 1 0 7 2 Neutral switch Bolt M5 2 4 0 4 2 9 2 11 MAINTENANCE SPECIFICATIONS LT LT Part to be tightened Part name Thread size Q ty Tightening torque Remarks Nm m kg ft lb LT LT SPEC ...

Page 34: ...Optional spring available No Oil capacity 0 059 L 59 cm3 Oil level 100 mm 3 94 in Recommended oil Fork oil 10W or equivalent Inner tube outer diameter 26 mm Inner tube bend limit 0 2 mm 0 008 in Rear suspension Shock absorber stroke 70 mm 2 76 in Spring free length 222 mm 8 74 in 218 mm 8 58 in Installed length 217 mm 8 54 in Spring rate K1 17 42 N mm 99 47 lb in 1 78 kgf mm K2 36 68 N mm 209 44 l...

Page 35: ...m 0 21 in 1 4 mm 0 06 in Pad thickness outer 5 3 mm 0 21 in 1 4 mm 0 06 in Master cylinder inside diameter 11 00 mm 0 43 in Caliper cylinder inside diameter 33 34 mm 1 31 in Brake fluid type DOT 3 or 4 Front brake lever free play 5 0 8 0 mm 0 20 0 31 in Drum brake type Leading trailing Brake drum inside diameter 110 0 mm 4 33 in 111 0 mm 4 37 in Lining thickness 4 0 mm 0 16 in 2 0 mm 0 08 in Shoe ...

Page 36: ...1 18 in end Drum inside diameter 130 mm 5 12 in 131 mm 5 16 in Lining thickness 4 0 mm 0 16 in 2 0 mm 0 08 in Shoe spring free length 1 52 0 mm 2 05 in 61 2 mm 2 41 in Shoe spring free length 2 48 0 mm 1 89 in 56 5 mm 2 22 in Throttle cable free play 3 7 mm 0 12 0 28 in SPEC 2 14 SPEC MAINTENANCE SPECIFICATIONS ...

Page 37: ... 17 Upper ring nut M25 75 7 5 54 See NOTE Lower ring nut M25 30 3 0 22 See NOTE Brake disc and wheel hub T110LSE M8 23 2 3 17 Brake camshaft and brake camshaft lever M6 7 0 7 5 0 Driven sprocket and rear wheel drive hub M8 30 3 0 22 Rear wheel axle nut M12 60 6 0 43 Rear shock absorber and frame M10 32 3 2 23 Rear shock absorber and swingarm M10 32 3 2 23 Swingarm pivot nut M12 51 5 1 37 Engine mo...

Page 38: ...me M6 9 0 9 6 5 Seat and seat bracket M6 7 0 7 5 0 SPEC 2 16 MAINTENANCE SPECIFICATIONS NOTE 1 First tighten the lower ring nut 30 Nm 3 0 m kg 22 ft lb by using a torque wrench then loosen the ring nut 1 4 turn 2 Then hold the lower ring nut and tighten the upper ring nut 75 Nm 7 5 m kg 54 ft lb by using a torque wrench Part to be tightened Thread size Tightening torque Remarks Nm m kg ft lb ...

Page 39: ... 0 48 Ω at 20 C 68 F Secondary coil resistance 5 68 8 52 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 7 5 12 5 kΩ Charging system Type A C magneto Model manufacturer F5TN MORIC Nominal output 14 V 100 W at 5 000 r min Lighting coil resistance color 0 24 0 36 Ω at 20 C 68 F Y B Charging coil resistance color 0 32 0 48 Ω at 20 C 68 F W B Rectifier regulator Regulator type Semiconductor s...

Page 40: ...Mica undercut depth 1 35 mm 0 05 in Starter relay Model manufacturer G4R D OMRON Amperage rating 50 A Coil resistance 54 66 Ω at 20 C 68 F Horn Type Plane Quantity 1 Model manufacturer GF 12 NIKKO Max amperage 1 5 A Performance 95 105 db 2 m Coil resistance 4 30 4 80 Ω Turn signal relay Relay type Condenser Model manufacturer FR 2201 MITSUBA Self canceling device built in No Flasher frequency 75 9...

Page 41: ...pter of this manual To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature A Width across flats B Thread diameter 10 mm 6 mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 mm 30 3 0 17 mm 12 mm...

Page 42: ...g groove Piston ring Cylinder inner surface Starter clutch gear inner surface Starter idle gear inner surface Kickstarter ratchet gear Kickstarter gear Kickstarter shaft Primary driven gear inner surface Clutch push rod Clutch pressure plate Friction plate Clutch shoe housing inner surface Cage Clutch shoe housing boss Oil pump assembly Shift guide inner surface Shift fork guide bar Shift shaft th...

Page 43: ...ce Transmission pinion gears inner surface Starter motor guard bolt Yamaha bond No 1215 Generator lead grommet Yamaha bond No 1215 Crankcase cover bolt Yamaha bond No 1215 Crankcase mating surface Yamaha bond No 1215 SPEC 2 21 LUBRICATION POINTS AND LUBRICANT TYPES ...

Page 44: ... Rear brake camshaft Brake torque rod bolt Front wheel axle Rear wheel axle Throttle grip tube guide inner surface Brake cable brake lever T110LE Brake lever pivot bolt Steering head bearing inner race Steering head bearing outer race Steering head upper bearing Steering head lower bearing Sidestand pivot bolt Swingarm pivot shaft Centerstand pivot shaft SPEC 2 22 LUBRICATION POINTS AND LUBRICANT ...

Page 45: ...h the right handlebar switch lead behind the handlebar Push in the coupler between the handlebar and speedometer assembly after connected ç Hock the wire harness onto the strap Push in the coupler between the handlebar and speedometer assembly after connected To headlight assembly ƒ To turn signal light To front brake switch ƒ 7 å å ç 1 1 2 3 4 8 6 A å å ç 1 1 2 3 4 5 6 A T110LE T110LSE ...

Page 46: ...ake hose T110LSE 7 Brake cable T110LE å Pass through the wire harness onto the cable guide Align the clamp with the white tape on the wire harness ç The wire harness should not be forced out from handle cover å ç A B B A 1 2 3 4 5 å ç A T110LE T110LSE B B A 1 2 3 4 5 7 1 3 4 5 7 1 3 4 5 7 1 3 4 5 6 1 3 4 5 6 ...

Page 47: ...lay 8 Negative lead 9 Air induction system hose air cut off valve assembly to air filter 0 Fuel hose q Fuel cock w Starter motor lead e Choke cable r Throttle cable t Main switch lead y Battery breather hose u Fuel cock vacuum hose i Air filter drain hose o Carburetor overflow hose 1 2 3 4 5 6 7 8 9 0 q w ç ƒ A B B A C C D 1 e t r 1 e r 1 e r t y å i o u ...

Page 48: ...starter cable neutral switch lead and A C magneto lead through the guide Install the negative terminal in this angle Pass the over flow hose through the guide ƒ Insert the drain hose into the guide Do not obstruct the clip for route the fuel cock vacuum hose Install the fuel hose clamp facing down 1 2 3 4 5 6 7 8 9 0 q w ç ƒ A B B A C C D 1 e t r 1 e r 1 e r t y å i o u ...

Page 49: ...hose 4 Cover 5 Main switch lead 6 Horn 7 Spark plug lead 8 Turn signal relay 9 Neutral switch lead 0 A C magneto lead q Protector w Main switch e Starter motor cover r Starter motor t Starter motor lead y Footrest u Brake hose holder T110LSE i Cable guide T110LSE o Brake hose T110LSE å Insert the end of the air vent hose into the hole in the frame ...

Page 50: ...nder 2 Battery breather hose 3 Starter motor lead 4 Rear brake light switch 5 Rear brake light switch lead 6 Battery negative lead 7 Fuse 8 Starter relay 9 Battery 0 C D I unit q Box w Battery positive lead e Wire harness å Insert the battery breather hose into the hose guide ...

Page 51: ... lead 9 Starter relay 0 Turn signal relay q Neutral switch lead w A C magneto lead e Fuel sender lead wire harness å Clamp the fuel sender lead wire harness Align the white tape of the wire harness with the guide on the fuel tank ç To the battery To the starter motor To the wire harness ƒ Pass the battery positive lead To the fuse To the starter motor ˆ To the C D I unit To the starter relay ...

Page 52: ... ADJUSTING THE CLUTCH RELEASE SYSTEM 3 18 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 3 19 CHECKING THE FUEL AND VACUUM HOSES 3 19 CHECKING THE CRANKCASE BREATHER HOSE 3 20 CHASSIS 3 21 ADJUSTING THE FRONT BRAKE T110LE 3 21 ADJUSTING THE REAR BRAKE 3 21 CHECKING THE FRONT BRAKE PADS T110LSE 3 22 CHECKING THE REAR BRAKE SHOES T110LSE 3 23 CHECKING THE FRONT AND REAR BRAKE SHOES T110LE 3 23 AD...

Page 53: ...ICATING THE SIDESTAND 3 35 LUBRICATING THE CENTERSTAND 3 35 ELECTRICAL SYSTEM 3 36 CHECKING AND CHARGING THE BATTERY 3 36 CHECKING THE FUSE 3 40 REPLACING THE HEADLIGHT BULBS 3 41 ADJUSTING THE HEADLIGHT BEAM 3 42 ...

Page 54: ...ce if necessary 6 Engine oil Replace Warm engine before draining Every 2 000 km 7 Engine oil filter Check clean and replace if necessary 8 Front brake T110LE Check operation and adjust brake lever free play Replace brake shoes if necessary 9 Front brake T110LSE Check operation fluid level and fluid leakage Replace brake pads if necessary 10 Rear brake Check operation and adjust brake pedal free pl...

Page 55: ...lace the internal components of the brake master cylinder and caliper and change the brake fluid 9 Replace the brake hoses every four years and if cracked or damaged It is recommended that these items be serviced by a Yamaha dealer 19 Centerstand and sidestand Check operation Repair if necessary 20 Battery Check specific gravity Check that the breather hose is working properly Correct if necessary...

Page 56: ... Remove 9main switch cover 1 9center panel 2 NOTE Remove the main switch cover by turning it in the direction of the arrow shown 3 Remove 9front panel 1 INSTALLING THE FRONT COWLINGS For installation reverse the removal procedure 2 Remove 9front cowlings left and right 1 1 1 ...

Page 57: ... Refer to REMOVING THE FRONT COWL INGS 9side panel 1 2 Remove 9rear panel 1 NOTE Remove the rear panel by sliding it in the direc tion of the arrow shown 3 Remove 9cover 1 9rear cowlings left and right 2 INSTALLING THE REAR COWLINGS 1 Install 9rear cowlings left and right 1 9cover 2 NOTE Before tightening the rear cowling screws make sure that all projections are securely fitted ...

Page 58: ...TALLING THE FRONTCOWL INGS REMOVING THE HEADLIGHT ASSEMBLY 1 Remove 9headlight assembly 1 2 Disconnect 9turn signal light coupler 1 9headlight connectors 2 INSTALLING THE HEADLIGHT ASSEMBLY 1 Connect 9headlight connectors 9turn signal light coupler 2 Install 9headlight assembly 1 NOTE Before tightening the headlight assembly screws make sure that all projections are securely fitted ...

Page 59: ...h O ring 1 Remove 9center panel 9front cowlings left and right Refer to REMOVING THE FRONT COWL INGS EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves NOTE 9Valve clearance adjustment should be made on a cold engine at room temperature 9When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compressio...

Page 60: ...clearance with a thick ness gauge 1 Out of specification Adjust CHK ADJ ADJUSTING THE VALVE CLEARANCE 3 7 5 Adjust 9valve clearance a Loosen the locknut 1 b Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip c Turn the adjusting screw 3 in direction a or b until the specified valve clearance is obtained Valve clearance cold Intake valve 0 05 0 09 mm 0 0020 0 0035 i...

Page 61: ...ed clearance is obtained CHK ADJ ADJUSTING THE VALVE CLEARANCE 3 8 7 Install 9tappet cover intake side 1 9O ring 2 8 Install 9tappet cover exhaust side 9O ring 9 Install 9front cowlings left and right 9center panel Refer to INSTALLING THE FRONT COWL INGS 6 Install 9camshaft sprocket cover 9O ring 9timing check plug with O ring 9center plug with O ring Locknut 7 Nm 0 7 m kg 5 0 ft lb 7 Nm 0 7 m kg ...

Page 62: ...EED NOTE Prior to adjusting the engine idling speed the air filter element should be clean and the engine should have adequate compression 1 Remove 9front cowling right Refer to REMOVING THE FRONT COWL INGS 2 Start the engine and let it warm up for sev eral minutes 3 Connect 9engine tachometer onto the spark plug lead CHK ADJ ADJUSTING THE ENGINE IDLING SPEED 3 9 Engine tachometer 90890 03113 Engi...

Page 63: ... 12 0 28 in ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed should be adjusted 1 Check 9throttle cable free play a Out of specification Adjust 2 Remove 9front cowling left Refer to REMOVING THE FRONT COWL INGS Throttle cable free play at the flange o...

Page 64: ...ylinder 1 2 a b 3 Adjust 9throttle cable free play a Pull back the adjusting nut cover b Loosen the locknut 1 c Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained d Tighten the locknut e Slide the adjusting nut cover to its original position w After adjusting the throttle cable free play start the engine and turn the handlebar to the right or left...

Page 65: ...spark plug with a spark plug cleaner or wire brush 7 Measure 9spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install 9spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect 9spark plug cap 10 Install 9front cowling right Refer to INSTALLING THE FRONT COWL INGS Spark plug type manufacturer C6HSA NGK Spark plug gap 0 6 0 7 mm 0 0...

Page 66: ...cification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Disconnect 9spark plug cap 4 Remove 9spark plug cC Before removing the spark plug use com pressed air to blow away any dirt accumulat ed in the spark plug well to prevent it from falling into the cylinder Compression gauge 90890 03081 Compression pressure at sea level...

Page 67: ...bon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table 7 Install 9spark plug 8 Connect 9spark plug cap 9 Install 9front cowling right Refer to INSTALLING THE FRONT COWL INGS Compression pressure with oil applied into the cylinder Reading Diagnosi...

Page 68: ...and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level cC Do not allow foreign materials to enter the crankcase NOTE 9Insert the oil level plug back into the oil filler hole without screwing it in and then remove it again to check the oil level 9Before checking the engine oil level wait a few minutes until the oil has settled 5 Start the engine war...

Page 69: ...ll 9oil level plug 9 Start the engine warm it up for several min utes and then turn it off 10 Check 9engine for engine oil leaks 11 Check 9engine oil level Refer to CHECKING THE ENGINE OIL LEVEL 1 CHANGING THE ENGINE OIL Quantity Total amount 1 0 L 1 06 US qt 0 88 lmp qt Periodic oil change amount 0 8 L 0 85 US qt 0 70 lmp qt EAS00075 CHANGING THE ENGINE OIL 1 Start the engine warm it up for sever...

Page 70: ... CLEANING THE AIR FILTER ELEMENT 1 Remove 9center panel 9front cowlings left and right Refer to REMOVING THE FRONT COWL INGS 2 Remove 9air filter case cover 1 9air filter element 2 3 Clean 9air filter element Apply compressed air to the outer surface of the air filter element 4 Check 9air filter element Damage Replace 7 Nm 0 7 m kg 5 0 ft lb 2 Check 9exhaust pipe joint bolt 1 Loose damage Tighten ...

Page 71: ...nce and possible overheating NOTE When installing the air filter element into the air filter case cover make sure their sealing sur faces are aligned to prevent any air leaks 6 Install 9front cowlings left and right 9center panel Refer to INSTALLING THE FRONT COWL INGS EAS00086 ADJUSTING THE CLUTCH RELEASE SYSTEM 1 Adjust 9clutch release system a Loosen the locknut 1 b Turn the adjusting screw 2 i...

Page 72: ... 2 Cracks damage Replace Refer to CARBURETOR in chapter 5 3 Install 9front cowling right Refer to INSTALLING THE FRONT COWL INGS EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses 1 Remove 9front cowling left Refer to REMOVING THE FRONT COWL INGS 2 Check 9fuel cock vacuum hose 1 9fuel hose 2 Cracks damage Replace Loose connection Connect...

Page 73: ...INSTALLING THE FRONT COWL INGS EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove 9front cowling right Refer to REMOVING THE FRONT COWL INGS 9side panel Refer to REMOVING THE REAR COWL INGS 2 Check 9crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly cC Make sure the crankcase breather hose is routed correctly ...

Page 74: ...ction a or b until the specified brake lever free play is obtained cC After adjusting the brake lever free play make sure there is no brake drag EAS00113 ADJUSTING THE REAR BRAKE 1 Check 9brake pedal free play a Out of specification Adjust Direction a a Brake lever free play is increased Direction b b Brake lever free play is decreased ADJUSTING THE FRONT BRAKE T110LE ADJUSTING THE REAR BRAKE Brak...

Page 75: ... is no brake drag 3 Adjust 9rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH Direction a a Brake pedal free play is increased Direction b b Brake pedal free play is decreased EAS00120 CHECKING THE FRONT BRAKE PADS T110LSE The following procedure applies to all of the brake pads 1 Operate the brake 2 Check 9front brake pad Wear indicator groove 1 almost disap peared Replace th...

Page 76: ...lies to both the front and rear brake shoes 1 Operate the brake 2 Check 9wear indicator 1 Reaches the wear limit line 2 Replace the front or rear brake shoes as a set Refer to FRONT WHEEL AND DRUM BRAKE T110LE in chapter 6 and REAR WHEEL AND BRAKE in chapter 6 EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake ...

Page 77: ...es on at the proper time 4 Install 9side panel Refer to INSTALLING THE REAR COWL INGS Direction a a Brake light comes on sooner Direction b b Brake light comes on later EAS00129 CHECKING THE FRONT BRAKE HOSE T110LSE 1 Check 9brake hose Cracks damage wear Replace 2 Check 9brake hose clamp Loose Connection Tighten the clamp bolt 3 Hold the vehicle upright and apply the front brake several times 4 Ch...

Page 78: ...ir to enter the hydraulic brake system considerably lengthening the bleeding procedure 9If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed 9hydraulic brake system a Fill the brake master cylinder reservoir to the proper level with the recommended brake fluid b Install th...

Page 79: ...fication k Fill the brake master cylinder reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL T110LSE w After bleeding the hydraulic brake system check the brake operation Bleed screw 6 Nm 0 6 m kg 4 3 ft lb EAS00140 ADJUSTING THE DRIVE CHAIN SLACK NOTE The drive chain slack must be checked at the tightest point on the chain cC A drive chain that ...

Page 80: ...ack a Out of specification Adjust Drive chain slack 25 35 mm 0 98 1 38 in 4 Adjust 9drive chain slack a Loosen the wheel axle nut 1 b Loosen both locknuts 2 c Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is obtained NOTE To maintain the proper wheel alignment adjust both sides evenly d Tighten both locknuts to specification e Tighten the wheel axle nut to sp...

Page 81: ...or non O ring chains EAS00115 CHECKING THE BRAKE FLUID LEVEL T110LSE 1 Stand the vehicle on a level surface NOTE Make sure the vehicle is upright 2 Check 9brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level w 9 9Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance...

Page 82: ...In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EASF0010 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface w Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check 9steering head Grasp the...

Page 83: ...nch 5 and tighten the upper ring nut 2 with a steering nut wrench w Do not overtighten the lower ring nut f Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD in chapter 6 g Slide the rubber cover to its original posi tion 5 Install 9f...

Page 84: ...hat there is no danger of it falling over 2 Check 9inner tube Damage scratches Replace 9oil seal Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check 9front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK in chapter 6 ...

Page 85: ...ies and the anticipated riding speed 9 9Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE Total weight of rider passenger cargo and accessories w It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately Basic weight with oil and 98 kg 216 lb a full fuel tank Maximum 162 kg 357 l...

Page 86: ...be are centered in the wheel groove 9 9Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement 9 9After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufactur er and of the same...

Page 87: ...n CHECKING THE TIRES CHECKING AND TIGHTENING THE SPOKES w 9 9New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done 9 9After a tire has been repaired or replaced be sure to tighten the tire air valve stem locknut 1 1 to specification NOTE For tires with a dire...

Page 88: ...OTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS00171 LUBRICATING THE LEVER AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the lever and pedals EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS00173 LUBRICATING THE CENTERSTAN...

Page 89: ...way from fire sparks or open flames e g welding equipment light ed cigarettes 9 9DO NOT SMOKE when charging or han dling batteries 9 9KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 9 9Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL 9 9Skin Wash with water 9 9Eyes Flush with water for 15 minutes and get...

Page 90: ...lectrolyte level The electrolyte level should be between the minimum level mark a and the maximum level mark b Below the minimum level mark Add dis tilled water to the proper level cC Add only distilled water Tap water contains minerals which are harmful to the battery 5 Check 9specific gravity Less than 1 280 Recharge the battery 6 Charge 9battery w Do not quick charge a battery Battery charging ...

Page 91: ...ed to the battery 9 9Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger 9 9Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks 9 9If the battery becomes hot...

Page 92: ...d 2 12 Lubricate 9battery terminals Recommended lubricant Dielectric grease 9 Connect 9battery breather hose 1 cC 9 9When checking the battery make sure the battery breather hose is properly installed and routed correctly If the battery breather hose is positioned so as to allow elec trolyte or hydrogen gas from the battery to contact the frame the vehicle and its fin ish may be damaged 9 9Make su...

Page 93: ...r to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 4 Replace 9blown fuse w Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could ...

Page 94: ...your hands away from the bulb until it has cooled down 4 Install 9headlight bulb Secure the new headlight bulb with the headlight bulb holder cC Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth ...

Page 95: ...M 1 Adjust 9headlight beam vertically a Loosen the bolt 1 b Slide the bottom of the headlight unit for ward a or backward b c Tighten the bolt 1 ADJUSTING THE HEADLIGHT BEAM Slide forward Headlight beam is a raised Slide backward Headlight beam is b lowered ...

Page 96: ...R HEAD 4 8 REMOVING THE CYLINDER HEAD 4 9 CHECKING THE CYLINDER HEAD 4 11 CHECKING TIMING CHAIN GUIDE 4 12 CHECKING THE TIMING CHAIN TENSIONER 4 13 INSTALLING THE CYLINDER HEAD 4 13 CAMSHAFT 4 17 REMOVING THE ROCKER ARMS AND CAMSHAFT 4 18 CHECKING THE CAMSHAFT 4 19 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4 19 CHECKING THE CAMSHAFT SPROCKET 4 21 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCK...

Page 97: ...TER 4 47 CLUTCH 4 48 REMOVING THE CLUTCH 4 49 CHECKING THE FRICTION PLATES 4 51 CHECKING THE CLUTCH PLATES 4 51 CHECKING THE CLUTCH SPRINGS 4 52 CHECKING THE CLUTCH HOUSING 4 52 CHECKING THE CLUTCH BOSS 4 52 CHECKING THE CLUTCH PRESSURE PLATE 4 53 CHECKING THE CLUTCH PUSH ROD 2 4 53 CHECKING THE PRIMARY DRIVEN GEAR 4 53 CHECKING THE CLUTCH SHOE HOUSING 4 54 CHECKING THE CLUTCH SHOE 4 54 CHECKING T...

Page 98: ...G THE CRANKSHAFT AND CONNECTING ROD 4 69 CHECKING THE CRANKCASE 4 71 CHECKING THE BEARINGS 4 71 CHECKING THE TIMING CHAIN GUIDE 4 71 CHECKING THE TIMING CHAIN 4 71 INSTALLING THE CRANKSHAFT 4 72 ASSEMBLING THE CRANKCASE 4 72 TRANSMISSION 4 74 REMOVING THE TRANSMISSION 4 75 DISASSEMBLING THE TRANSMISSION 4 75 CHECKING THE SHIFT FORKS 4 76 CHECKING THE SHIFT DRUM ASSEMBLY 4 77 CHECKING THE TRANSMISS...

Page 99: ...ENG ...

Page 100: ...E FRONT COWL INGS in chapter 3 side panel rear cowlings left and right Refer to REMOVING THE REAR COWL INGS in chapter 3 drive sprocket Refer to DRIVE CHAIN AND SPROCK ETS in chapter 6 ENGINE OIL 1 Drain engine oil completely from the crankcase Refer to CHANGING THE ENGINE OIL in chapter 3 CARBURETOR 1 Drain carburetor assembly Refer to CARBURETOR in chapter 5 MUFFLER AND EXHAUST PIPE 1 Remove exh...

Page 101: ...s 1 footrest 2 Remove starter motor guard bolts 1 starter motor guard 2 3 Remove air induction system pipe bolts 1 air induction system pipe 2 BRAKE PEDAL 1 Remove rear brake light switch spring brake pedal spring circlip brake pedal 1 1 2 2 Remove exhaust pipe nuts 1 exhaust pipe 2 1 2 ...

Page 102: ...BRACKET 1 Remove 9front cowling bracket bolts 1 9front cowling bracket 2 WIRE CABLE AND HOSE 1 Remove 9negative battery lead 1 9positive battery lead 2 9battery breather hose 2 Remove 9spark plug cap 1 9air induction system hose air cut off valve assembly to cylinder head 2 4 3 3 Remove 9air induction system vacuum hose 1 9fuel cock vacuum hose 2 2 1 ...

Page 103: ...washer 9rear upper mounting bolt 1 9front mounting bolt 2 9rear lower mounting bolt 3 9engine assembly w Securely support the vehicle so there is no danger of it falling over 1 4 Remove 9crankcase breather hose 1 1 2 3 1 5 Disconnect 9stator coil coupler 1 9pickup coil coupler 2 9neutral switch coupler 3 6 Disconnect 9starter motor lead coupler 1 ...

Page 104: ...upler 9stator coil coupler 9negative battery lead 2 Install 9crankcase breather hose 9fuel cock vacuum hose 9air induction system vacuum hose 9air induction system hose air cut off valve assembly to cylinder head 9spark plug cap FRONT COWLING 1 Install 9front cowling bracket 9front cowling bracket bolts SHIFT PEDAL 1 Install 9shift pedal 1 9shift pedal bolt 2 NOTE 9Install the shift pedal to the s...

Page 105: ...guard bolt 1 2 Install 9footrest 9footrest bolts MUFFLER 1 Install 9exhaust pipe 9exhaust pipe nuts 2 Install 9muffler 9washers 9upper muffler bolt 9washer 9lower muffler bolt 9muffler nut 9exhaust pipe joint bolt ENGINE OIL 1 Fill 9engine oil Refer to CHANGING THE ENGINE OIL in chapter 3 1 23 Nm 2 3 m kg 17 ft lb 12 Nm 1 2 m kg 8 6 ft lb 7 Nm 0 7 m kg 5 0 ft lb Yamaha bond No 1215 90890 85505 38 ...

Page 106: ...to CARBURETOR in chapter 5 2 Adjust 9throttle cable free play 9rear brake light operation timing Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY and ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3 Throttle cable free play at the flange of the throttle grip 3 7 mm 0 12 0 28 in ...

Page 107: ...NDER HEAD 1 Intake manifold 2 Tappet cover intake side 3 Cylinder head 4 Spark plug 5 Tappet cover exhaust side 6 Timing chain guide exhaust side 7 Camshaft sprocket 8 Camshaft sprocket cover 9 Dowel pin 0 Gasket q Timing chain tensioner ...

Page 108: ...chapter 5 9exhaust pipe Refer to REMOVING THE ENGINE 2 Remove 9air induction system pipe bolts 9air induction system pipe 1 9air induction system pipe gasket 3 Remove 9intake manifold bolts 9intake manifold 1 with O ring 5 Remove 9tappet cover intake side 1 9tappet cover exhaust side 2 9camshaft sprocket cover screws 9camshaft sprocket cover 3 with O ring 1 1 4 Remove 9spark plug cap 1 9spark plug...

Page 109: ...rk c on the camshaft sprocket with the stationary point er d on the cylinder head 7 Loosen 9camshaft sprocket bolt 1 NOTE While holding the generator rotor with a wrench 2 loosen the camshaft sprocket bolt 8 Remove 9timing chain tensioner bolts 9timing chain tensioner 1 9gasket 9 Remove 9camshaft sprocket bolt 1 9camshaft sprocket 2 9timing chain 3 NOTE To prevent the timing chain from falling int...

Page 110: ... at a time After all of the nuts are fully loosened remove them 11 Remove 9dowel pins 1 9gasket 2 9timing chain guide exhaust side 3 EAS00227 CHECKING THE CYLINDER HEAD 1 Eliminate 9combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching 9spark plug bore threads 9valve seats 2 Check 9cylinder head Damage scratches Replace ...

Page 111: ...e c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times CHECKING TIMING CHAIN GUIDE 1 Check 9timing chain guide exhaust side Damage wear Replace Maximum cylinder head warpage 0 03 mm 0 0012 ...

Page 112: ...hain 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 2 Check 9cap bolt 9one way cam 9timing chain tensioner rod Damage wear Replace the defective part s EAS00232 INSTALLING THE CYLINDER HEAD 1 Install 9timing chain guide exhaust side 1 9dowel pins 2 9gasket 3 1 2 In...

Page 113: ... I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head d Install the timing chain onto the camshaft sprocket and then install the camshaft sprocket onto the camshaft NOTE 9When installing the camshaft sprocket be sure to keep the timing chain as tight as possible on the exhaust side 9Align the projection e on the camshaft sprock et with the slot in the camshaft cC Do...

Page 114: ...g chain ten sioner 2 onto the cylinder w Always use a new gasket c Turn the timing chain tensioner rod counter clockwise with a thin screwdriver 1 make sure it releases and then install the cap 6 Tighten 9camshaft sprocket bolt cC Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the pos sibility of the bolt coming loose and damag ing the engine 7 Turn 9crankshaft seve...

Page 115: ...e clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 10 Install 9camshaft sprocket cover screws 9camshaft sprocket cover 11 Install 9tappet cover exhaust side 9tappet cover intake side 12 Install 9spark plug 13 Install 9intake manifold bolts 9intake manifold 14 Connect 9air induction system pipe bolts 9air induction system pipe 7 Nm 0 7 m kg 5 0 ft lb 18 Nm 1...

Page 116: ...ENG 4 17 CAMSHAFT EASf0020 CAMSHAFT 1 Locknut 2 Adjusting screw 3 Rocker arm 4 Rocker arm shaft 5 Camshaft 6 Camshaft retainer ...

Page 117: ...sen 9locknuts 1 9adjusting screws 2 2 Remove 9camshaft retainer 1 3 Remove 9camshaft 1 NOTE Screw an 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft 4 Remove 9rocker arm shafts 9rocker arms NOTE Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2 Slide hammer bolt 90890 01085 Weight 90890 01084 ...

Page 118: ...e the camshaft 3 Check 9camshaft oil passage Obstructions Blow out with compressed air EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check 9rocker arm Damage wear Replace Camshaft lobe dimension limit Intake a a 25 745 mm 1 0136 in b b 21 015 mm 0 8274 in Exhaust a a 25 749 mm 1 0137 in b b 20 924 mm 0 8238...

Page 119: ...r arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm Replace the rocker arm and rocker arm shaft as a set Rocker arm inside diameter 10 000 10 015 mm 0 3937 0 3943 in Limit 10 030 mm 0 3949 in Rocker arm shaft outside diameter 9 981 9 991 mm 0 3930 0 3933 in Limit 9 950 mm 0 3917 in ...

Page 120: ...er 9camshaft sprocket cover Damage wear Replace the defective part s a EAS00219 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Lubricate 9camshaft journals 2 Lubricate 9rocker arm inside surface 9camshaft oil passage 3 Install 9camshaft retainer 1 9camshaft retainer bolt NOTE 9Apply locking agent LOCTITE to the threads of camshaft retainer bolt 9Install the camshaft retainer with the bent ends facing i...

Page 121: ...4 22 ENG VALVES AND VALVE SPRINGS EASF0024 VALVES AND VALVE SPRINGS 1 Valve cotter 2 Upper spring seat 3 Valve spring 4 Valve stem seal 5 Lower spring seat 6 Intake valve 7 Exhaust valve ...

Page 122: ...s NOTE Before removing the internal parts of the cylin der head e g valves valve springs valve seats make sure the valves properly seal 1 Check 9valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage...

Page 123: ...nstalled in its original place EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure 9valve stem to valve guide clearance Out of specification Replace the valve guide Valve spring compressor 90890 04019 Valve stem to valve guide clearance Valve guide inside diameter a a Valve stem diameter b b Valve stem to valve guide clear a...

Page 124: ...obtain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat 3 Eliminate 9carbon deposits from the valve face and valve seat 4 Check 9valve face Pitting wear Grind the valve face 9valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure 9valve margin thickness a Out of specification Replace the ...

Page 125: ...on deposits from the valve face and valve seat 2 Check 9valve seat Pitting wear Replace the cylinder head 3 Measure 9valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve s...

Page 126: ...tem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure ...

Page 127: ...cation Replace the valve spring 2 Measure 9compressed valve spring force a Out of specification Replace the valve spring b Installed length 3 Measure 9valve spring tilt a Out of specification Replace the valve spring Valve spring free length Intake and exhaust valve springs 33 75 mm 1 33 in Limit 32 05 mm 1 2618 in Compressed valve spring force installed Intake and exhaust valve springs 138 148 N ...

Page 128: ...eburr 9valve stem end with an oil stone 2 Lubricate 9valve stem 1 9valve stem seal 2 with the recommended lubricant 3 Install 9valve 1 9lower spring seat 2 9valve stem seal 3 9valve spring 4 9upper spring seat 5 into the cylinder head NOTE Install the valve spring with the larger pitch a facing up b Smaller pitch Recommended lubricant Engine oil ...

Page 129: ...ve cotters by compressing the valve spring with the valve spring compressor 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer cC Hitting the valve tip with excessive force could damage the valve Valve spring compressor 90890 04019 ...

Page 130: ...ENG CYLINDER AND PISTON EASF0027 CYLINDER AND PISTON 1 Cylinder 2 Cylinder gasket 3 Dowel pin 4 Top ring 5 2nd ring 6 Oil ring 7 Piston 8 Piston pin 9 Piston pin clip 4 31 ...

Page 131: ...oving the piston pin clip cover the crankcase opening with a clean rag to pre vent the piston pin clip from falling into the crankcase 9Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore area of the piston If both areas are deburred and the piston pin is still difficult to remove remove it with a piston pin puller set 4 Remove 9top ring 92nd ring 9oil ring NO...

Page 132: ...b If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter P with a micrometer a 5 mm from the bottom edge of the piston d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Cylinder bore C 51 000 51 015 mm 2 0079 2 0085 in Limit 5...

Page 133: ...side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install 9piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown a 40 mm Piston to cylinder clearance 0 020 0 025 mm 0 0008 0 0010 in Limit 0 15 mm 0 0059 in Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston ring side clearance Top ring 0 ...

Page 134: ... lubrication system 2 Measure 9piston pin outside diameter a Out of specification Replace the piston pin 3 Measure 9piston pin bore diameter of the piston b Out of specification Replace the piston Piston ring end gap Top ring 0 10 0 25 mm 0 0039 0 0098 in Limit 0 4 mm 0 0157 in 2nd ring 0 10 0 25 mm 0 0039 0 0098 in Limit 0 4 mm 0 0157 in Oil ring rails 0 20 0 70 mm 0 0079 0 0276 in Piston pin out...

Page 135: ...the manufacturer s marks or numbers face up 2 Install 9piston 1 9piston pin 2 9piston pin clip 3 NOTE 9Apply engine oil to the piston pin 9Make sure the arrow mark a on the piston points towards the exhaust side of the cylin der 9Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase Piston pin to piston pin bore clear...

Page 136: ... 5 Offset 9piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring å forward 6 Install 9cylinder 1 NOTE 9While compressing the piston rings with one hand install the cylinder with the other hand 9Pass the timing chain and timing chain guide intake side through the timing chain cavity Recommended lubricant Engine oil ...

Page 137: ...ch gear 2 Starter clutch roller 3 Starter clutch spring cap 4 Starter clutch spring 5 Starter clutch 6 Woodruff key 7 Generator rotor 8 Starter clutch idle gear shaft 9 Starter clutch idle gear 0 Stator coil lead holder q Pickup coil w Stator coil e Gasket r Dowel pin t Crankcase cover left ...

Page 138: ...shift pedal 9drive sprocket cover Refer to REMOVING THE DRIVE CHAIN AND SPROCKETS in chapter 6 3 Disconnect 9stator coil coupler 1 9pickup coil coupler 2 5 Remove 9generator rotor nut 1 9washer NOTE 9While holding the generator rotor 2 with the sheave holder 3 loosen the generator rotor nut 9Do not allow the sheave holder to touch the projection on the generator rotor Sheave holder 90890 01701 4 R...

Page 139: ...dle gear 2 9starter clutch gear 3 9washer 2 Remove 9starter clutch rollers 1 9starter clutch spring caps 9starter clutch springs 3 Remove 9starter clutch bolt 9starter clutch 1 NOTE 9While holding the generator rotor 2 with the sheave holder remove the starter clutch bolt 9Do not allow the sheave holder to touch the projection on the generator rotor Flywheel puller 90890 01362 Sheave holder 90890 ...

Page 140: ...es a Damage pitting wear Replace the starter clutch gear 4 Check 9starter clutch operation a Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch b When turning the starter clutch gear clock wise å the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear coun terc...

Page 141: ...ING THE GENERATOR 1 Install 9woodruff key 9generator rotor 9generator rotor nut NOTE 9Clean the tapered portion of the crankshaft and the generator rotor hub 9When installing the generator rotor make sure the woodruff key is properly sealed in the key way of the crankshaft 2 Tighten 9generator rotor nut 1 NOTE 9While holding the generator rotor 2 with the sheave holder 3 tighten the generator roto...

Page 142: ...4 43 ENG GENERATOR AND STARTER CLUTCH 3 Apply 9sealant on to the generator lead grommet 4 Install 9gasket 9crankcase cover Yamaha bond No 1215 90890 85505 10 Nm 1 0 m kg 7 2 ft lb ...

Page 143: ...TER 1 Kickstarter lever 2 Crankcase cover right 3 Gasket 4 Dowel pin 5 Kickstarter spring guide 1 6 Kickstarter spring 7 Kickstarter spring guide 2 8 Kickstarter ratchet gear clip 9 Kickstarter ratchet gear 0 Kickstarter gear q Kickstarter shaft EASF0035 KICKSTARTER ...

Page 144: ...E OIL in chapter 3 2 Remove 9front cowling right Refer to REMOVING THE FRONT COWL INGS in chapter 3 9muffler 9footrest 9brake pedal Refer to REMOVING THE ENGINE 4 Remove 9crankcase cover bolts 9crankcase cover right 1 9gasket 9dowel pins 5 Remove 9kickstarter shaft assembly 1 3 Remove 9kickstarter lever bolt 1 9kickstarter lever 2 ...

Page 145: ...ing 2 9kickstarter spring guide 2 3 9circlip 4 9kickstarter ratchet gear clip 5 9kickstarter ratchet gear 6 9circlip 7 9shim 8 9wave washer 9 9kickstarter gear 0 9kickstarter shaft q 2 Check 9kickstarter spring Damage wear Replace 3 Measure 9kickstarter ratchet gear clip force with a spring gauge Out of specification Replace the kick starter ratchet gear clip Kickstarter ratchet gear clip force 0 ...

Page 146: ...starter lever bolt ENG 2 1 4 47 KICKSTARTER EAS00340 INSTALLING THE KICKSTARTER 1 Install 9kickstarter shaft assembly 1 9kickstarter ratchet gear clip 2 9kickstarter spring 3 NOTE Turn the kickstarter spring clockwise and install its end into the hole a in the crankcase 10 Nm 1 0 m kg 7 2 ft lb 2 1 a 3 Yamaha bond No 1215 90890 85505 10 Nm 1 0 m kg 7 2 ft lb ...

Page 147: ...utch pressure plate bolt 6 Clutch pressure plate 7 Friction plate 8 Clutch plate 1 9 Clutch plate 2 0 Clutch push rod 1 q Clutch shoe housing nut w Clutch shoe housing e Cage r Clutch shoe housing boss t Clutch shoe y Clutch release shift arm u Clutch release adjusting screw ENG 4 48 CLUTCH ...

Page 148: ...ENGINE 9kickstarter lever Refer to KICKSTARTER 9crankcase cover left Refer to GENERATOR AND STARTER CLUTCH 4 Remove 9clutch pressure plate bolts 1 9clutch springs 9clutch pressure plate 2 NOTE Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them 5 Remove 9thrust bearing 1 9clutch push rod 1 2 9friction plates 3 9clutch...

Page 149: ...boss nut 1 9lock washer 2 9clutch boss 3 9washer 4 9clutch housing 5 9collar 6 9spacer 7 9clutch push rod 2 8 9 Remove 9clutch shoe housing nut 1 9washer NOTE 9Loosen the clutch shoe housing nut while hold ing the generator rotor 2 with the sheave holder 3 9Do not allow the sheave holder to touch the projection on the generator rotor Universal clutch holder 90890 04086 Sheave holder 90890 01701 ...

Page 150: ...ction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check 9clutch plate Damage Replace the clutch plates as a set 2 Measure 9clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutc...

Page 151: ...OUSING 1 Check 9clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause erratic clutch operation 2 Check 9bearing Damage wear Replace the bearing and clutch housing EAS00285 CHECKING THE CLUTCH BOSS 1 Check 9clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss ...

Page 152: ...e 9clutch push rod 2 bending limit Out of specification Replace the clutch push rod 2 EAS00292 CHECKING THE PRIMARY DRIVEN GEAR 1 Check 9primary drive gear on the clutch shoe housing 9primary driven gear on the clutch housing Damage wear Replace the clutch shoe housing and clutch housing as a set Excessive noise during operation Replace the clutch shoe housing and clutch housing as a set Clutch pu...

Page 153: ...OE 1 Check 9clutch shoe Scratches Smooth using coarse sandpa per Damage wear Replace 2 Measure 9clutch shoe groove depth a Groove is worn away Replace CHECKING THE CAGE 1 Check 9cage 1 Damage wear cracks Replace 9rollers 2 Wear bend Replace 9cage springs 3 Wear Replace Clutch shoe housing inside diame ter 105 mm 4 13 in Limit 106 mm 4 17 in Clutch shoe groove depth 1 20 mm 0 0472 in Limit 0 1 mm 0...

Page 154: ...gs 2 9rollers 3 9clutch shoe housing boss 4 2 Tighten 9clutch shoe housing nut 1 NOTE 9While holding the generator rotor 2 with the sheave holder 3 tighten the clutch shoe housing nut 9Do not allow the sheave holder to touch the projection on the generator rotor 3 Install 9clutch push rod 2 1 9spacer 2 9collar 3 9clutch housing 4 9washer 5 9clutch boss 6 9lock washer 7 9clutch boss nut 8 Sheave ho...

Page 155: ... the clutch boss 2 with the univer sal clutch holder 3 tighten the clutch boss nut 5 Bend the lock washer tab along a flat side of the nut 6 Lubricate 9friction plates 9clutch plates 1 9clutch plate 2 with the recommended lubricant 7 Install 9friction plates 9clutch plate 2 with springs 9clutch plates 1 NOTE First install a friction plate and then alternate between a clutch plate and a friction pl...

Page 156: ...ENG 4 57 ENG OIL PUMP EASF0032 OIL PUMP 1 Oil pump driven gear 2 Oil pump assembly 3 Gasket 4 Oil filter 5 Oil pump drive gear 6 Oil strainer 7 Gasket 8 Engine oil drain bolt ...

Page 157: ... 5 9oil pump housing 6 4 58 OIL PUMP REMOVING THE OIL PUMP 1 Drain 9engine oil completely from the crankcase Refer to CHANGING THE ENGINE OIL in chapter 3 2 Remove 9clutch shoe Refer to CLUTCH 3 Remove 9oil filter 1 4 Remove 9oil pump drive gear 1 9oil pump driven gear 2 5 Remove 9oil pump assembly 1 9gasket 2 9oil strainer 3 ...

Page 158: ...r to outer rotor tip clearance a 9outer rotor to oil pump housing clearance b 9oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 15 mm 0 0059 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 06 0 10 mm 0 0024 0 0039 in Limit 0 15 mm 0 0...

Page 159: ...SSEMBLING THE OIL PUMP 1 Lubricate 9inner rotor 9outer rotor 9oil pump shaft with the recommended lubricant 2 Install 9oil pump shaft to the oil pump housing 9pin 1 9inner rotor 2 9outer rotor 9oil pump housing cover 9screw NOTE When installing the inner rotor align the pin in the oil pump shaft with the groove a in the inner rotor 3 Check 9oil pump operation Refer to CHECKING THE OIL PUMP Recomme...

Page 160: ... b in the crankshaft journal 4 61 OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install 9gasket 9oil pump assembly 1 NOTE Install the gasket with section a in the position as shown in the illustration cC After tightening the bolts make sure the oil pump turns smoothly 7 Nm 0 7 m kg 5 0 ft lb ...

Page 161: ...2 Shift drum segment 3 Washer 4 Thrust bearing 5 Guide 6 Pawl holder 7 Shift guide 8 Shift guide spring 9 Shift fork guide bar 0 Shift pedal q Shift shaft w Shift lever e Shift shaft spring stopper r Shift shaft spring t Stopper lever spring y Stopper lever assembly ...

Page 162: ... 9thrust bearing 2 4 63 SHIFT SHAFT REMOVING THE SHIFT SHAFT 1 Drain 9engine oil completely from the crankcase Refer to CHANGING THE ENGINE OIL in chapter 3 2 Remove 9clutch Refer to CLUTCH 9oil pump driven gear Refer to OIL PUMP 4 Remove 9shift guide 1 9pawl holder 2 9guide 3 9dowel pin ...

Page 163: ...ssembly 3 7 Remove 9circlip 1 9washer 2 9shift shaft spring 3 9shift lever 4 9shift shaft 5 8 Remove 9stopper lever assembly 1 9stopper lever spring 2 9 Remove 9circlip 1 9washer 2 9stopper lever holder 3 9stopper lever 4 10 Remove 9shift drum segment 1 9dowel pins 4 64 SHIFT SHAFT ...

Page 164: ...NG THE STOPPER LEVER 1 Check 9stopper lever 1 Bends damage Replace Roller turns roughly Replace 9stopper lever spring Damage wear Replace CHECKING THE SHIFT GUIDE 1 Check 9shift guide 1 9pawl holder 2 9guide 3 Bends damage Replace 9shift guide spring Damage wear Replace CHECKING THE OIL SEAL 1 Check 9oil seal Damage wear Replace 4 65 SHIFT SHAFT ...

Page 165: ...1 INSTALLING THE SHIFT SHAFT 1 Install 9shift drum segment 1 NOTE Apply locking agent LOCTITE to the threads of shift drum segment screw 3 Install 9shift lever assembly 1 9shift shaft spring stopper 2 9shift shaft assembly 3 NOTE 9Align the punched mark a in the shift lever assembly with the punched mark b in the shift shaft assembly 9Hook the end of the shift shaft spring onto the shift shaft spr...

Page 166: ...e bar retainer 3 Dowel pin 4 Left crankcase 5 Starter motor lead holder 6 Gear position pointer 7 Neutral switch 8 Crankshaft assembly 9 Timing chain 0 Timing chain guide intake side ENG CRANKCASE AND CRANKSHAFT EASF0037 CRANKCASE AND CRANKSHAFT ...

Page 167: ...HAFT 9oil pump drive gear Refer to OIL PUMP 9generator 9starter clutch Refer to GENERATOR AND STARTER CLUTCH 4 Remove 9timing chain guide intake side bolts 1 9timing chain guide intake side 2 9timing chain 3 5 Remove 9shift fork guide bar retainer bolts 1 9shift fork guide bar retainer 2 9shift fork guide bar spring 4 68 2 1 3 CRANKCASE AND CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1 Remove ...

Page 168: ...n the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly 8 Remove 9crankshaft spacer 9crankshaft assembly NOTE Use the crankcase separating tool w Never use the hammer to tapping and removing the crankshaft directory EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1 Measure 9crankshaft runout Out of specification Replace the crank shaft bear...

Page 169: ...e crank shaft 4 Check 9crankshaft sprocket 1 Damage wear Replace the crankshaft 9bearing 2 Cracks damage wear Replace the crank shaft 5 Check 9crankshaft journal Scratches wear Replace the crankshaft 9crankshaft journal oil passage Obstructions Blow out with compressed air Big end side clearance 0 11 0 41 mm 0 0043 0 0161 in Crankshaft width 42 95 43 00 mm 1 691 1 693 in ...

Page 170: ...bstructions Blow out with compressed air EAS00401 CHECKING THE BEARINGS 1 Check 9bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace CHECKING THE TIMING CHAIN GUIDE 1 Check 9timing chain guide intake side Damage wear Replace CHECKING THE TIMING CHAIN 1 Check 9timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a s...

Page 171: ...e hand while turning the nut of the installing tool with the other 9 9Operate the installing tool until the crank shaft bottoms against the bearing EAS00416 ASSEMBLING THE CRANKCASE 1 Apply 9 9sealant onto the crankcase mating surfaces NOTE Do not allow any sealant to come into contact with the oil gallery 1 2 Install 9dowel pins 2 3 Install 9right crankcase onto the left crankcase NOTE Tap lightl...

Page 172: ...air 7 Install 9shift fork guide bar spring 9shift fork guide bar retainer 9shift fork guide bar retainer bolts NOTE Apply locking agent LOCTITE to the shift fork guide bar retainer bolts 8 Install 9timing chain 9timing chain guide intake side 9timing chain guide intake side bolts NOTE Apply locking agent LOCTITE to the threads of timing chain guide intake side bolts 4 73 Yamaha bond No 1215 90890 ...

Page 173: ... gear 3 4th wheel gear 4 3rd wheel gear 5 Side plate 6 Side plate spring 7 Drive axle 2nd wheel gear 8 Drive sprocket 9 Main axle 1st pinion gear 0 4th pinion gear q 3rd pinion gear w 2nd pinion gear e Shift fork guide bar r Shift fork R t Shift fork L y Shift drum ...

Page 174: ...t fork guide bar spring 9shift fork R 2 9shift fork L 3 9shift drum 4 NOTE Note the position of each part Pay particular attention to location and direction of shift forks 2 Remove 9main axle assembly 1 9drive axle assembly 2 DISASSEMBLING THE TRANSMISSION 1 Remove 9washer 1 92nd pinion gear 2 93rd pinion gear 3 9circlip 4 94th pinion gear 5 9main axle 1st pinion gear 6 ...

Page 175: ... 5 93rd wheel gear 6 9side plate 7 9side plate spring 8 9drive axle 2nd wheel gear 9 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to both of the shift forks 1 Check 9shift fork cam follower 1 9shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check 9shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace w Do not attempt to straig...

Page 176: ...ain axle runout with a centring device and dial gauge 1 Out of specification Replace the main axle 2 Measure 9drive axle runout with a centring device and dial gauge 1 Out of specification Replace the drive axle 3 Check 9transmission gears Blue discoloration pitting wear Replace the defective gear s 9transmission gear dogs Cracks damage rounded edges Replace the defective gear s Main axle runout l...

Page 177: ...he following sequence R L 4 78 TRANSMISSION 4 Check 9transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies NOTE When reassembling the drive axle press the 2nd wheel gear 1 onto the drive axle 2 as shown 5 Check 9transmission gear movement Rough movement Replace the defective part s 6 Check 9circlips Bends damage looseness R...

Page 178: ... Check 9transmission 9shift drum 9shift forks Rough movement Repair NOTE 9Oil each gear shaft and bearing thoroughly 9Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely ...

Page 179: ...ENG 4 80 ...

Page 180: ... 5 ASSEMBLING THE CARBURETOR 5 7 INSTALLING THE CARBURETOR 5 7 MEASURING AND ADJUSTING THE FUEL LEVEL 5 8 CHECKING THE FUEL COCK OPERATION 5 9 AIR INDUCTION SYSTEM 5 10 AIR INJECTION 5 10 AIR CUT OFF VALVE 5 10 REMOVING THE AIR INDUCTION SYSTEM 5 12 CHECKING THE AIR INDUCTION SYSTEM 5 12 INSTALLING THE AIR INDUCTION SYSTEM 5 12 ...

Page 181: ...CARB ...

Page 182: ...etor top cover 5 Throttle valve spring 6 Jet needle set 7 Throttle valve 8 Throttle stop screw set 9 Pilot air screw set 0 Air vent hose q Fuel hose w Carburetor joint e Needle jet r Main jet t Pilot jet y Needle valve u Float i Float chamber rubber gasket o Float pivot pin p Float chamber a Fuel drain screw s Carburetor overflow hose ...

Page 183: ...front cowlings left and right Refer to REMOVING THE FRONT COWL INGS in chapter 3 2 Loosen 9fuel drain screw 1 3 Drain 9fuel from float chamber 4 Remove 9carburetor top cover 1 1 1 1 2 1 3 5 Remove 9starter plunger assembly 1 from carburetor body 9gasket 6 Disconnect 9fuel hose 1 9carburetor overflow hose 2 9air vent hose 3 ...

Page 184: ...e 10 Remove 9throttle valve assembly 1 9throttle valve spring 2 11 Remove 9throttle valve 1 9jet needle set 2 NOTE Push the jet needle holder 3 with a Phillips screwdriver and then turn it to remove the jet needle holder DISASSEMBLING THE CARBURETOR NOTE The following parts can be cleaned and inspect ed without disassembly 9Coasting enricher 9Starter plunger 9Throttle stop screw 9Pilot air screw ...

Page 185: ...her cover 9coasting enricher spring 1 9coasting enricher 2 1 2 1 1 3 Remove 9throttle stop screw set 1 2 Remove 9pilot air screw set 1 1 1 2 3 4 Remove 9float chamber 1 9float chamber rubber gasket 5 Remove 9main jet 1 9needle jet 2 9pilot jet 3 ...

Page 186: ...ructions Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check 9float chamber body Dirt Clean 4 Check 9float chamber rubber gasket Cracks damage wear Replace 6 Remove 9float pivot pin 1 9float 2 9needle valve 3 5 Check 9float Damage Replace ...

Page 187: ...amage wear Replace 1 2 1 2 3 4 5 6 7 Check 9coasting enricher 1 9coasting enricher spring 2 Cracks damage Replace 8 Check 9jet needle 1 9needle jet 2 9main jet 3 9pilot jet 4 9pilot air screw 5 9throttle stop screw 6 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 9 Check 9throttle valve Damage scratches wear Replace ...

Page 188: ...o secure it in place 2 Install 9throttle valve assembly NOTE Align the slit a of the throttle valve with the tab b of the carburetor body 3 Install 9carburetor joint 9carburetor joint clamp screw 9carburetor assembly 9bolts 4 Adjust 9engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3 11 Check 9hose joints Cracks damage Replace 12 Check 9air vent hose 9fuel hoses Cracks dam...

Page 189: ...e b Place the vehicle on a suitable stand to ensure that the vehicle is standing straight up c Install the fuel level gauge 1 onto the fuel drain pipe 2 d Loosen the fuel drain screw 3 e Hold the fuel level gauge vertically next to the float chamber 4 f Measure the fuel level a Throttle cable free play at the flange of the throttle grip 3 7 mm 0 12 0 28 in Fuel level below the float chamber mating...

Page 190: ...gain g Repeat steps a to f until the fuel level is within specification EAS00506 CHECKING THE FUEL COCK OPERA TION 1 Remove 9rear cowling left Refer to REMOVING THE REAR COWL INGS in chapter 3 2 Place a container under the end of the fuel hose 1 3 Check 9fuel cock operation a Suck on the end of the vacuum hose 1 4 Install 9rear cowling left Refer to INSTALLING THE REAR COWL INGS in chapter 3 1 1 1...

Page 191: ...agm Normally the air cut off valve is open to allow fresh air to flow into the exhaust port During sudden deceleration the butterfly valve suddenly closes negative pressure is generat ed and the air cut off valve is closed in order to prevent after burning Additionally at high engine speeds and when the pressure decreases the air cut off valve automatically closes to guard against a loss of perfor...

Page 192: ...EM 5 11 1 Air cut off valve assembly 2 Air induction system hose air cut off valve assembly to cylinder head 3 Air induction system vacuum hose 4 Air induction system hose air cut off valve assembly to air filter 5 Air filter ...

Page 193: ...ir filter 9air cut off valve Cracks damage Replace 1 1 REMOVING THE AIR INDUCTION SYS TEM 1 Remove 9front cowlings left and right Refer to REMOVING THE FRONT COWL INGS in chapter 3 9rear cowling left Refer to REMOVING THE REAR COWL INGS in chapter 3 9air filter 1 2 Remove 9air cut off valve assembly 1 INSTALLING THE AIR INDUCTION SYS TEM For installation reverse the removal procedure ...

Page 194: ...RAKE SHOE PLATE 6 17 CHECKING THE REAR WHEEL 6 17 CHECKING THE REAR WHEEL DRIVE HUB 6 18 CHECKING THE REAR BRAKE 6 18 ASSEMBLING THE BRAKE SHOE PLATE 6 19 INSTALLING THE REAR WHEEL 6 19 FRONT BRAKE T110LSE 6 21 FRONT BRAKE CALIPER 6 21 REPLACING THE FRONT BRAKE PADS 6 22 DISASSEMBLING THE FRONT BRAKE CALIPER 6 24 CHECKING THE FRONT BRAKE CALIPER 6 26 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIP...

Page 195: ...NG HEAD 6 53 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 6 54 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 6 55 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 6 57 CHECKING THE SWINGARM 6 58 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 6 58 DRIVE CHAIN AND SPROCKETS 6 60 REMOVING THE DRIVE CHAIN AND SPROCKETS 6 61 CHECKING THE DRIVE CHAIN 6 62 INSTALLING THE DRIVE CHAIN AND SP...

Page 196: ...E DISC T110LSE EASF0044 CHASSIS FRONT WHEEL AND BRAKE DISC T110LSE 1 23 Nm 2 3 m kg 17 ft lb LS LS 39 Nm 3 9 m kg 28 ft lb 2 3 4 5 6 5 7 1 Front wheel axle 2 Brake disc 3 Spacer 4 Oil seal 5 Bearing 6 Spacer 7 Speedometer gear unit ...

Page 197: ...w Securely support the vehicle so that there is no danger of it falling over 2 Remove 9speedometer cable 1 9axle nut 2 9washer 3 3 Elevate 9front wheel NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 4 Remove 9front wheel axle 1 9spacer 2 9speedometer gear unit 3 9front wheel 5 Remove 9brake disc 1 ...

Page 198: ... 9tire Damage wear Replace Refer to CHECKING THE TIRES in chap ter 3 3 Check 9spokes Bends damage Replace Loose Tighten Tap the spokes with a screwdriver Refer to CHECKING AND TIGHTENING THE SPOKES in chapter 3 4 Measure 9front wheel radial runout a 9front wheel lateral runout b Over the specified limits Replace Front wheel radial runout limit 1 0 mm 0 04 in Front wheel lateral runout limit 0 5 mm...

Page 199: ... damage to the vehicle 9 9After a tire has been repaired or replaced be sure to tighten the tire air valve stem locknut 1 1 properly 6 Check 9wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings 9oil seals Damage wear Replace 7 Replace 9wheel bearings 9oil seals a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE To preve...

Page 200: ...brake disc Damage galling Replace 2 Measure 9brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflection turn the handlebar to the left or right to ensure that the front wheel is sta tionary c Remove the brake caliper d Hold the d...

Page 201: ...hten the brake disc bolts in stages and in a crisscross pattern d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1 Check 9speedometer clutch Bends damage wear Replace...

Page 202: ...E DISC NOTE Make sure the projection a on the speedometer gear unit fits between the projections on the outer tube 3 Tighten 9wheel axle nut 4 Connect 9speedometer cable 1 w Make sure the brake cable is routed properly cC Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smooth ly Recommended lubricant Lithium soap based grease ...

Page 203: ...L AND DRUM BRAKE T110LE 1 Front wheel axle 2 Collar 3 Oil seal 4 Bearing 5 Spacer 6 Oil seal 7 Speedometer clutch 8 Speedometer drive gear 9 Brake shoe 0 Brake camshaft q Brake shoe plate w Speedometer driven gear e Brake shoe wear indicator r Brake camshaft lever ...

Page 204: ...djusting nut 9brake cable 9boot 9compression spring 9pin 9speedometer cable 9axle nut 9washer 3 Elevate 9front wheel NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 4 Remove 9front wheel axle 9collar 9front wheel 9brake shoe plate assembly EAS00524 DISASSEMBLING THE BRAKE SHOE PLATE 1 Remove 9bushing 1 with the special tool 2 9speedometer driven gear 3 Meter gear bus...

Page 205: ...he position on the brake camshaft lever where it is aligned with the punch mark in the brake camshaft EAS00526 CHECKING THE FRONT WHEEL 1 Check 9wheel axle 9tire 9front wheel 9spokes Refer to FRONT WHEEL AND BRAKE DISC T110LSE 2 Measure 9front wheel radial runout 9front wheel lateral runout Refer to FRONT WHEEL AND BRAKE DISC T110LSE 3 Check 9spacer 9collar Damage wear Replace 4 Check 9wheel beari...

Page 206: ... applies to all of the brake shoes 1 Check 9brake shoe lining Glazed areas Repair Sand the glazed areas with course sandpa per NOTE After sanding the glazed areas clean the brake shoe with a cloth 2 Measure 9brake shoe lining thickness a Out of specification Replace w Do not allow oil or grease to contact the brake shoes NOTE Replace the brake shoes as a set if either is worn to the wear limit Bra...

Page 207: ... brake shoe wear indicator with the notch in the brake camshaft c Align the punch mark in the brake camshaft with the mark on the brake camshaft lever d Check that the brake shoes are properly positioned 4 Check 9brake drum inner surface Oil deposits Clean Remove the oil with a rag soaked in lacquer thinner or solvent Scratches Repair Lightly and evenly polish the scratches with an emery cloth 5 C...

Page 208: ...INSTALLING THE FRONT WHEEL 1 Lubricate 9wheel axle 9wheel bearings 9oil seal lips 9speedometer drive gear 9speedometer driven gear 2 Install 9front wheel NOTE Make sure the slot in the brake shoe plate fits over the stopper on the outer tube 3 Tighten 9wheel axle nut w Make sure the brake cable is routed properly NOTE Before tightening the wheel axle nut push down hard on the handlebar several tim...

Page 209: ... lever 3 Pin 4 Drive chain puller right 5 Brake shoe wear indicator 6 Brake shoe plate 7 Brake camshaft 8 Brake shoe 9 Rear wheel 0 Cotter pin q Brake torque rod w Rear wheel drive hub damper e Rear wheel drive hub r Drive chain case lower t Drive chain puller left y Rear wheel axle u Brake rod 6 14 ...

Page 210: ...that the rear wheel is elevated 1 Remove 9drive chain case screws lower 9drive chain case lower 1 2 Remove 9brake rod adjusting nut 1 9brake rod 2 9compression spring 3 9washer 9pin 4 NOTE Press down on the brake pedal to remove the pin from the brake rod 3 Remove 9cotter pin 9brake torque rod nut 1 9washer 9brake torque rod bolt 9brake torque rod 2 4 Loosen 9chain puller locknuts left and right 1...

Page 211: ...ut 1 9washer 9rear wheel axle 2 9washer 9collar 6 Remove 9rear wheel assembly 1 NOTE Push the rear wheel forward and remove the drive chain from the driven sprocket 7 Remove 9brake shoe plate assembly 1 8 Remove 9collar 1 9rear wheel drive hub assembly 2 9 Remove 9spacer 1 ...

Page 212: ... Rear wheel side 2 Remove 9brake camshaft lever nut 9brake camshaft lever bolt 9brake camshaft lever 1 9brake shoe wear indicator 9brake camshaft NOTE When removing the brake camshaft lever mark the position on the brake camshaft lever where it is aligned with the punch mark in the brake camshaft EAS00566 CHECKING THE REAR WHEEL 1 Check 9wheel axle 9rear wheel 9wheel bearings 9oil seals Refer to F...

Page 213: ...9rear wheel drive hub Cracks damage Replace 9rear wheel drive hub dampers Damage wear Replace EAS00526 CHECKING THE REAR BRAKE The following procedure applies to all of the brake shoes 1 Check 9brake shoe lining Refer to FRONT WHEEL AND DRUM BRAKE T110LE 2 Measure 9brake shoe lining thickness 9brake drum inside diameter Refer to FRONT WHEEL AND DRUM BRAKE T110LE 3 Check 9brake drum inner surface 9...

Page 214: ...camshaft with the mark on the brake camshaft lever d Check that the brake shoes are properly positioned EAS00571 INSTALLING THE REAR WHEEL 1 Lubricate 9spacer 9collar 9wheel axle 9wheel bearings 9rear brake camshaft 9brake torque rod bolt 9oil seal lips 2 Install 9brake torque rod to brake shoe plate 9washer 9cotter pin 3 Install 9pin 9washer 9compression spring 9brake rod 9brake rod adjusting nut...

Page 215: ...JUSTING THE DRIVE CHAIN SLACK in chapter 3 5 Tighten 9wheel axle nut cC Do not loosen the wheel axle nut after tight ening it to the specified torque 6 Install 9drive chain case lower Drive chain slack 25 35 mm 0 98 1 38 in 60 Nm 6 0 m kg 43 ft lb 7 Nm 0 7 m kg 5 0 ft lb ...

Page 216: ... kg 25 ft lb 3 2 LS 4 1 5 LS 6 Nm 0 6 m kg 4 6 ft lb 6 7 8 9 0 1 Brake pad retaining pin 2 Air bleed screw 3 Brake caliper 4 Brake caliper bracket 5 Lower brake caliper retaining bolt 6 Brake caliper piston 7 Brake caliper dust seal 8 Brake caliper piston seal 9 Brake pad 0 Brake pad spring ...

Page 217: ... brake com ponents 9 9Use only clean or new brake fluid for clean ing brake components 9 9Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 9 9Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES 9 9Flush with water for 15 minutes and get immediate medical a...

Page 218: ...ds and a new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring NOTE Make sure the brake pad spring is installed cor rectly as shown...

Page 219: ...ecommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check 9brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00619 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system Recommended lubricant Lithi...

Page 220: ...ng 3 Remove 9brake caliper bracket 1 4 Remove 9brake caliper piston 1 9brake caliper piston seal 2 9brake caliper dust seal 3 a Blow compressed air into the brake hose joint opening to force out the piston from the brake caliper w 9 9Cover the brake caliper piston with a rag Be careful not to get injured when the piston are expelled from the brake caliper 9 9Never try to pry out the brake caliper ...

Page 221: ...s disassembled 1 Check 9brake caliper piston 1 Rust scratches wear Replace the brake caliper pistons 9brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly 9brake caliper body 3 Cracks damage Replace the brake caliper assembly 9brake fluid delivery passages brake caliper body Obstructions Blow out with compressed air w Whenever a brake caliper is disassembled replace the pisto...

Page 222: ...e the brake caliper piston seals 1 Install 9brake caliper 1 temporarily 9copper washers 9brake hose 2 9union bolt 3 w Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING cC When installing the brake hose onto the brake caliper 1 1 make sure the brake pipe a a touches the projection b b on the brake caliper 2 Remove 9brake caliper 3 Install 9brake pad spri...

Page 223: ...er does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock cC Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed 9brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check 9brake fluid level Below the minimum lev...

Page 224: ...DER 26 Nm 2 6 m kg 19 ft lb 1 2 3 5 4 6 8 7 1 Brake master cylinder kit 2 Brake master cylinder reser voir cap 3 Brake master cylinder reser voir diaphragm 4 Brake master cylinder 5 Brake master cylinder holder 6 Brake hose 7 Brake lever 8 Front brake light switch ...

Page 225: ...right Refer to REMOVING THE FRONT COWL INGS in chapter 3 9headlight assembly Refer to REMOVING THE HEADLIGHT ASSEMBLY in chapter 3 9speedometer assembly Refer to HANDLEBAR 2 Remove 9union bolt 1 9copper washers 2 9brake hose NOTE To collect any remaining brake fluid place a con tainer under the master cylinder and the end of the brake hose 3 Remove 9brake master cylinder assembly 1 4 Remove 9brake...

Page 226: ...rake master cylinder reservoir diaphragm 3 7 Remove 9brake hose 1 9brake hose retainers 2 9brake hose holder 3 EAS00590 CHECKING THE FRONT BRAKE MAS TER CYLINDER 1 Check 9brake master cylinder 1 Damage scratches wear Replace 9brake fluid delivery passages 2 brake master cylinder body Obstructions Blow out with compressed air 2 Check 9brake master cylinder kit Damage scratches wear Replace ...

Page 227: ...ternal brake compo nents should be cleaned and lubricated with clean or new brake fluid 9 9Never use solvents on internal brake com ponents 1 Install 9brake hose Refer to ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 2 Install 9brake master cylinder 1 NOTE 9Install the brake master cylinder holder with the UP mark facing up 9Adjust the brake master cylinder to the proper angle 9First tighten t...

Page 228: ...nated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance 9 9Refill 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 9 9When refilling be careful that water does not enter the brake master cylinder reser voir Water will signi...

Page 229: ...r 3 6 Check 9brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL T110LSE in chapter 3 7 Check 9brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM T110LSE in chapter 3 ...

Page 230: ...CHAS 6 35 FRONT FORK EASF0054 FRONT FORK 1 Front fork cap bolt 2 Dust seal 3 Oil seal clip 4 Oil seal 5 Fork spring 6 Damper rod 7 Inner tube 8 Outer tube 9 Damper rod bolt 0 Front fender ...

Page 231: ...at the front wheel is elevated 2 Remove 9front cowlings left and right Refer to REMOVING THE FRONT COWL INGS in chapter 3 3 Remove T110LSE 9brake caliper assembly 9brake hose retainers Refer to FRONT BRAKE T110LSE 9front wheel Refer to FRONT WHEEL AND BRAKE DISC T110LSE 4 Remove T110LE 9front wheel Refer to FRONT WHEEL AND DRUM BRAKE T110LE 5 Remove 9front fender bolts left and right 9screws left ...

Page 232: ...lt support the front fork leg 9 Remove 9front fork leg EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove 9fork spring 2 Drain 9fork oil NOTE Stroke the inner tube 1 several times while draining the fork oil 3 Remove 9dust seal 1 9oil seal clip 2 with a flat head screwdriver cC Do not scratch the inner tube ...

Page 233: ...le holding the damper rod assembly with a 10 mm hexagon nut socket wrench 1 and the Thandle 2 loosen the damper rod assembly bolt 3 5 Remove 9inner tube 9rebound spring 9damper rod NOTE Pull out the inner tube and damper rod together 6 Remove 9oil seal 1 2 Rag T handle 90890 01326 ...

Page 234: ...ing free length a Out of specifications Replace 3 Check 9damper rod 1 Damage wear Replace Obstructions Blow out all of the oil pas sages with compressed air cC 9 9The front fork leg has a built in damper adjusting rod and a very sophisticated inter nal construction which are particularly sen sitive to foreign material 9 9When disassembling and assembling the front fork leg do not allow any foreign...

Page 235: ...ont fork leg be sure to replace the oil seal 9Before assembling the front fork leg make sure all of the components are clean 1 Install 9damper rod 1 9rebound spring 9inner tube 2 cC Allow the damper rod to slide slowly down the inner tube 2 2 until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate 9inner tube outer surface 3 Tighten 9damper rod asse...

Page 236: ...al faces up NOTE 9Before installing the oil seal lubricate its lips with lithium soap based grease 9Lubricate the outer surface of the inner tube with fork oil 9Before installing the oil seal cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation 5 Install 9oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove T han...

Page 237: ...owing procedure applies to both of the front fork legs 1 Install 9front fork leg 1 9front fork cap bolt 2 Temporarily tighten the lower bracket pinch bolt NOTE Pull up the inner tube until it is stopped then install the front fork cap bolt 2 2 Tighten 9lower bracket pinch bolt 1 9front fork cap bolt 2 Quantity each front fork leg 0 059 L 59cm3 Recommended oil Fork oil 10W or equivalent Front fork ...

Page 238: ...T WHEEL AND BRAKE DISC T110LSE 9brake hose retainers 9brake caliper assembly Refer to FRONT BRAKE T110LSE 5 Install T110LE 9front wheel Refer to FRONT WHEEL AND DRUM BRAKE T110LE 6 Install 9front cowlings left and right Refer to INSTALLING THE FRONT COWL INGS in chapter 3 10 Nm 1 0 m kg 7 2 ft lb 7 Nm 0 7 m kg 5 0 ft lb ...

Page 239: ...3 2 m kg 23 ft lb 16 Nm 1 6 m kg 12 ft lb 53 Nm 5 3 m kg 38 ft lb 1 Rear view mirror left and right 2 Throttle grip 3 Right handlebar switch 4 Handlebar 5 Left handlebar switch 6 Handlebar grip 7 Starter cable 8 Throttle cable 9 Handlebar bracket ...

Page 240: ...G THE FRONT COWL INGS in chapter 3 9headlight assembly Refer to REPLACING THE HEADLIGHT BULBS in chapter 3 9rear view mirrors left and right 3 Disconnect 9speedometer cable 1 9speedometer assembly 2 4 Disconnect 9meter assembly couplers 1 9right handlebar switch couplers 2 9left handlebar switch coupler 3 9front brake light switch coupler 4 5 Remove 9plastic locking ties 5 6 Remove 9brake master c...

Page 241: ...throttle cable 1 9throttle grip 2 9 Remove 9washer 9starter lever 1 9starter cable 2 9spring washer 10 Remove 9left handlebar switch 1 11 Remove 9handlebar grip 1 NOTE Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar ...

Page 242: ...s damage Replace w Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS00670 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface w Securely support the vehicle so that there is no danger of it falling over 2 Install 9handlebar bracket 1 NOTE Align the projection a in the handlebar bracket with the slit b in the steering shaft 53 Nm 5 3 m kg 38 ft lb ...

Page 243: ...uch the handlebar grip until the rub ber adhesive has fully dried 5 Install 9left handlebar switch 1 NOTE Align the projection a on the left handlebar switch with the hole in the handlebar 16 Nm 1 6 m kg 12 ft lb 6 Install 9throttle grip 1 9throttle cable 2 NOTE Lubricate the inside of the throttle grip with a thin coat of lithium soap based grease and install it onto the handlebar 7 Install 9righ...

Page 244: ...pter 2 10 Adjust 9throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 11 Adjust 9brake lever free play T110LE 9Refer to ADJUSTING THE FRONT BRAKE T110LE in chapter 3 Throttle cable free play at the flange of the throttle grip 3 7 mm 0 12 0 28 in Brake lever free play T110LE 11 Nm 1 1 m kg 7 9 ft lb 7 Nm 0 7 m kg 5 0 ft lb 10 20 mm 0 39 0 79 in ...

Page 245: ...HAS 6 50 STEERING HEAD EASF0057 STEERING HEAD 1 Rubber cover 2 Upper ring nut 3 Lower ring nut 4 Ball race cover 5 Bearing inner race 6 Upper bearing 7 Bearing outer race 8 Lower bearing 9 Lower bracket ...

Page 246: ...fer to FRONT FORK 9handlebar Refer to HANDLEBAR 3 Remove 9rubber cover 9upper ring nut 1 9lower ring nut 2 NOTE Hold the lower ring nut with the steering nut wrench and then remove the upper ring nut with the ring nut wrench w Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash 9bearings 9bearing races Steering nut wrench 90890 014...

Page 247: ...he bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new rubber seal and new bearing races cC If the bearing race is not installed properly the steering head pipe could be damaged NOTE 9Always replace the bearings and bearing races as a set 9Whenever the steering head is disassembled replace the rubber seal 4 Check 9lower bracket 1 along with the steering stem Bends ...

Page 248: ...EAD 1 Lubricate 9upper bearing 9lower bearing 9bearing races 2 Install 9lower ring nut 9upper ring nut Refer to CHECKING AND ADJUSTING THE STEERING HEAD in chapter 3 3 Install 9front fork legs Refer to FRONT FORK Recommended lubricant Lithium soap based grease ...

Page 249: ...HAS 6 54 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 1 Rear shock absorber 2 Brake torque rod 3 Swingarm 4 Bushing 5 Swingarm pivot shaft 6 Drive chain case upper ...

Page 250: ...s no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove 9rear cowlings left and right Refer to REMOVING THE REAR COWL INGS in chapter 3 9muffler Refer to REMOVING THE ENGINE in chapter 4 9rear wheel Refer to REAR WHEEL AND BRAKE 1 3 Remove 9drive chain case screws upper 9drive chain case upper 1 1 4 Remove 9cotter pin 9nut 9washer 9brak...

Page 251: ...e the tightening torque of the swingarm pivot shaft nut b Measure the swingarm side play å by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers and bearings d Check the swingarm vertical movement by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the washer and bushings Swingarm sid...

Page 252: ...AR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both rear shock absorber assemblies 1 Check 9rear shock absorber rod Bends damage Replace the rear shock absorber assembly 9rear shock absorber Oil leaks Replace the rear shock absorber assembly 9spring Damage wear Replace the rear shock absorber assembly 9bushings Damage wear Replace 9bolts Bends damage wear Replace ...

Page 253: ...flat surface Bends Replace w Do not attempt to straighten a bent pivot shaft 3 Wash 9swingarm pivot shaft 9washer 9bushings 4 Check 9washer Damage wear Replace 9bushings Damage wear Replace EAS00711 EAS00699 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1 Lubricate 9swingarm pivot shaft Recommended cleaning solvent Kerosene Recommended lubricant Lithium soap based grease ...

Page 254: ...er nuts 9rear shock absorber bolts 4 Install 9brake torque rod to swingarm 5 Install 9drive chain case upper 6 Install 9rear wheel Refer to REAR WHEEL AND BRAKE 9muffler Refer to REMOVING THE ENGINE in chapter 4 9rear cowlings left and right Refer to INSTALLING THE REAR COWL INGS in chapter 3 51 Nm 5 1 m kg 37 ft lb 32 Nm 3 2 m kg 23 ft lb 16 Nm 1 6 m kg 12 ft lb 7 Nm 0 7 m kg 5 0 ft lb ...

Page 255: ...RIVE CHAIN AND SPROCKETS DRIVE CHAIN AND SPROCKETS 1 Rear wheel drive hub 2 Driven sprocket 3 Lock washer 4 Collar 5 Oil seal 6 Bearing 7 Master link 8 Drive chain 9 Drive sprocket 0 Circlip q Drive sprocket cover ...

Page 256: ...ger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove 9rear wheel 9rear wheel drive hub assembly Refer to REAR WHEEL AND BRAKE 1 3 Remove 9drive sprocket cover bolts 9drive sprocket cover 1 4 Remove 9master link clip 1 9master link plate 2 9master link body 3 5 Remove 9drive chain 1 2 6 Remove 9circlip 1 9drive sprocket 2 ...

Page 257: ...inner dimension a outer dimension b 2 915 Link section c of the drive chain Out of specification Replace the drive chain drive sprocket and rear wheel sprock et as a set NOTE 9While measuring the 15 link section push down on the drive chain to increase its tension 9Perform this measurement at two or three dif ferent places 2 Check 9drive chain Stiffness Clean and lubricate or replace 3 Clean 9driv...

Page 258: ...a set Bent teeth Replace the drive chain and sprockets as a set b Correct 1 Drive chain roller 2 Drive chain sprocket New 1 2 1 EAS00714 INSTALLING THE DRIVE CHAIN AND SPROCKETS 1 Install 9driven sprocket 2 9lock washers 1 9driven sprocket bolts 9driven sprocket nuts NOTE Tighten the bolts in a crisscross pattern 2 Bend 9lock washer tab 1 NOTE Bend the lock washer tabs along a flat side of each bo...

Page 259: ...ation 9 9Never install a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 7 Adjust 9drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 cC A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chai...

Page 260: ... 11 ELECTRIC STARTING SYSTEM 7 15 CIRCUIT DIAGRAM 7 15 TROUBLESHOOTING 7 16 STARTER MOTOR 7 18 REMOVING THE STARTER MOTOR 7 19 DISASSEMBLING THE STARTER MOTOR 7 19 CHECKING THE STARTER MOTOR 7 19 ASSEMBLING THE STARTER MOTOR 7 21 INSTALLING THE STARTER MOTOR 7 21 CHARGING SYSTEM 7 22 CIRCUIT DIAGRAM 7 22 TROUBLESHOOTING 7 23 LIGHTING SYSTEM 7 25 CIRCUIT DIAGRAM 7 25 TROUBLESHOOTING 7 26 CHECKING T...

Page 261: ...ELEC ...

Page 262: ...ICAL SYSTEM ELECTRICAL COMPONENTS 1 Main switch 2 Positive battery lead 3 Negative battery lead 4 Battery 5 Fuse 6 Rear brake light switch 7 Ignition coil 8 Wire harness 1 8 7 6 5 2 3 4 ELEC ELECTRICAL COMPONENTS 7 1 ...

Page 263: ...ELEC ELECTRICAL COMPONENTS 7 2 1 Horn 2 Turn signal relay 3 Fuel gauge 4 Starter relay 5 C D I unit 6 Neutral switch 7 Rectifier regulator 1 7 2 6 5 4 3 ...

Page 264: ...he pocket tester to 0 and to the Ω 1 range 9When checking 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 illustr...

Page 265: ...ELEC CHECKING SWITCH CONTINUITY 7 4 ...

Page 266: ... B P Ch Dg B Y R L W L BLACK B B CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch ELEC 7 5 ...

Page 267: ... SWITCHES 1 Horn switch 2 Dimmer switch 3 Turn signal switch 4 Neutral switch 5 Rear brake light switch 6 Fuse 7 Start switch 8 Light switch 9 Front brake light switch T110LSE 0 Front brake light switch T110LE q Main switch ...

Page 268: ...bulbs used on this vehicle are shown in the illustration on the left 9Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The major ity of these types of bulbs can be removed from their respective socket by turning them counterclockwise 9Bulb C is used for turn signal and tail brake lights and can be removed from the socket by push...

Page 269: ...the transparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check 9bulb for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester pr...

Page 270: ...ter No continuity Replace NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester 90890 03...

Page 271: ... W B R Br R L W R W B B Br R O O W Y R B Y B W Br L W Br L W Y R L B B Y R L W L B W L B Br G Y G Y Br Br W Br W Br W Br W Br W Br L B L N R Ch Dg Ch Dg Ch Dg L G Y P B Y G G Y Y B P HI LO OFF PUSH Ch B Dg L B P B L B P Ch Dg Br B B B Ch Dg Ch Dg B B L Y Ch Dg G Y Dg B L Ch Br R W W R G B R W Br B O Y Y R W W R R W Br R B B G Y Br BLACK BLACK 1 9 0 2 3 4 5 6 7 8 q w e r t t y u i o p a s d d f f g...

Page 272: ...8 1 Fuse 9Check the fuse for continuity Refer to CHECKING THE FUSE in chapter 3 9Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 9Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 9Is the battery OK YES NO 9Clean the battery terminals 9Recharge or replace the battery Minimum open circuit voltage 12 8 V or more at 20 C EAS00740 3 Spark plug 9Check ...

Page 273: ... plug cap resistance 7 5 12 5 kΩ at 20 C 68 F EAS00742 4 Ignition spark gap 9Disconnect the spark plug cap from the spark plug 9Connect the ignition checker 1 as shown 2 Spark plug cap 9Set the main switch to ON 9Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs 9Measure the ignition spark gap a 9Is there a spark and is the spark gap within sp...

Page 274: ...il as shown Negative tester probe terminal 1 1 Positive tester probe spark plug lead 2 2 9Measure the secondary coil resistance 9Is the ignition coil OK 1 2 1 2 Primary coil resistance 0 32 0 48 Ω at 20 C 68 F EAS00748 7 Pickup coil resistance 9Disconnect the pickup coil coupler from the wire harness 9Connect the pocket tester Ω 100 to the pickup coil terminal as shown Positive tester probe white ...

Page 275: ...754 9 Wiring 9Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM 9Is the ignition system wiring properly con nected and without defects YES NO Properly connect or repair the ignition system wiring Replace the C D I unit ...

Page 276: ... Y R B Y B W Br L W Br L W Y R L B B Y R L W L B W L B Br G Y G Y Br Br W Br W Br W Br W Br W Br L B L N R Ch Dg Ch Dg Ch Dg L G Y P B Y G G Y Y B P HI LO OFF PUSH Ch B Dg L B P B L B P Ch Dg Br B B B Ch Dg Ch Dg B B L Y Ch Dg G Y Dg B L Ch Br R W W R G B R W Br B O Y Y R W W R R W Br R B B G Y Br BLACK BLACK 1 9 0 2 3 4 5 6 7 8 q w e r t t y u i o p a s d d f f g h j k l z x c v b n m Br G Y T110...

Page 277: ...rter motor 4 starter relay 5 main switch 6 start switch 7 wiring connections of the entire starting system NOTE 9Before troubleshooting remove the following part s 1 front cowling right 2 rear cowling 3 headlight assembly 4 engine guard 9Troubleshoot with the following special tool s EAS00739 2 Battery 9Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 9Is ...

Page 278: ...ite YES NO Replace the starter relay R R W 1 2 3 4 Br R L W R W Br R L W R W Properly connect or repair the starting system wiring The starting sys tem circuit is OK EAS00766 7 Wiring 9Check the entire starting system wiring Refer to CIRCUIT DIAGRAM 9Is the starting system wiring properly con nected and without defects YES NO EAS00749 5 Main switch 9Check the main switch for continuity Refer to CH...

Page 279: ...ELEC STARTER MOTOR 7 18 EASF0061 STARTER MOTOR 1 Starter motor yoke 2 Armature 3 Brush set 4 Starter motor lead 5 Starter motor front cover ...

Page 280: ...OVING THE ENGINE in chapter 4 2 Remove 9starter motor 1 3 Remove 9starter motor lead 1 DISASSEMBLING THE STARTER MOTOR 1 Remove 9starter motor front cover bolts with washers 9starter motor front cover 1 9gasket 2 9washer 3 9armature 4 EAS00769 CHECKING THE STARTER MOTOR 1 Check 9commutator Dirt Clean with 600 grit sandpaper ...

Page 281: ... to ensure proper operation of the commutator 4 Measure 9armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter motor Commutator wear limit 16 6 mm 0 65 in Mica undercut 1 35 mm 0 05 in Pocket tester 90890 03112 Armatur...

Page 282: ... EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install 9washer to armature 9armature in start motor front cover 1 9gasket 9starter motor yoke 9starter motor front cover bolts with washers 9O ring NOTE Align the mark a on the starter motor yoke with the mark b on the starter motor front cover INSTALLING THE STARTER MOTOR For installation reverse the removal procedure Brush length wear limit 3 5 mm 0 14 i...

Page 283: ... W Sb P R R R B Y W B R Br R L W R W B B Br R O O W Y R B Y B W Br L W Br L W Y R L B B Y R L W L B W L B Br G Y G Y Br Br W Br W Br W Br W Br W Br L B L N R Ch Dg Ch Dg Ch Dg L G Y P B Y G G Y Y B P HI LO OFF PUSH Ch B Dg L B P B L B P Ch Dg Br B B B Ch Dg Ch Dg B B L Y Ch Dg G Y Dg B L Ch Br R W W R G B R W Br B O Y Y R W W R R W Br R B B G Y Br BLACK BLACK 1 9 0 2 3 4 5 6 7 8 q w e r t t y u i ...

Page 284: ...special tool s EAS00739 2 Battery 9Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 9Is the battery OK YES NO 9Clean the battery terminals 9Recharge or replace the battery Engine tachometer 90890 03113 Pocket tester 90890 03112 Minimum open circuit voltage 12 8 V or more at 20 C EAS00738 1 Fuse 9Check the fuse for continuity Refer to CHECKING THE FUSE in c...

Page 285: ...g circuit is OK NO YES EAS00776 4 Charging coil resistance 9Disconnect the stator coil coupler from the wire harness 9Connect the pocket tester Ω 1 to the charging coil terminals as shown Positive tester probe white 1 1 Negative tester probe black 2 2 9Measure the charging coil resistances 9Is the charging coil OK YES NO W B Y R W 1 2 EAS00779 5 Wiring 9Check the wiring connections of the entire c...

Page 286: ...r R O O W Y R B Y B W Br L W Br L W Y R L B B Y R L W L B W L B Br G Y G Y Br Br W Br W Br W Br W Br W Br L B L N R Ch Dg Ch Dg Ch Dg L G Y P B Y G G Y Y B P HI LO OFF PUSH Ch B Dg L B P B L B P Ch Dg Br B B B Ch Dg Ch Dg B B L Y Ch Dg G Y Dg B L Ch Br R W W R G B R W Br B O Y Y R W W R R W Br R B B G Y Br BLACK BLACK 1 9 0 2 3 4 5 6 7 8 q w e r t t y u i o p a s d d f f g h j k l z x c v b n m Br...

Page 287: ...terminals as shown Positive tester probe yellow 1 1 Negative tester probe black 2 2 9Measure the lighting coil resistances 9Is the lighting coil OK YES NO W B Y R W 1 2 EAS00787 3 Wiring 9Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM 9Is the lighting system wiring properly con nected and without defects YES NO Properly connect or repair the lighting system wiring Replace the sta...

Page 288: ...ight bulb socket or both 3 Voltage 9Connect the pocket tester AC 20 V to the headlight and high beam indicator light con nectors as shown åWhen the dimmer switch is set to When the dimmer switch is set to Headlight Positive tester probe green 1 1 or yellow 2 2 Negative tester probe black 3 3 High beam indicator light Positive tester probe yellow 4 4 Negative tester probe black 5 5 9Set the main sw...

Page 289: ... the meter light coupler wire harness side as shown Positive tester probe blue 1 1 Negative tester probe black 2 2 9Set the main switch to ON 9Start the engine 9Measure the voltage AC 12 V of blue lead terminal 1 on the meter light coupler wire harness side 9Is the voltage within specification Br G Ch L B Dg L B Br Dg G Ch 1 2 YES NO Replace the rectifi er regulator This circuit is OK 2 Voltage 9C...

Page 290: ...BLACK W P Y W L W Sb Y W L W W Sb P R R R B Y W B R Br R L W R W B B Br R O O W Y R B Y B W Br L W Br L W Y R L B B Y R L W L B W L B Br G Y G Y Br Br W Br W Br W Br W Br W Br L B L N R Ch Dg Ch Dg Ch Dg L G Y P B Y G G Y Y B P HI LO OFF PUSH Ch B Dg L B P B L B P Ch Dg Br B B B Ch Dg Ch Dg B B L Y Ch Dg G Y Dg B L Ch Br R W W R G B R W Br B O Y Y R W W R R W Br R B B G Y Br BLACK BLACK 1 9 0 2 3 ...

Page 291: ...rn switch a Turn signal switch s Tail brake light d Rear turn signal light f Front turn signal light h Neutral switch j Fuel sender l Fuel gauge x Turn signal indicator light c Neutral indicator light v 1st gear position indicator light b 2nd gear position indicator light n 3rd gear position indicator light m 4th gear position indicator light ...

Page 292: ...s the battery OK YES NO 9Clean the battery terminals 9Recharge or replace the battery Pocket tester 90890 03112 Minimum open circuit voltage 12 8 V or more at 20 C 68 F 9 9Any of the following fail to light turn sig nal light brake light or an indicator light 9 9The horn fails to sound Replace the main switch EAS00783 3 Main switch 9Check the main switch for continuity Refer to CHECKING THE SWITCH...

Page 293: ...r to CHECKING THE SWITCHES 9Is the horn switch OK YES NO Replace the left han dlebar switch 2 Voltage 9Connect the pocket tester DC 20 V to the horn connector at the horn terminal as shown Positive tester probe brown 1 1 Negative tester probe ground 9Set the main switch to ON 9Measure the voltage DC 12 V of brown lead terminal at the horn terminal 9Is the voltage within specification YES NO The wi...

Page 294: ...black 2 2 9Set the main switch to ON 9Pull in the brake lever or push down on the brake pedal 9Measure the voltage DC 12 V of green yel low lead terminal 1 on the tail brake light coupler wire harness side 9Is the voltage within specification 2 Brake light switches 9Check the brake light switches for continuity Refer to CHECKING THE SWITCHES 9Is the brake light switch OK YES NO Replace the tail br...

Page 295: ...er to CHECKING THE SWITCHES 9Is the turn signal switch OK YES NO Replace the turn sig nal light bulb socket or both YES NO Replace the left han dlebar switch 3 Voltage 9Connect the pocket tester DC 20 V to the turn signal relay coupler as shown Positive tester probe brown 1 1 Negative tester probe ground 9Set the main switch to ON 9Measure the voltage DC 12 V on brown lead terminal 1 at the turn s...

Page 296: ...ate 3 3 Negative tester probe ground Positive tester probe dark green 4 4 Negative tester probe ground B Ch L Dg Y L Dg B G Y Ch 2 1 4 Voltage 9Connect the pocket tester DC 20 V to the turn signal relay coupler as shown Positive tester probe brown white 1 1 Negative tester probe ground 9Set the main switch to ON 9Measure the voltage DC 12 V on brown white lead terminal 1 at the turn sig nal relay ...

Page 297: ...ch 9Check the neutral switch for continuity Refer to CHECKING THE SWITCHES 9Is the neutral switch OK YES NO Replace the neutral switch YES NO This circuit is OK The wiring circuit from the turn signal switch to the turn signal light coupler is faulty and must be repaired 9Set the main switch to ON 9Set the turn signal switch to 4 or 6 9Measure the voltage DC 12 V of the chocolate 1 or dark green l...

Page 298: ... voltage DC 12 V of the sky blue 1 white 2 pink 3 yellow white 4 or blue white 5 lead terminal at the meter assembly coupler wire harness side 9Is the voltage within specification L B Br Dg G Ch Sb P W Y W L W Y W L W Sb P W Br G Ch L B Dg 1 2 3 5 4 SIGNALING SYSTEM YES NO This circuit is OK The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired EAS008...

Page 299: ... specification Br L Dg G B Ch Dg B Br Ch L G 1 SIGNALING SYSTEM YES NO Check the wiring connections of the entire signaling sys tem YES NO Replace the fuel level gauge 3 Fuel level gauge 9Set the main switch to ON 9Move the float up 1 or down 2 9Check that the fuel level gauge needle moves to F or E NOTE Before reading the fuel level gauge leave the float in one position either up or down for at l...

Page 300: ...TRBL SHTG CHAPTER 8 TROUBLESHOOTING TROUBLESHOOTING 8 1 ELECTRICAL SYSTEM 8 1 COMPRESSION SYSTEM 8 2 INTAKE AND EXHAUST SYSTEM 8 3 ...

Page 301: ...TRBL SHTG ...

Page 302: ...ug wire is faulty 8 Spark plug cap is faulty C D I unit 8 C D I unit is broken CHARGING COIL see page 7 24 PICKUP COIL see page 7 13 8 Windings are broken SPARK PLUG 8 Wet carbon deposits 8 Electrodes 8 Improper gap 8 Broken EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM STARTER MOTOR see page 7 18 8 Starter motor is broken or faulty 8 Starter relay is broken 8 Starter switch is broken...

Page 303: ...TRBL SHTG TROUBLESHOOTING 8 2 COMPRESSION SYSTEM ...

Page 304: ...8 3 INTAKE AND EXHAUST SYSTEM FUEL COCK 8 Clogged FUEL HOSE 8 Clogged damaged or kinked FUEL TANK CAP 8 Clogged AIR FILTER ELEMENT 8 Dirty or clogged DRY TYPE EXHAUST PIPE 8 Cracked or broken 8 Carbon deposits SILENCER 8 Clogged ...

Page 305: ...TRBL SHTG ...

Page 306: ......

Page 307: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 308: ...wn Ch Chocolate Dg Dark green G Green L Blue O Orange Sb Sky blue P Pink R Red W White Y Yellow Br W Brown White G Y Green Yellow L B Blue Black L R Blue Red L W Blue White R W Red White Y R Yellow Red Y W Yellow White COLOR CORD R Br W R R W OFF ON Br R R OFF START B L W L W B B Sb W P Y W L W Sb W P Y W L W G G L Dg Ch Br B G R Br Br R Br L W L W R W R W R W R OFF ON L B Y R Y Sb Y W P L W W L W...

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