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Yamaha T135SE, Service Manual

The Yamaha T135SE service manual is a valuable resource for owners of this high-performance motorcycle. It provides detailed instructions and diagrams for maintenance, repairs, and troubleshooting. Easily accessible for free download at manualshive.com, this comprehensive manual ensures optimal performance and longevity for your Yamaha T135SE.

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7-16

CHAS

FRONT BRAKE

FRONT BRAKE

EASF0052

FRONT BRAKE CALIPER

35 Nm (3.5 m•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

http://www.motorcycle.in.th

Summary of Contents for T135SE

Page 1: ...T135 SERVICE MANUAL 5YP F8197 E0 T135SE T135S Sniper Jupiter MX Spark 135 Exciter 135LC Manual Clutch and Automatic http www motorcycle in th ...

Page 2: ...http www motorcycle in th ...

Page 3: ...UAL 2005 by Yamaha Motor Co Ltd First edition April 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited EAS00000 http www motorcycle in th ...

Page 4: ...ls 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 MANUALINFORMATION Particularly important information is distinguished in this manual by the following Q The Safety Alert...

Page 5: ...asy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections Aset 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 encircled alphabe...

Page 6: ...http www motorcycle in th ...

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

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Page 9: ...LECTRICALSYSTEM CHASSIS ENGINE PERIODIC CHECKS AND ADJUSTMENTS GENERALINFORMATION GEN INFO TRBL SHTG ELEC CHAS ENG CHK ADJ SPEC TABLE OF CONTENTS 4 7 8 9 3 2 1 COOLINGSYSTEM COOL 5 CARBURETOR CARB 6 EAS00011 http www motorcycle in th ...

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Page 11: ...1 ENGINE SERIALNUMBER 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVALAND DISASSEMBLY 1 2 REPLACEMENTPARTS 1 2 GASKETS OILSEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OILSEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIALTOOLS 1 5 http www motorcycle in th ...

Page 12: ...GEN INFO http www motorcycle in th ...

Page 13: ...IFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The number 1 is stamped into the center of the frame ENGINE SERIALNUMBER The engine serial number 1 is stamped into the crankcase NOTE Designs and specifications are subject to change without notice 1 1 http www motorcycle in th ...

Page 14: ...ts 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 but inferior i...

Page 15: ...IRCLIPS 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 1 300 000 300 003 1 300 002 1 300 001 3 4 1 2 EAS00023 LOCK WASHERS PLATES AND COT TER PINS A...

Page 16: ...veral 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 revitalizer a...

Page 17: ...eparating tool This tool is necessary for separating the crankcase 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 is used to loosen and tighten the steering ring nut Crankshaft instoller pot This tool is necessary for installing the crankshaft ...

Page 18: ...o check the cooling syatem 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 holder This tool is used for holding the generator roter 90890 ...

Page 19: ...g driver Mechanical seal installer These tools are used to install the water pump seal Valve spring compressor Attachment This tool is used when removing or installing the valve and valve spring 90890 04108 Ø22 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 cranksh...

Page 20: ... needed to remove and installing the valve guide 90890 04117 Valve guide installer 4 5 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 http www motorcycle in th ...

Page 21: ...NE 2 4 TIGHTENING TORQUES 2 9 CHASSIS 2 11 TIGHTENING TORQUES 2 13 ELECTRICAL 2 15 CONVERSION TABLE 2 17 GENERALTIGHTENING TORQUE SPECIFICATIONS 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 18 ENGINE 2 18 CHASSIS 2 20 COOLING SYSTEM DIAGRAMS 2 21 CABLE ROUTING 2 22 http www motorcycle in th ...

Page 22: ...SPEC http www motorcycle in th ...

Page 23: ...2 31 in Compression ratio 10 9 1 Compression pressure STD 560 kPa 80 psi 5 6 kgf cm2 at 500 r m with electric starter Starting system Kick and electric starter Lubrication system Wet sump Engine idling speed 1 300 1 500 r min Oil type or grade Engine oil SAE 20W40 type SF or higher grade motor oil Periodic oil change amount 0 8 L 0 70 Imp qt 0 85 US qt Total amount 1 15 L 1 01 Imp qt 1 22 US qt Oi...

Page 24: ...ant mesh 4 speed Operation Left foot operation Gear ratio 1st 34 12 2 833 2nd 30 16 1 875 3rd 23 17 1 353 4th 23 22 1 045 Chassis Frame type Diamond Caster angle 25 3 Trail 73 0 mm 2 87 in Tire Type With tube Size front 60 100 17M C 33P rear 80 90 17M C 44P Model manufacturer front IRC NF63B Vee Rubber V304 rear IRC NR78Y Vee Rubber V304 Min tire tread depth front 0 8 mm 0 03 in rear 0 8 mm 0 03 i...

Page 25: ...l 90 mm 3 54 in Electrical Ignition system DC C D I Generator system A C magneto Battery type manufacturer GM5Z 3B LOCALMADE Battery capacity 12 V 5 AH Headlight type Krypton bulb Bulbs voltage wattage quantity Headlight 12 V 32 W 32 W 1 Auxiliary light 12 V 5 W 2 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 Meter light 12 V 1 7 W 1 High b...

Page 26: ...n 29 912 mm 1 1776 in B 25 019 25 119 mm 0 9850 0 9889 in 24 989 mm 0 9838 in Camshaft runout limit 0 03 mm 0 0012 in Timing chain Timing chain type No of links SILENTCHAIN 96 Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 9 985 10 000 mm 0 3931 0 3937 in 10 030 mm 0 0012 in Rocker arm shaft outside diameter 9 966 9 976 mm 0 3924 0 3928 in 9 950 mm 0 3917 in Roc...

Page 27: ...rgin thickness IN 0 5 0 9 mm 0 20 0 36 in EX 0 5 0 9 mm 0 20 0 36 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 Guide inside diameter IN 3 950 4 050 mm 0 1555 0 1594 in 4 542 mm 0 1788 in EX 3 950 4 050 mm 0 1555 0 1594 in 4 542 mm 0 1788 in Valve stem to guide clearance IN 0 0010 0 037mm 0 0 0015 in 0 080...

Page 28: ...n bore inside diameter 14 002 14 013 mm 0 5513 0 5517 in 14 043 mm 0 5529 in Piston pin outside diameter 13 995 14 000 mm 0 5510 0 5512 in 13 975 mm 0 5502 in Piston rings Top ring Ring type Barrel Dimensions B T 0 80 1 90 mm 0 03 0 07 in End gap installed 0 10 0 25 mm 0 0098 in 0 00 0 01 in 0 40 mm 0 0157 in Ring side clearance installed 0 030 0 065 mm 0 0012 0 0026 in 0 10 mm 0 0039 in 2nd ring ...

Page 29: ... 59 1 68 mm 0 06 0 07 in Plate quantity 3 Max warpage 0 05 mm 0 0020 in Clutch springs Free length 40 5 mm 1 60 in 38 5 mm 1 52 in Spring quantity 4 Clutch release method Inner push cam push Clutch shoe thickness 2 0 mm 0 08 in Clutch shoe groove depth 1 0 mm 0 04 in 0 1 mm 0 0039 in Clutch housing inside diameter 116 mm 4 57 in 117 mm 4 6063 in Weight outside diameter 116 mm 4 57 in 115 mm 4 5276...

Page 30: ...air jet 1 55 Valve seat size ø2 Throttle valve size 2 0 Float height 9 2 mm 0 3622 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 11 mm 0 15 mm clearance 0 0024 0 0043 in 0 0059 in Oil pump housing to inner rotor and 0 06 0 11 mm 0 15 mm outer rotor clearance 0 0024 0 0043 in 0 0059 in SPE...

Page 31: ... 5 0 Element cover Bolt M6 3 10 1 0 7 2 Engine oil drain bolt Bolt M35 1 32 3 2 23 Oil pump cover plate Bolt M6 2 10 1 0 7 2 Intake manifold engine side Bolt M6 2 10 1 0 7 2 Carburetor assembly Bolt M6 2 10 1 0 7 2 Resonator Bolt M6 1 10 1 0 7 2 Exhaust pipe Nut M8 2 15 1 5 11 Muffler and muffler bracket Bolt M8 1 17 1 7 13 Muffler and passenger footrest Bolt M10 1 38 3 8 28 Air filter assembly Bo...

Page 32: ...3 Shift drum segment Bolt M6 1 12 1 2 9 0 Shift drum stopper lever Bolt M6 1 10 1 0 7 2 Shift lever stopper screw Screw M8 1 10 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 Screw M5 2 4 0 4 2 9 Starter motor Bolt M6 2 10 1 0 7 2 Part to be tightened Part name Thread size Q ty Tightening torque Remarks Nmm kgft lb LT LT LT LT LT LT LT http www motorcycle ...

Page 33: ... 5 mm 4 11 in Recommended oil Fork oil 10W or equivalent Inner tube outer diameter 26 mm 1 02 in Inner tube bend limit 0 2 mm 0 0079 in Rear suspension Shock absorber stroke 27 5 mm 1 0827 in Spring free length 115 4 mm 4 54 in 113 1 mm 4 4528 in Installed length 106 4 mm 4 19 in Spring rate K1 220 N mm 22 43 kgf mm 1256 2 lb in K2 316 N mm 32 22 kgf mm 1804 36 lb in Stroke K1 0 0 8 0 mm 0 00 0 31...

Page 34: ...8 mm 0 03 in Pad thickness outer 5 3 mm 0 21 in 0 8 mm 0 03 in Master cylinder inside diameter 11 mm 0 43 in Caliper cylinder inside diameter 33 3 mm 1 31 in Brake fluid type DOT3 or 4 Rear brake Drum brake type Leading trailing Rear brake pedal free play pedal 25 35 mm 0 98 1 38 in end Drum inside diameter 130 mm 5 12 in 131 0 mm 5 16 in Lining thickness 4 mm 0 16 in 2 mm 0 08 in Shoe spring free...

Page 35: ...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 46 4 6 33 Rear shock absorber and swingarm M10 46 4 6 33 Swingarm pivot nut M12 66 6 6 48 Engine mounting nut M8 34 3 4 25 Engine mounting nut M10 72 7 2 52 Swingarm and drive chain case M6 7 0 7 5 0 Drive chain adjust...

Page 36: ...n 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 Fuel tank and frame M6 7 0 7 5 0 Fuel cock and fuel tank M6 7 0 7 5 0 Seat and seat bracket M6 7 0 7 5 0 Part to be tightened Thread size Tightening torque Remarks Nmm kg ft lb http www motorcycle in th ...

Page 37: ...Secondary coil resistance 5 68 8 52 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 5 0 kΩ Charging system Type A C magneto Model manufacturer F5YP PTMORIC Nominal output 14 V 105 W at 5 000 r min Lighting coil resistance color 0 29 0 43 Ω at 20 C 68 F Y B Charging coil resistance color 0 38 0 58 Ω at 20 C 68 F W B Rectifier regulator Regulator type Semiconductor short circuit Model manuf...

Page 38: ...05 in Starter relay T135SE Model manufacturer G4R THA OMRON Amperage rating 50 A Coil resistance 54 66 Ω at 20 C 68 F Horn Type Plane Quantity 1 Model manufacturer GF 12 THA NIKKO Max amperage 1 5 A Performance 95 105 db 2 m Coil resistance 4 30 4 80 Ω at 20 C 68 F Turn signal relay Relay type Condenser Model manufacturer FZ222SD THA DENSO Self canceling device built in No Flasher frequency 75 95 ...

Page 39: ...mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 mm 30 3 0 17 mm 12 mm 55 5 5 19 mm 14 mm 85 8 5 22 mm 16 mm 130 13 0 A nut B bolt General tightening torques Nm m kg EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data CONVERSION TABLE Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in ME...

Page 40: ...el and ratchet wheel guide Kickstarter gear inner surface Kickstarter shaft Primary driven gear and primary drive gear 2 inner surface Clutch push rod 1 2 ball and main axle inside surface Clutch housing inside surface and crankshaft outer surface Clutch boss housing clutch plate and friction plate inside surface Clutch boss nut and lock washer contact surface Clutch shoe housing inner surface Cag...

Page 41: ...surface Transmission pinion gears inner surface Generator lead grommet Yamaha bond No 1215 Crankcase mating surface Yamaha bond No 1215 Timing chain tensioner bolts Yamaha bond No 1215 SPEC 2 19 LUBRICATION POINTS AND LUBRICANT TYPES http www motorcycle in th ...

Page 42: ...ke torque rod bolt Front wheel axle Rear wheel axle Upper brake caliper retaining bolt Lower brake caliper retaining bolt Throttle grip tube guide inner surface 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 http www motorcycle in th ...

Page 43: ... Radiator outlet hose 8 Over flow hose 9 Coolant reservoir tank å Align the white paint mark on the clamp with the white paint mark on the radiator Band the end of the cover before install the pro jection of the reservoir tank ç Install the hook of the cover end into the slit of the bracket å å ç 1 2 3 1 2 3 4 4 5 6 7 8 9 A A B B A A B B http www motorcycle in th ...

Page 44: ...pler in front of the handlebar left ç Pass through the choke cable into the wireharness Connect the couplers in front of the handlebar left side Do not pass the brake hose into the bracket ƒ Pass through into the wire guide follow the routing order Brake hose throttle cable and wireharness Hook the strap of the wirehar ness onto the bracket Pass through the brake hose into the wire guide on the ha...

Page 45: ...the front brake switch Route the right handlebar switch lead behind the handle bar and connect the coupler with handlebar right side and then set the turn signal light relay Take care not to bend the choke cable when installing å ç ƒ ˆ B B A A C C B B A A 1 2 3 4 5 6 7 4 5 6 7 8 D D http www motorcycle in th ...

Page 46: ...le å Route inside of the choke cable Pass through the throttle cable choke cable and speedometer cable into the cable guide ç Pass through the C D I unit lead in front of the stay Check that the connection of the acceleration pump cable from case after adjusting and clamp the throttle cable and acceleration pump cable Clamp the breather pipe ƒ Cover the throttle cable adjust ing nut completely Cla...

Page 47: ...e stopped ˆ Pass through the fuel hose and vacuum hose into the cable guide Route the overflow pipe to the left side of the engine and inside of the neutral switch lead Route the vacuum hose onto the fuel hose Route the fuel hose onto the cable guide µ Pass through the turn signal light lead into the guide http www motorcycle in th ...

Page 48: ...n hose t Protector å Pass through the fan relay lead into the frame pipe and fuel tank Close the clamp end until stop contact to the fuel tank ç Pass through the positive lead into the starter relay and breather pipe T135SE Pass through the starter motor lead under the wireharness T135SE Outside of the frame ƒ Be sure does not over the out side of the frame Set in the connected point to the bracke...

Page 49: ...6 7 8 9 0 q w e r t A A B B C A A B B C ˆ Route the overflow pipe in front of the cross pipe frame Pass through the drain hose and battery breather pipe into the guide Pass through the drain hose into the hole of the protector http www motorcycle in th ...

Page 50: ...rness å Turn the downward of the sep arate part Route the brake hose through as shown ç Close the clamp certainly Wireharness and cable guide clearance is wit in 16 mm when straight the steering con dition Pass through the wireharness into the main switch and cable guide Pass through the hone lead and turn signal light lead under the wireharness Route the brake hose as shown ƒ Clamp the bend hose ...

Page 51: ... qw e r C C ˆ To the A C magneto Cover the protector completely after the coupler connected Set the connected point below the pipe end Pass through the high tension cord fan motor lead and ther mo sensor lead into the cut part on the plate http www motorcycle in th ...

Page 52: ...hoke cable å Route the acceleration pump cable into the right side of the stay Route the throttle cable into the left side of the stay ç Black plating joint Pass through the fuel sender lead in to the side hole of the fuel tank Clamp the fuel sender lead onto the hook of the box ƒ White plating joint http www motorcycle in th ...

Page 53: ...ING THE COMPRESSION PRESSURE 3 15 CHECKING THE ENGINE OILLEVEL 3 17 CHANGING THE ENGINE OIL 3 18 CHECKING THE OILFILTER 3 19 CHECKING THE EXHAUSTSYSTEM 3 19 CLEANING THE AIR FILTER ELEMENT 3 20 ADJUSTING THE CLUTCH RELEASE SYSTEM 3 21 CHECKING THE CARBURETOR JOINTAND INTAKE MANIFOLD 3 21 CHECKING THE FUELAND VACUUM HOSES 3 22 CHECKING THE CRANKCASE BREATHER PIPE 3 23 CHECKING THE COOLANTLEVEL 3 23...

Page 54: ...E SPOKES 3 40 CHECKING AND LUBRICATING THE CABLES 3 41 LUBRICATING THE LEVER AND PEDALS 3 41 LUBRICATING THE SIDESTAND 3 41 LUBRICATING THE CENTERSTAND 3 41 ELECTRICALSYSTEM 3 42 CHECKING AND CHARGING THE BATTERY 3 42 CHECKING THE FUSE 3 46 REPLACING THE HEADLIGHTBULBS 3 47 ADJUSTING THE HEADLIGHTBEAM 3 48 http www motorcycle in th ...

Page 55: ... the limit 7 Rear brake 9Check operation and adjust brake pedal free play 9Replace brake shoes Whenever worn to the limit 8 Brake hose 9Check for cracks or damage 9Replace Every 4 years 9 Wheels 9Check runout spoke tightness and for damage 9Tighten spokes if necessary 10 Tires 9Check tread depth and for damage 9Replace if necessary 9Check air pressure 9Correct if necessary 11 Wheel bearings 9Check...

Page 56: ...em 9Check coolant level and vehicle for coolant leakage 9Change the YAMAHA GENUINE COOLANT Every 3 years 23 Front and rear brake switches 9Check operation 24 Moving parts and ca bles 9Lubricate 25 Throttle grip housing and cable 9Check operation and free play 9Adjust the throttle cable free play if necessary 9Lubricate the throttle grip housing and cable 26 Air induction system 9Check the air cut ...

Page 57: ...tallation reverse the removal procedure EASF0004 COVERS REMOVING THE SIDE COWLINGS 1 Remove 9screws 9bolts 9side cowlings left and right INSTALLING THE SIDE COWLINGS For installation reverse the removal procedure REMOVING THE FRONT COWLING 1 Remove 9screws 9front cowling http www motorcycle in th ...

Page 58: ...lower 1 9main switch cover 2 9screws 9center panel upper 3 NOTE Remove the main switch cover by turning it in the direction of the arrow shown 2 Remove 9screw 9 inner panel 1 INSTALLING THE CENTER PANELS For installation reverse the removal procedure REMOVING THE REAR COWLINGS 1 Remove 9screws 9center panel lower 2 Remove 9screws 9storage compartment 1 http www motorcycle in th ...

Page 59: ...rear cowlings left and right 1 9screws 9screw with washer 2 NOTE Before tightening the rear cowling screws make sure that all projections left and right are securely fitted 2 Install 9rear panel 1 9storage compartment 2 9screws NOTE Make sure that all projections are securely fit ted 1 3 Install 9center panel upper 1 9screw http www motorcycle in th ...

Page 60: ...NG THE HEADLIGHT ASSEMBLY 1 Connect 9headlight connectors 1 2 Install 9headlight assembly 9screws 2 Disconnect 9headlight connectors 1 1 REMOVING THE HEADLIGHT ASSEMBLY 1 Remove 9screws 9headlight assembly 1 http www motorcycle in th ...

Page 61: ...de cowlings left and right 9front cowling Refer to REMOVING THE SIDE COWL INGS AND REMOVING THE FRONT COWLING CHK ADJ ADJUSTING THE VALVE CLEARANCE 3 7 2 Drain 9cooling system Refer to CHANGING THE COOLANT 3 Remove 9AIS resonator mount bolt 9AIS resonator 9spark plug 9bracket Refer to CHANGING THE COOLANT cC Be sure to remove the AIS hose before removing the AIS resonator otherwise to brake the AI...

Page 62: ...ck plug 1 with O ring 9center plug 2 with O ring 9 Measure 9valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align the I mark a on the camshaft sprocket with the stationary point er b on the cylinder head Valve clearance cold Intake valve 0 10 0 14 mm 0 0039 0 0055 in Exhaust valve 0 16 0 20 mm 0 0063 0 0079 i...

Page 63: ... obtained 9 Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica tion d Measure the valve clearance again e If the valve clearance is still out of specifica tion repeat all of the valve clearance adjustment steps until the specified clear ance is obtained Direction aa Valve clearance is increased Direction bb Valve clearance is decreased Tappet adjusting tool 44 ...

Page 64: ... 9radiator outlet cover 9radiator inlet hose 15 Install 9AIS resonator 9AIS resonator mount bolt 9spark plug 16 Fill 9cooling system Refer to CHANGING THE COOLANT 17 Install 9front cowling 9side cowlings left and right Refer to INSTALLING THE SIDE COWL INGS and INSTALLINGTHEFRONT COWLING 7 Nm 0 7 m kg 5 0 ft lb 7 Nm 0 7 m kg 5 0 ft lb 10Nm 1 0 m kg 7 2 ft lb 10Nm 1 0 m kg 7 2 ft lb 12 5Nm 1 25 m k...

Page 65: ...e engine idling speed the air filter element should be clean and the engine should have adequate compression 1 Remove 9side cowlings left and right 9front cowling 9rear cowling left Refer to REMOVING THESIDECOWL INGS REMOVING THE FRONTCOWL ING and REMOVINGTHEREARCOWL INGS 2 Start the engine and let it warm up for sev eral minutes 3 Connect 9engine tachometer onto the spark plug lead 4 Check 9engin...

Page 66: ...EED ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 3 7 mm 0 12 0 28 in a 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 9center panel lower Refer to REMOVING THE CENTERPAN ELS Th...

Page 67: ...position w After adjusting the throttle cable free play start the engine and turn the handlebar to the right or left to ensure that this does not cause the engine idling speed to change 4 Adjust 9accelerator pump cable a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until align the projection c on the accel erator pump lever with projection d on the bracket e within 1mm c Tig...

Page 68: ...k plug cC Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder Spark plug type manufacturer CPR8EA 9 NGK 5 Check 9electrode 1 Damage wear Replace the spark plug 9insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean 9spark plug with a spark plug cleaner or wire b...

Page 69: ...R ANCE 3 Start the engine warm it up for several min utes and then turn it off 4 Disconnect 9spark plug cap 5 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 8 Install 9spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect 9spa...

Page 70: ...minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table Compression pressure with oil applied into the cylinder Reading Diagnosis Piston ring s wear Higher than with or damage out oil Repair Piston valves cyl Same as without inder head gasket oil or piston possibly defective Repair 1 6 Install 9compression gauge 1 7 Measure 9co...

Page 71: ...ine oil level should be between the minimum level mark a 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...

Page 72: ...Install 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 CHANGING THE ENGINE OIL Quantity Total amount 1 15 L 1 22 US qt 1 01 Imp gt Periodic oil change amount 0 8 L 0 85 US qt 0 70 Imp gt 2 EAS00075 CHANGING THE ENGINE OIL 1 Start the engine warm it up for...

Page 73: ... Replace 3 Install 9oil filter element 9O ring 1 9oil filter element cover CHANGING THE ENGINE OIL CHECKING THE EXHAUST SYSTEM 10 Nm 1 0 m kg 7 2 ft lb 1 CHECKING THE EXHAUST SYSTEM 1 Check 9exhaust pipe nuts 1 Loose damage Tighten replace 9exhaust pipe gasket Exhaust gas leaks Tighten replace 15 Nm 1 5 m kg 11 ft lb http www motorcycle in th ...

Page 74: ...t Damage Replace 5 Install 9air filter element 9air filter case cover 9breather hose cC Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carbure tor tuning leading to poor engine perfor mance NOTE When installing the air filter el...

Page 75: ...n completely then turn the adjusting screw out the speci fied number of turns c Tighten the locknut NOTE Hold the adjusting screw and tighten the lock nut Adjusting screw 1 8 turns out 8 Nm 0 8 m kg 6 0 ft lb EAS00094 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1 Remove 9side cowlings left and right 9center panels upper and lower 9front cowling 9rear cowlings left and right 9inner panel Refe...

Page 76: ...ES The following procedure applies to all of the fuel and vacuum hoses 1 Remove 9side cowlings left and right 9center panels upper and lower 9front cowling 9rear cowlings left and right 9inner panel Refer to COVERS 2 Check 9fuel cock vacuum hose 1 9fuel hose 2 Cracks damage Replace Loose connection Connect properly 3 Install 9inner panel 9rear cowlings left and right 9front cowling 9center panels ...

Page 77: ...onnect properly cC Make sure the crankcase breather pipe is routed correctly EAS00103 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface NOTE Make sure the vehicle is upright 2 Check 9coolant level The coolant level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level 3 Install 9inner panel 9...

Page 78: ... utes and then turn it off 4 Check 9coolant level NOTE Before checking the coolant level wait a few minutes until it settles EAS00104 CHECKING THE COOLING SYSTEM 1 Remove 9side cowlings left and right 9front cowling Refer to REMOVING THE SIDE COWL INGS and REMOVING THE FRONT COWLING 2 Check 9radiator 1 9water pump inlet hose 2 9radiator outlet hose 3 9radiator inlet hose 4 9thermostat outlet hose ...

Page 79: ...refore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped pre...

Page 80: ... 99 If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor 99 If coolant splashes on your clothes quickly wash it away with water and then with soap and water 99 If coolant is swallowed induce vomiting and get immediate medical attention Recommended antifreeze YAMAHAGENUINE COOLANT High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum...

Page 81: ... surfaces immediately wash them with water 99 Do not mix different types of antifreeze 11 Install 9radiator cap 9coolant reservoir cap 9coolant reservoir tank cover 12 Start the engine warm it up for several min utes and then stop it 13 Check 9coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Before checking the coolant level wait a few minutes until the coolant has settled 14 Install 9front ...

Page 82: ... 1 38 in 2 Adjust 9brake pedal free play a Turn the adjuster 1 in direction a or b until the specified brake pedal free play is obtained cC After adjusting the brake pedal free play make sure there is no brake drag 3 Adjust 9rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHTSWITCH Direction aa Brake pedal free play is increased Direction bb Brake pedal free play is decreased http www ...

Page 83: ...NG THE FRONT BRAKE PADS in chapter 7 EAS00126 CHECKING THE REAR BRAKE SHOES 1 Operate the brake 2 Check 9wear indicator 1 Reaches the wear limit line 2 Replace the brake shoes as a set Refer to REAR WHEELAND BRAKE in chapter 7 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 light switch is properly adjusted ...

Page 84: ...he rear brake light comes on at the proper time Direction aa Brake light comes on sooner Direction bb Brake light comes on later EAS00129 CHECKING THE FRONT BRAKE HOSE 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 Check 9brake hose Brake fluid leakage Replace the ...

Page 85: ... caution could allow air 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 br...

Page 86: ...ill the brake master cylinder reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL 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 Adrive chain that is too tight will ove...

Page 87: ...f specification Adjust Drive chain slack 25 35 mm 0 93 1 38 in 4 Adjust 9drive chain slack a Loosen the wheel axle nut b Loosen both locknuts 1 c Turn both adjusting nuts 2 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 specification D...

Page 88: ...OTE 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 99 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance 99 Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in...

Page 89: ...zontal 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 bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove 9s...

Page 90: ...r 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 7 g Slide the rubber cover to its original posi tion 5 Install 9front cowlings left and rig...

Page 91: ...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 FRONTFORK in chapter 7 http www motorcycle in th ...

Page 92: ...eight including cargo rider passenger and accessories and the anticipated riding speed 99 Operation 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 ...

Page 93: ...ed in the wheel groove 99 Patching 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 99 After 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 manufacturer and of the same design No gua...

Page 94: ...E TIRES CHECKING AND TIGHTENING THE SPOKES w 99 New 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 99 After a tire has been repaired or replaced be sure to tighten the tire air valve stem locknut 11to specification NOTE For tires with a direction of rotati...

Page 95: ...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 CENTERSTAND Lubricate t...

Page 96: ...rks or open flames e g welding equipment light ed cigarettes 99 DO NOT SMOKE when charging or han dling batteries 99 KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 99 Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILYCONTACT EXTERNAL 99 Skin Wash with water 99 Eyes Flush with water for 15 minutes and get immediate medical...

Page 97: ...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 7 Check 9specific gravity Less than 1 280 Recharge the battery 8 Charge 9battery w Do not quick charge a battery Battery charging amperage and time...

Page 98: ...tery 99 Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger 99 Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted Acorroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks 99 If the battery becomes hot to the touch ...

Page 99: ... 9battery band Recommended lubricant Dielectric grease 11 Connect 9battery breather hose 1 cC 99 When 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 99 Make sure the battery breat...

Page 100: ...eck 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 possibly cause a fir...

Page 101: ...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 moistened with alcoho...

Page 102: ...eadlight 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 http www motorcycle in th ...

Page 103: ... 7 CYLINDER 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 CAMSHAFTSPROCKET 4 21 INSTALLING THE CAMSHAFTAND ROCKER ARM...

Page 104: ...UTCH 4 50 CHECKING THE FRICTION PLATES 4 52 CHECKING THE CLUTCH PLATES 4 52 CHECKING THE CLUTCH SPRINGS 4 53 CHECKING THE CLUTCH HOUSING 4 53 CHECKING THE CLUTCH BOSS 4 53 CHECKING THE CLUTCH PRESSURE PLATE 4 54 CHECKING THE CLUTCH PUSH RODS 4 54 CHECKING THE PRIMARYDRIVEN GEAR 4 54 CHECKING THE CLUTCH SHOE HOUSING 4 55 CHECKING THE CLUTCH SHOE 4 55 CHECKING THE CAGE 4 55 CHECKING THE CLUTCH RELEA...

Page 105: ... 4 68 KICKSTARTER 4 70 REMOVING THE KICKSTARTER 4 71 CHECKING THE KICKSTARTER 4 73 INSTALLING THE KICKSTARTER 4 74 TRANSMISSION 4 76 REMOVING THE TRANSMISSION 4 77 DISASSEMBLING THE TRANSMISSION 4 77 CHECKING THE SHIFTFORKS 4 78 CHECKING THE SHIFTDRUM ASSEMBLY 4 79 CHECKING THE TRANSMISSION 4 79 INSTALLING THE TRANSMISSION 4 80 http www motorcycle in th ...

Page 106: ...ENG http www motorcycle in th ...

Page 107: ...rear cowlings left and right Refer to COVERS in chapter 3 9drive sprocket Refer to DRIVE CHAIN AND SPROCK ETS in chapter 7 COOLING SYSTEM 1 Drain 9coolant completely from the water jacket Refer to CHANGING THE COOLANT in chapter 3 2 Remove 9radiator assembly 9water pump assembly Refer to RADIATOR and WATER PUMP in chapter 5 ENGINE OIL 1 Drain 9engine oil completely from the crankcase Refer to CHAN...

Page 108: ...r bolt 1 9washer 9upper muffler bolt 2 9washers 9nut 9muffler 3 BRAKE PEDAL 1 Remove 9rear brake light switch spring 9brake pedal spring 9cotter pin 9brake pedal SHIFT PEDAL 1 Remove 9shift pedal bolt 1 9shift pedal 2 9sprocket cover 1 FOOTREST 1 Remove 9footrest bolts 1 9footrest 1 2 3 http www motorcycle in th ...

Page 109: ...side cowling bracket 2 WIRE CABLE AND HOSE 1 Disconnect 9neutral switch lead coupler 1 9stator coil lead coupler 2 9pick up coil lead coupler 3 9crankcase breather pipe 2 Remove 9starter motor lead coupler T135SE 3 Remove 9spark plug cap 4 3 4 Remove 9fuel cock vacuum hose 1 1 http www motorcycle in th ...

Page 110: ...6 9plate nuts front and rear 2 9washers front and rear 9plate bolts front and rear 7 9front mounting nut 3 9washer 9front mounting bolt 8 9plate left and right 9 9rear upper mounting nut 4 9washer 9rear upper mounting bolt 0 9pivot shaft nut 3 9washer 9pivot shaft q 9engine assembly w Securely support the vehicle so there is no danger of it falling over 1 5 Remove 9crankcase breather pipe 1 A A B ...

Page 111: ...left and right 4 9plate bolts front and rear 5 9washers front and rear 9plate nuts front and rear 9rear lower mounting bolt 6 9washer 9rear lower mounting nut 2 Temporary tighten 9plate nuts front and rear 7 3 Tighten 9pivot shaft nut 8 9rear upper mounting nut 9 9front mounting nut 0 9plate nuts front and rear 7 9rear lower mounting nut q 34 Nm 3 4 m kg 25 ft lb 34 Nm 3 4 m kg 25 ft lb 72 Nm 7 2 ...

Page 112: ...ickup coil lead coupler 9stator coil lead coupler 2 Install 9crankcase breather pipe 9fuel cock vacuum hose 9spark plug cap SIDECOWLINGBRACKET 1 Install 9side cowling bracket 9side cowling bracket bolts SHIFT PEDAL 1 Install 9sprocket cover 9shift pedal 1 9shift pedal bolt 2 NOTE Align the punch mark a in the shift pedal with the punch mark b in the shift shaft 1 2 a b 7 Nm 0 7 m kg 5 0 ft lb 10 N...

Page 113: ...AKE LIGHTSWITCH in chapter 3 FOOTREST 1 Install 9footrest 9footrest bolts 1 Throttle cable free play at the flange of the throttle grip 3 7 mm 0 12 0 28 mm 23 Nm 2 3 m kg 17 ft lb COOLING SYSTEM 1 Install 9water pump assembly 9radiator assembly Refer to RADIATOR and WATER PUMP in chapter 5 2 Fill 9coolant Refer to CHANGING THE COOLANT in chapter 3 ENGINE OIL 1 Fill 9engine oil Refer to CHANGING TH...

Page 114: ...ft lb 13 Nm 1 3 m kg 9 5 ft lb 22 Nm 2 2 m kg 16 ft lb 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 ft lb LS E E EASF0023 CYLINDER HEAD 1 Water pump 2 Spark plug 3 Cylinder head cover 4 Dowel pin 5 Camshaft sprocket 6 Cylinder head 7 Timing chain guide exhaust side 8 Timing chain tensioner 9 Dowel pin 0 Gasket http www motorcycle in th ...

Page 115: ... in chapter 3 9carburetor assembly Refer to CARBURETOR in chapter 6 9muffler Refer to REMOVING THE ENGINE 2 Drain 9cooling system Refer to CHANGING THE COOLANT in chapter 3 3 Remove 9water pump assembly bolts 9water pump assembly 9O rings 4 Remove 9spark plug cap 1 9spark plug 2 5 Remove 9cylinder head cover bolts 9cylinder head cover 9gasket 9dowel pin 9O ring http www motorcycle in th ...

Page 116: ...et 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 cap bolt 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 falli...

Page 117: ... 1 2 of a turn 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 ...

Page 118: ...mit 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 in http www m...

Page 119: ...iming 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 2 Install 9cylinder head 9washers 9cylinder hea...

Page 120: ...t 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 c on the camshaft sprock et with the slot in the camshaft cC Do not turn the crankshaft...

Page 121: ... NOTE Apply the YAMAHAbond 1215 onto the bolts c Turn the timing chain tensioner rod counter clockwise with a thin screwdriver 1 make sure it releases and then tighten the cap bolt to specification 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 ...

Page 122: ...r head Out of alignment Correct Refer to the installation steps above 9 Measure 9valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 10 Install 9O rings 9water pump assembly 9water pump assembly bolts 11 Install 9spark plug 12 Install 9intake manifold bolts 9intake manifold with carburetor 10 Nm 1 0 m kg 7 2 ft lb 13 Nm 1 3 m kg 9 5 ft lb 10 Nm 1 0 m kg...

Page 123: ... 3 1 2 6 E E E 7 Nm 0 7 m kg 5 0 ft lb 7 Nm 0 7 m kg 5 0 ft lb LS E 4 17 CAMSHAFT EASf0020 CAMSHAFT 1 Locknut 2 Adjusting screw 3 Camshaft retainer 4 Camshaft 5 Rocker arm shaft 6 Rocker arm http www motorcycle in th ...

Page 124: ...ocker arms and camshaft remove the cylinder head 1 Loosen 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 http www motorcycle in th ...

Page 125: ...shaft 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 aa29 613 mm 1 1659 in bb25 043 mm 0 9859 in Exhaust aa29 912 mm 1 1776 in bb24 989 mm 0 9838 in http www moto...

Page 126: ...ker 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 9 985 10 000 mm 0 3931 0 3937 in Limit 9 950 mm 0 3917 in Rocker arm shaft outside diameter 9 966 9 976 mm 0 3924 0 3928 in Limit 9 950 mm 0 3917 in Rocker arm to ...

Page 127: ...shaft sprocket a 1 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 Install the camshaft retainer with the bent ends facing inward Recommended lubricant Engine oil Recommended lubricant Molybdenum disulfide grease 7 Nm 0 7 m kg 5 0 ft lb http www m...

Page 128: ...INGS 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 6 7 7 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 http www motorcycle in th ...

Page 129: ... 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 at the valve...

Page 130: ...S00239 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 spring compressor attachment 90890 04108 Valve stem to valve guide clearance Valve guide inside diameter aa Valve stem diameter bb Valve stem to valve g...

Page 131: ... NOTE Apply the YAMAHAbond 1215 onto the bolts c Turn the timing chain tensioner rod counter clockwise with a thin screwdriver 1 make sure it releases and then tighten the cap bolt to specification 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 ...

Page 132: ...r head Out of alignment Correct Refer to the installation steps above 9 Measure 9valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 10 Install 9O rings 9water pump assembly 9water pump assembly bolts 11 Install 9spark plug 12 Install 9intake manifold bolts 9intake manifold with carburetor 10 Nm 1 0 m kg 7 2 ft lb 13 Nm 1 3 m kg 9 5 ft lb 10 Nm 1 0 m kg...

Page 133: ... 3 1 2 6 E E E 7 Nm 0 7 m kg 5 0 ft lb 7 Nm 0 7 m kg 5 0 ft lb LS E 4 17 CAMSHAFT EASf0020 CAMSHAFT 1 Locknut 2 Adjusting screw 3 Camshaft retainer 4 Camshaft 5 Rocker arm shaft 6 Rocker arm http www motorcycle in th ...

Page 134: ...ocker arms and camshaft remove the cylinder head 1 Loosen 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 http www motorcycle in th ...

Page 135: ...shaft 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 aa29 613 mm 1 1659 in bb25 043 mm 0 9859 in Exhaust aa29 912 mm 1 1776 in bb24 989 mm 0 9838 in http www moto...

Page 136: ...ker 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 9 985 10 000 mm 0 3931 0 3937 in Limit 9 950 mm 0 3917 in Rocker arm shaft outside diameter 9 966 9 976 mm 0 3924 0 3928 in Limit 9 950 mm 0 3917 in Rocker arm to ...

Page 137: ...shaft sprocket a 1 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 Install the camshaft retainer with the bent ends facing inward Recommended lubricant Engine oil Recommended lubricant Molybdenum disulfide grease 7 Nm 0 7 m kg 5 0 ft lb http www m...

Page 138: ...INGS 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 6 7 7 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 http www motorcycle in th ...

Page 139: ... 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 at the valve...

Page 140: ...S00239 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 spring compressor attachment 90890 04108 Valve stem to valve guide clearance Valve guide inside diameter aa Valve stem diameter bb Valve stem to valve g...

Page 141: ...oper 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 valve Valve m...

Page 142: ...ts 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 seat width...

Page 143: ...all 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 to clean o...

Page 144: ...lace 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 47 33 mm 1 86 in Limit 44 96 mm 1 77 in Compressed valve spring force installed Intake and exhaust valve springs 135 6 156 0 N 13 83 15...

Page 145: ...m 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 Molybudemium oil http www motorcycle in th ...

Page 146: ...e 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 Valve spring compressor attachment 90890 04108 http www motorcycle in th ...

Page 147: ... AND PISTON E 4 5 6 7 9 8 3 3 2 1 E 7 E EASF0027 CYLINDER AND PISTON 1 Cylinder 2 Cylinder gasket 3 Dowel pin 4 Top ring 5 2nd ring 6 Oil ring 7 Piston pin clip 8 Piston pin 9 Piston 4 31 http www motorcycle in th ...

Page 148: ... piston pin clip cover the crankcase opening with a clean rag to prevent 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 NOTE When re...

Page 149: ...ecification 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 54 000 54 010 mm 2 1260 2 1264 in Limit 54 100 mm 2 1299 in Taper...

Page 150: ...iminate 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 0015 0 048 mm 0 0006 0 0019 in Limit 0 15 mm 0 0059 Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston ring side clearance Top ring 0 030 0 065 mm 0 0012 ...

Page 151: ...n 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 01 0 03 in Piston pin outside diameter 1...

Page 152: ...anufacturer 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 mark a on the piston points towards the exhaust side of the cylinder 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 clearance Piston ...

Page 153: ... onto them 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 http www motorcycle in th ...

Page 154: ...20 ft lb E T135SE EASF0034 GENERATOR AND STARTER CLUTCH 1 Starter clutch 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 Pickup coil q Stator coil w Gasket e Dowel pin r Crankcase cover left http www motorcycle in th ...

Page 155: ...dal 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 Remove 9c...

Page 156: ...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 0170...

Page 157: ...amage 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 terclockwi...

Page 158: ...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 rotor nut 9D...

Page 159: ...e cover bolt thread as shown one 5 Install 9gasket 9crankcase cover 4 43 ENG GENERATOR AND STARTER CLUTCH 3 Apply 9sealant on to the generator lead grommet Yamaha bond No 1215 90890 85505 Yamaha bond No 1215 90890 85505 10 Nm 1 0 m kg 7 2 ft lb http www motorcycle in th ...

Page 160: ... 1 0 m kg 7 2 ft lb 32 Nm 3 2 m kg 23 ft lb 7 Nm 0 7 m kg 5 0 ft lb 4 44 OILPUMP 1 Oil drain bolt 2 O ring 3 Spring 4 Oil strainer 5 Oil filter cover 6 O ring 7 Oil filter 8 Gear cover 9 Oil pump assembly 0 Gasket EASF0035 OILPUMP http www motorcycle in th ...

Page 161: ...OIL in chapter 3 2 Remove 9generator Refer to GENERATOR AND STARTER CLUTCH 3 Remove 9clutch release shift arm 4 Remove 9gear cover 5 Remove 9oil pump assembly 1 9gasket DISASSEMBLING THE OILPUMP 1 Remove 9screw 9pump cover 1 9pin 2 9inner rotor 3 9outer rotor 4 9oil pump housing 5 9oil pump driven cover 6 http www motorcycle in th ...

Page 162: ...er rotor clearance c Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing 3 Check 9oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s 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 11 mm 0 0024 0 0043 in Limit 0 15 mm 0 0059 in Oil pump housin...

Page 163: ...il pump shaft to the oil pump housing 9inner rotor 1 9outer rotor 9pin 2 9oil pump housing cover 3 9screw 4 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 OILPUMP Recommended lubricant Engine oil 1 Nm 0 1 m kg 0 7 ft lb http www motorcycle in th ...

Page 164: ...ILPUMP 1 Install 9gasket 1 9oil pump assembly 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 http www motorcycle in th ...

Page 165: ... Clutch spring 3 Clutch pressure plate 4 Friction plate 1 5 Clutch plate 6 Friction plate 2 7 Cushion ring 8 Seat plate 9 Clutch push rod 1 0 Clutch boss nut q Clutch boss w Clutch housing e Clutch push rod 2 r Clutch release shift arm t Clutch release adjusting screw y Clutch shoe housing nut u Primary drive gear i Clutch shoe housing o Cage p Clutch shoe housing boss a Clutch shoe http www motor...

Page 166: ...ter lever Refer to KICKSTARTER 9crankcase cover left Refer to GENERATOR AND STARTER CLUTCH 5 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 6 Remove 9clutch push rod 1 1 9friction plates 1 2 9friction plates 2 3 9clutch plate 4 9c...

Page 167: ...tch boss nut 1 9lock washer 2 9clutch boss 3 9washer 4 9clutch housing 5 9spacer 6 9clutch push rod 2 7 10 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 http ww...

Page 168: ...n 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 clutch pl...

Page 169: ...CHECKING THE CLUTCH HOUSING 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 EAS00285 CHECKING THE CLUTCH BOSS 1 Check 9clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause erratic clutch operation Clu...

Page 170: ...tch push rod 2 2 Measure 9clutch push rods bending limit Out of specification Replace the clutch push rod EAS00292 CHECKING THE PRIMARYDRIVEN 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...

Page 171: ... 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 116 mm 4 57 in Limit 117 mm 4 61 in Clutch shoe groove depth 1 0 mm 0 04 in Limit 0 1 mm 0 004 in http ...

Page 172: ...tion to turn the lateral direction And then take care comes off to install them onto the crankshaft 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 9clutch housing 3 9washer 4 9clutch boss...

Page 173: ...ce the cushion ring 2 toward as shown illustration and then install it onto the clutch boss 9First install the seat plate cushion ring and then alternate between a clutch plate and a friction plate 8 Install 9clutch springs 9clutch pressure plate 1 9clutch pressure plate bolts 2 NOTE 9Align the punch mark a on the pressure plate with clutch housing mark b 9Tighten the clutch pressure plate bolts i...

Page 174: ...E E E E LS SHIFT SHAFT EASF0032 SHIFT SHAFT 1 Shift pedal 2 Washer 3 Spring 4 Shift fork guide bar 5 Shift guide 6 Pawl holder 7 Guide 8 Washer 9 Thrust bearing 0 Dowel pin q Shift shaft w Shift lever assembly e Stopper lever spring r Stopper lever assembly t Collar y Plate u Shift drum segment http www motorcycle in th ...

Page 175: ...HANGING THE ENGINE OIL in chapter 3 2 Remove 9clutch Refer to CLUTCH 3 Remove 9shift pedal 9crankcase cover bolts 9crankcase cover left 4 Remove 9shift fork guide bar 1 9washer 2 9shift guide spring 5 Remove 9shift guide 1 9pawl holder 2 9guide 3 9dowel pin 4 6 Remove 9washers 1 9thrust bearing 2 http www motorcycle in th ...

Page 176: ...ove 9shift shaft assembly 1 9shift lever assembly 2 8 Remove 9stopper lever assembly 3 9stopper lever spring 4 9collar 9 Remove 9stopper lever spring 1 9stopper lever 2 9collar 3 10 Remove 9plate 9shift drum segment 1 http www motorcycle in th ...

Page 177: ...30 CHECKING 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 4 Damage wear Replace CHECKING THE OILSEAL 1 Check 9oil seal Damage wear Replace http www motorcycle in th ...

Page 178: ...2 Install 9collar 9stopper lever 1 9stopper lever spring 2 NOTE 9Apply locking agent LOCTITE R to the stopper lever bolt 9Hook the ends 3 of the stopper lever spring onto the stopper lever and the crankcase boss 9Mesh the stopper lever with the shift drum seg ment assembly 3 Install 9shift lever assembly 1 9shift shaft assembly 2 LT 12 Nm 1 2 m kg 9 0 ft lb http www motorcycle in th ...

Page 179: ... 7 2 ft lb E 4 Nm 0 4 m kg 3 0 ft lb 4 63 CRANKCASE AND CRANKSHAFT EASF0037 CRANKCASE AND CRANKSHAFT 1 Neutral switch 2 Right crankcase 3 Dowel pin 4 Timing chain 5 Timing chain guide intake side 6 Crankshaft assembly 7 Left crankcase http www motorcycle in th ...

Page 180: ...5SE in chapter 8 3 Remove 9cylinder head Refer to CYLINDER HEAD 9cylinder 9piston Refer to CYLINDER AND PISTON 9clutch Refer to CLUTCH 9shift shaft Refer to SHIFTSHAFT 9generator 9starter clutch Refer to GENERATOR AND STARTER CLUTCH 9oil pump assembly Refer to OILPUMP 4 Remove 9neutral switch 1 9timing chain guide intake side bolts 9timing chain guide intake side 2 9timing chain 3 http www motorcy...

Page 181: ...case not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly 7 Remove 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 bearing or bo...

Page 182: ...specification Replace the 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 Big end side clearance 0 11 0 41 mm 0 0043 0 0161 in Crankshaft width 45 95 46 00 mm 1 809 1 811 in http www motorcycle in th ...

Page 183: ...livery passages Obstructions 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 camshaf...

Page 184: ...ter with one hand while turning the nut of the installing tool with the other 99 Operate the installing tool until the crank shaft bottoms against the bearing EAS00416 ASSEMBLING THE CRANKCASE 1 Apply 99 sealant 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...

Page 185: ...6 Check 9crankshaft and transmission operation Rough movement Repair 7 Install 9timing chain 9timing chain guide intake side 9timing chain guide intake side bolts NOTE Apply locking agent LOCTITE R to the threads of timing chain guide intake side bolts 10 Nm 1 0 m kg 7 2 ft lb 4 Nm 0 4 m kg 3 0 ft lb 10 Nm 1 0 m kg 7 2 ft lb http www motorcycle in th ...

Page 186: ...lb 4 70 1 Oil level plug 2 Kickstarter lever 3 Crankcase cover right 4 Gasket 5 Washer 6 Kickstarter gear 7 Guide stopper 8 Collar 9 Kickstarter spring 0 Washer q Spring w Kickstarter ratchet gear e Kickstarter shaft ENG KICKSTARTER EASF0033 KICKSTARTER http www motorcycle in th ...

Page 187: ...r 9rear cowlings left and right Refer to COVERS in chapter 3 9carburetor assembly Refer to CARBURETOR in chapter 6 9muffler 9footrest 9Brake pedal Refer to REMOVING THE ENGINE 3 Remove 9cylinder head Refer to CYLINDER HEAD 9cylinder 9piston Refer to CYLINDER AND PISTON 4 Remove 9kickstarter nut 1 9kickstarter lever 2 5 Remove 9oil level plug 9crankcase cover bolts 9crankcase cover right 3 9gasket ...

Page 188: ...r to SOILPUMP 9generator 9starter clutch Refer to GENERATOR AND STARTER CLUTCH 7 Remove 9starter motor T135SE Refer to STARTER MOTOR in chapter 8 8 Remove 9engine Refer to REMOVING THE ENGINE 9 Separate 9crankcase Refer to CRANKCASE 10 Remove 9guide stopper 9kickstarter shaft assembly http www motorcycle in th ...

Page 189: ...ckstarter spring 3 9collar 4 9washer 5 9spring 6 9kickstarter ratchet gear 7 9kickstarter shaft EAS00339 CHECKING THE KICKSTARTER 1 Check 9kickstarter ratchet gear 1 9kickstarter gear 2 Damage wear Replace 2 Check 9kickstarter spring Damage wear Replace http www motorcycle in th ...

Page 190: ...lockwise to 3 4 turns b 2 Install 9guide stopper 3 9guide stopper bolts 9kickstarter gear 4 3 Install 9crankcase Refer to CRANKCASE 4 Install 9engine Refer to REMOVING THE ENGINE 5 Install 9starter motor T135SE Refer to STARTER MOTOR T135SE in chapter 8 6 Install 9oil pump assembly Refer to OILPUMP 9generator Refer to GENERATOR AND STARTER CLUTCH 9shift shaft Refer to SHIFTSHAFT 9clutch Refer to C...

Page 191: ...HEAD 10 Install 9muffler 9footrest 9brake pedal Refer to REMOVING THE ENGINE 9inner panel 9center panels left and right 9front cowling 9side cowlings left and right Refer to COVERS in chapter 3 11 Fill 9coolant completely from the water jacket Refer to CHANGING THE COOLANT in chapter 3 9engine oil completely from the crankcase Refer to CHANGING THE ENGINE OIL in chapter 3 http www motorcycle in th...

Page 192: ... Shift fork guide bar 2 Shift fork R 3 Shift fork L 4 Shift drum 5 2nd pinion gear 6 3rd pinion gear 7 4th pinion gear 8 Main axle 1st pinion gear 9 1st wheel gear 0 4th wheel gear q 3rd wheel gear w 2nd wheel gear e Side plate spring r Side plate t Washer y Drive axle http www motorcycle in th ...

Page 193: ...e bar springs 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 9washer 5 94th pinion gear 6 9main axle 1st pinion gear 7 http www motorcycle in th ...

Page 194: ...dure 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 straighten a bent shift fork guide bar 3 Check 9shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and sh...

Page 195: ...out 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 limit 0 03 mm...

Page 196: ...as shown 5 Check 9transmission gear movement Rough movement Replace the defective part s 6 Check 9circlips Bends damage looseness Replace EAS00426 INSTALLING THE TRANSMISSION 1 Install 9shift fork guide bar 1 9shift fork R 2 9shift fork L 3 9shift drum 4 NOTE 9The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R L 9Be sure instal...

Page 197: ...mission 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 http www motorcycle in th ...

Page 198: ...ENG http www motorcycle in th ...

Page 199: ...RADIATOR 5 3 CHECKING THE RADIATOR 5 4 CHECKING THE THERMOSTAT 5 6 DISASSEMBLING THE WATER PUMP 5 6 CHECKING THE WATER PUMP 5 7 ASSEMBLING THE WATER PUMP 5 8 INSTALLING THE THERMOSTAT 5 8 INSTALLING THE WATER PUMP 5 9 INSTALLING THE RADIATOR 5 9 http www motorcycle in th ...

Page 200: ...COOL http www motorcycle in th ...

Page 201: ...Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 1 Radiator cap 2 Bracket 3 Water pump inlet hose 4 Radiator outlet hose 5 Radiator inlet hose 6 Bracket 7 Thermostat housing cover 8 Thermostat 9 Radiator assembly 0 Fan motor assembly http www motorcycle in th ...

Page 202: ... 8 6 0 q 1 9 2 4 3 LS LS LS 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 1 O ring 2 O ring 3 Water pump cover 4 Gasket 5 Plate 6 Impeller 7 Plate 8 Housing cover gasket 9 Bearing 0 Water pump seal q Water pump housing http www motorcycle in th ...

Page 203: ... toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counter clockwise to remove 1 Remove 9side cowlings left and right 9front cowling 9center panels 9seat assembly with battery box 9inner panel Refer to REMOVING THE FRONTCOWL INGS in chapter 3 2 Drain 9cooling water Refer to CHANGING THE COOLANT in chapter 3 3 Di...

Page 204: ...AS00455 CHECKING THE RADIATOR 1 Check 9radiator fins Obstruction Clean Apply compressed air to the rear of the radi ator Damage Repair or replace NOTE Straighten any flattened fins with a thin flat head screwdriver 2 Check 9radiator hoses 9radiator pipes Cracks damage Replace http www motorcycle in th ...

Page 205: ...e radiator cap 3 b Apply the specified pressure for ten seconds and make sure there is no drop in pressure 4 Check 9radiator fan motor Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 93 2 122 6 kPa 0 93 1 23 kg cm2 13 5 17 8 psi Radiator cap tester 11 90890 01325 Radiator cap tester adapter 22 90890 01352 http www motorcycle in th ...

Page 206: ...ng the water observe the thermo stat and thermometer s indicated tempera ture 1 Thermometer 2 Water 3 Thermostat 4 Container å Fully closed Fully open NOTE If the accuracy of the thermostat is in doubt replace it Afaulty thermostat could cause seri ous overheating or overcooling 2 Check 9thermostat housing cover 9thermostat housing Cracks damage Replace EAS00470 DISASSEMBLING THE WATER PUMP 1 Remo...

Page 207: ...p housing cover 9water pump housing 9impeller 9rubber damper 9rubber damper holder 9water pump seal 9oil seal Cracks damage wear Replace 4 Remove 9water pump seal 4 NOTE Remove the water pump seal from the inside of the water pump housing 2 Check 9bearing Rough movement Replace 2 Remove 9plate NOTE Slide the plate as shown and then remove the plate from the water pump housing http www motorcycle i...

Page 208: ...al 1 NOTE Install the water pump seal with the special tools å Push down 2 Lubricate 9water pump seal 1 Mechanical seal installer 90890 04145 22 Middle driven shaft bearing driver 90890 04058 33 Recommended lubricant Lithium soap base grease 3 Install 9impeller 9plate NOTE 9Align the slit in the impeller shaft with the slot of the plate 9After installation check that the impeller shaft rotates smo...

Page 209: ... 5 9 COOL COOLING SYSTEM 1 2 a b LS LS EAS00478 INSTALLING THE WATER PUMP 1 Install 9O rings 9water pump housing 1 w Always use a new O ring NOTE 9Align the projection a on the impeller shaft with the slit b on the camshaft 9Lubricate the O ring with a thin coat of lithium soap based grease 2 Install 9water pump housing cover 2 9water pump inlet hose 9water pump outlet hose 10 Nm 1 0 m kg 7 2 ft l...

Page 210: ...d pressure with the gauge 5 Measure 9radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR 6 Install 9inner panel 9seat assembly with battery box 9center panels 9front cowling 9side cowlings left and right Refer to REMOVING THE FRONTCOWL INGS in chapter 3 Radiator cap tester 90890 01325 Radiator cap tester adapter 90890 01352 http www mo...

Page 211: ...LLING THE CARBURETOR 6 10 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 11 CHECKING THE FUELCOCK OPERATION 6 13 AIR INDUCTION SYSTEM 6 14 AIR INJECTION 6 14 AIR CUT OFF VALVE 6 14 AIR INDUCTION SYSTEM DIAGRAMS 6 15 REMOVING THE AIR INDUCTION SYSTEM 6 16 CHECKING THE AIR INDUCTION SYSTEM 6 16 INSTALLING THE AIR INDUCTION SYSTEM 6 16 http www motorcycle in th ...

Page 212: ...CARB http www motorcycle in th ...

Page 213: ...op cover 3 Throttle valve spring 4 Needle set 5 Throttle valve 6 Throttle stop screw set 7 Pilot air screw set 8 Needle jet 9 Main jet 0 Needle valve assembly q Float w Float chamber rubber gasket e Float pivot pin r Float chamber t Fuel drain screw y Carburetor overflow hose u Throttle position sensor http www motorcycle in th ...

Page 214: ... on the hot engine 1 Remove 9battery 9seat assembly with battery box 2 Remove 9starter relay 1 T135SE 3 Remove 9positive lead 1 from the battery box 1 1 4 Remove 9negative lead from the frame 5 Loosen 9rear cowling left Refer to REMOVING THE REAR COWL INGS in chapter 3 http www motorcycle in th ...

Page 215: ...filter assembly bolt 9 Remove 9carburetor top cover 1 9o ring 9choke cable 2 9accelerator pump cable 3 10 Remove 9throttle valve assembly 1 9throttle valve spring 2 11 Remove 9throttle valve 1 9jet needle set 2 9holder 3 cC Do not make a burr when remove the holder 33from throttle valve 11 1 2 3 http www motorcycle in th ...

Page 216: ...loosen the bolts 2 3 1 5 4 14 Remove 9carburetor assembly 13 Disconnect 9fuel hose 1 9carburetor overflow hose 2 9vacuum sensing hose 3 9air vent hose 4 9vacuum sensing hose 5 1 2 15 Remove 9intake manifold bolt 9intake manifold 1 9joint 2 16 Move 9air filter assembly http www motorcycle in th ...

Page 217: ...screw set 1 3 Remove 9throttle stop screw set 1 DISASSEMBLING THE CARBURETOR NOTE The following parts can be cleaned and inspect ed without disassembly 9Coasting enricher 9Throttle stop screw 9Pilot air screw 1 4 Remove 9float chamber 1 9float chamber rubber gasket http www motorcycle in th ...

Page 218: ... 2 6 Remove 9float pivot pin 1 9float 2 9needle valve 3 EAS00485 CHECKING THE CARBURETOR 1 Check 9carburetor body 9float chamber Cracks damage Replace 2 Check 9fuel passages Obstructions 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 http www motorcycle in th ...

Page 219: ...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 5 Check 9float Damage Replace 9 Check 9throttle valve Damage scratches wear Replace http www motorcycle in th ...

Page 220: ...Check 9accelerator pump stuck or unsmooth operation Replace the float chamber 11 Check 9air vent hose 9fuel hoses Cracks damage wear Replace Obstructions Clean Blow out the hoses with compressed air http www motorcycle in th ...

Page 221: ...mber with the gasket removed to the top of the float NOTE The float arm should rest on the needle valve without depressing it c If the float height is not within specification check the needle valve seat and needle valve d If either the needle valve seat or needle valve is worn replace them both e If both the needle valve seat and needle valve are fine adjust the float height by bending the float ...

Page 222: ...5 4 Install 9carburetor assembly 9intake manifold bolts 9clamp screw 5 Install 9throttle valve assembly NOTE 9Align the slit a of the throttle valve with the tab b of the carburetor body 9Be careful to fall off the O ring on the carbure tor top cover when installing the throttle valve assembly 6 Install 9accelerator pump cable 1 9choke cable 2 9o ring 9carburetor top cover 3 10 Nm 1 0 m kg 7 2 ft ...

Page 223: ...e position sensor resis tance Out of specification Replace the throttle position sensor B LLY 2 1 Maximum throttle position sensor resistance 3 7 kΩ at 20 C blue black blue Positive pocket tester probe blue terminal 11 Negative pocket tester probe black blue terminal 22 8 Adjust 9throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the f...

Page 224: ...hin the specified range d After adjusting the throttle position sensor angle tighten the throttle position sensor screws B LLY 2 3 1 B LLY 4 3 Throttle position sensor voltage 0 5 V blue yellow Digital circuit tester 90890 03174 Positive digital circuit tester probe blue terminal 44 Negative digital circuit tester probe yellow terminal 33 Throttle position sensor input volt age 5V at 20 C yellow b...

Page 225: ... COWL INGS in chapter 3 2 Place a container under the end of the fuel hose 1 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 Fuel flows Fuel cock is OK Fuel does not flow Replace the fuel cock http www motorcycle in th ...

Page 226: ... to 700 C AIR CUT OFF VALVE The air cutoff valve is operated by the intake gas pressure through the piston valve diaphragm Normally the air cut off valve is open to allow fresh air to flow into the exhaust port å to During sudden deceleration the throttle valve suddenly closes negative pressure ç is gen erated and the air cutoff valve is closed in order to prevent after burning Additionally at hig...

Page 227: ...CARB AIR INDUCTION SYSTEM 6 15 AIR INDUCTION SYSTEM DIAGRAMS 1 Bend hose air filter case to air cut off valve 2 Air cut off valve 3 AIS resonator 4 Vacuum sensing hose 1 2 3 4 http www motorcycle in th ...

Page 228: ...s damage Replace the reed valve 3 Check 9air cut off valve Cracks damage Replace 2 1 1 2 REMOVING THE AIR INDUCTION SYS TEM 1 Disconnect 9vacuum sensing hose 9bend hose 2 Remove 9air cut cut off valve assembly 1 9reed valve assembly 2 INSTALLING THE AIR INDUCTION SYS TEM 1 Install 9reed valve assembly 1 9air cut cut off valve assembly 2 2 Connect 9vacuum sensing hose 9bend hose 10 Nm 1 0 m kg 7 2 ...

Page 229: ...ING THE FRONTBRAKE CALIPER 7 19 CHECKING THE FRONTBRAKE CALIPER 7 21 ASSEMBLING AND INSTALLING THE FRONTBRAKE CALIPER 7 22 FRONTBRAKE MASTER CYLINDER 7 24 DISASSEMBLING THE FRONTBRAKE MASTER CYLINDER 7 25 CHECKING THE FRONTBRAKE MASTER CYLINDER 7 26 ASSEMBLING AND INSTALLING THE FRONTBRAKE MASTER CYLINDER 7 27 FRONT FORK 7 30 REMOVING THE FRONTFORK LEGS 7 31 DISASSEMBLING THE FRONTFORK LEGS 7 32 C...

Page 230: ...HECKING THE REAR SHOCK ABSORBER ASSEMBLIES 7 52 CHECKING THE SWINGARM 7 53 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 7 53 DRIVE CHAIN AND SPROCKETS 7 55 REMOVING THE DRIVE CHAIN AND SPROCKETS 7 56 CHECKING THE DRIVE CHAIN 7 57 INSTALLING THE DRIVE CHAIN AND SPROCKETS 7 58 http www motorcycle in th ...

Page 231: ...C EASF0044 CHASSIS FRONT WHEELAND BRAKE DISC 1 23 Nm 2 3 m kg 17 ft lb LS LS 40 Nm 4 0 m kg 29 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 http www motorcycle in th ...

Page 232: ...t 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 http www motorcycle in th ...

Page 233: ... 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 0 02 in http www ...

Page 234: ...icle 99 After a tire has been repaired or replaced be sure to tighten the tire air valve stem locknut 11properly 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 prevent damaging the whee...

Page 235: ...lling 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 dial gauge at a right...

Page 236: ...c 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 Brake disc thickn...

Page 237: ...etween the projections on the outer tube 3 Tighten 9wheel axle nut 4 Connect 9speedometer cable 1 NOTE Be sure that slit a on the speedometer cable meshes with the projection b on the speedome ter gear unit 2 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...

Page 238: ...30 Nm 3 0 m kg 22 ft lb 0 0 8 LS 4 7 y 9 1 3 2 5 6 q LS w e r LS 1 Collar 2 Brake camshaft 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 puller left t Rear wheel axle y Brake rod http www motorcycle in th ...

Page 239: ...suitable stand so that the rear wheel is elevated 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 9chain puller adjusting nuts left and right 2 h...

Page 240: ...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 http www motorcycle in th ...

Page 241: ...move 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 FRONTWHEELAND BRAKE DI...

Page 242: ...G THE TIRES in chap ter 3 3 Measure 9radial wheel runout 9lateral wheel runout Refer to FRONTWHEELAND BRAKE DISC EAS00567 CHECKING THE REAR WHEELDRIVE HUB 1 Check 9rear wheel drive hub Cracks damage Replace 9rear wheel drive hub dampers Damage wear Replace http www motorcycle in th ...

Page 243: ...il or grease to contact the brake shoes NOTE Replace the brake shoes as a set if either is worn to the wear limit 3 Measure 9brake drum inside diameter a Out of specification Replace the wheel 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 Check 9brake...

Page 244: ...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 1 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 NOTE Press ...

Page 245: ...lack Refer to ADJUSTING 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 Drive chain slack 25 35 mm 0 98 1 38 in 60 Nm 6 0 m kg 43 ft lb http www motorcycle in th ...

Page 246: ... 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 http www motorcycle in th ...

Page 247: ...s 99 Use only clean or new brake fluid for clean ing brake components 99 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 99 Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES 99 Flush with water for 15 minutes and get immediate medical attention EAS00581...

Page 248: ...e 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 Brake pad wear l...

Page 249: ...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 Lithium soap based gre...

Page 250: ... 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 99 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton are expelled from the brake caliper 99 Never try to pry out the brake caliper piston b Remove t...

Page 251: ...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 piston seals 2 Check 9...

Page 252: ...r 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 11 make sure the brake pipe aa touches the projection bb on the brake caliper 2 Remove 9brake caliper 3 Install 9brake pad springs 9brake pads 9brake pad retaining pin 9brake caliper Ref...

Page 253: ...r 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 6 Bleed 9brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 7 Check 9brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper lev...

Page 254: ...g 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 http www motorcycle in th ...

Page 255: ...owling Refer to REMOVING THE SIDE COWL INGS and REMOVING THE FRONT COWLING in chapter 3 9headlight assembly Refer to REMOVING THE HEADLIGHT ASSEMBLY in chapter 3 2 Remove 9union bolt 1 9copper washers 2 9brake hose NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove 9brake master cylinder assembly 1 4 Remove 9brake light swit...

Page 256: ...inder reservoir diaphragm3 7 Remove 9brake hose 1 9brake hose clamp 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 http www motorcycle in th ...

Page 257: ...NDER w 99 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid 99 Never use solvents on internal brake com ponents 1 Install 9brake master cylinder 1 NOTE 9Install the brake master cylinder holder with the mark facing up 9Adjust the brake master cylinder to the proper angle 9First tighten the upper bolt then the lower bolt Recommended br...

Page 258: ... Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance 99 Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance 99 When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower th...

Page 259: ...brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check 9brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 http www motorcycle in th ...

Page 260: ...RONT FORK 23 Nm 2 3 m kg 17 ft lb 1 43 Nm 4 3 m kg 31 ft lb 5 6 9 8 4 3 2 7 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 http www motorcycle in th ...

Page 261: ...ger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Remove 9side cowlings left and right 9front cowling 9center panels 9inner panel Refer to COVERS in chapter 3 3 Remove 9brake caliper assembly 9brake hose clamp Refer to FRONTBRAKE 9front wheel Refer to FRONTWHEELAND BRAKE DISC 4 Remove 9front fender bolts 9washers 9collars 9front fender 1 http w...

Page 262: ...e front fork leg 7 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 http www motorcycle in th ...

Page 263: ... damper rod assembly with a 10 mm hexagon nut socket wrench 1 and the T handle 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 http www motorcycle in th ...

Page 264: ...th 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 99 The 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 99 When disassembling and assembling the front fork leg do not allow any foreign material to ...

Page 265: ...eg 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 22until 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 assembly bolt 1 ...

Page 266: ...OTE 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 handle 90890 013...

Page 267: ...s 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 0 064 L 2 26 Imp oz 2 16 US oz Recommended oil Fork oil 10W or equivalent Front fork leg o...

Page 268: ...RONT FORK 7 38 3 Install 9front fender 4 Install 9front wheel Refer to FRONTWHEELAND BRAKE DISC 9brake hose clamp 9brake caliper assembly Refer to FRONTBRAKE 10 Nm 1 0 m kg 7 2 ft lb http www motorcycle in th ...

Page 269: ...3 Nm 2 3 m kg 17 ft lb 1 2 3 4 5 6 7 8 8 9 0 9 1 Rear view mirror left and right 2 Throttle grip 3 Throttle housing 4 Master cylinder 5 Handlebar 6 Left handlebar switch 7 Handlebar grip 8 Starter cable 9 Throttle cable 0 Handlebar bracket http www motorcycle in th ...

Page 270: ...er to REMOVING THE FRONTCOWL INGS in chapter 3 9headlight assembly Refer to REPLACING THE HEADLIGHT BULBS in chapter 3 3 Disconnect 9meter assembly couplers 1 9right handlebar switch coupler 2 9left handlebar switch coupler 3 9front brake light switch connectors 4 4 Disconnect 9speedometer cable 1 9choke cable 2 5 Remove 9speedometer assembly 3 6 Remove 9rear view mirrors left and right 9brake mas...

Page 271: ... holder 1 8 Remove 9throttle cable 1 9throttle grip 2 9 Remove 9grip end 1 10 Remove 9handlebar grip 1 NOTE Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar http www motorcycle in th ...

Page 272: ...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 http www moto...

Page 273: ...bber adhesive with a clean rag w Do not touch the handlebar grip until the rub ber adhesive has fully dried 5 Install 9throttle grip 1 9throttle cable 2 9throttle housing NOTE Lubricate the inside of the throttle grip with a thin coat of lithium soap based grease and install it onto the handlebar 6 Install 9lever holder 1 NOTE Align the projection a on the right handlebar switch with the hole in t...

Page 274: ...9plastic locking ties Refer to CABLE ROUTING in chapter 2 9 Adjust 9throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 7 mm 0 12 0 28 in 11 Nm 1 1 m kg 8 0 ft lb http www motorcycle in th ...

Page 275: ...0 m kg 22 ft lb 2nd 75 Nm 7 5 m kg 54 ft lb LS 1 43 Nm 4 3 m kg 31 ft lb LS 2 3 4 5 6 6 7 4 8 1 Upper ring nut 2 Lower ring nut 3 Ball race cover 4 Bearing inner race 5 Upper bearing 6 Bearing outer race 7 Lower bearing 8 Lower bracket http www motorcycle in th ...

Page 276: ... 3 9front fork Refer to FRONTFORK 9handlebar Refer to HANDLEBAR 3 Remove 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 0...

Page 277: ...ce 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 cracks damage...

Page 278: ...te 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 FRONTFORK Recommended lubricant Lithium soap based grease http www motorcycle in th ...

Page 279: ...R SHOCK ABSORBER ASSEMBLYAND SWINGARM 46 Nm 4 6 m kg 33 ft lb LS 46 Nm 4 6 m kg 33 ft lb 66 Nm 6 6 m kg 48 ft lb 1 2 3 4 4 5 6 1 Rear shock absorber 2 Brake torque rod 3 Swingarm 4 Bushing 5 Swingarm pivot shaft 6 Drive chain case http www motorcycle in th ...

Page 280: ... of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove 9center panel 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 WHEELAND BRAKE 1 3 Remove 9drive chain case bolts 9drive chain case 1 1 4 Remove 9cotter pin 9washer 9brake torque rod 1 h...

Page 281: ...que 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 side play at the end of...

Page 282: ...SEMBLIES 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 http www motorcycle in th ...

Page 283: ...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 http www motorcycle in th ...

Page 284: ...ear shock absorber bolts 4 Install 9brake torque rod to swingarm 5 Install 9drive chain case 6 Install 9rear wheel Refer to REAR WHEELAND 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 66 Nm 6 6 m kg 48 ft lb 46 Nm 4 6 m kg 33 ft lb 16 Nm 1 6 m kg 12 ft lb 10 Nm 1 0 m kg 7 2 ft lb http www motorcycle in th ...

Page 285: ... 7 Nm 0 7 m kg 5 0 ft lb 30 Nm 3 0 m kg 20 ft lb LS 7 1 2 3 4 6 5 8 q 9 0 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 http www motorcycle in th ...

Page 286: ... a suitable stand so that the rear wheel is elevated 2 Remove 9rear wheel 9rear wheel drive hub assembly Refer to REAR WHEELAND BRAKE 2 1 3 Remove 9shift pedal bolt 9shift pedal 1 9drive sprocket cover bolts 9drive sprocket cover 2 4 Remove 9master link clip 1 9master link plate 2 9master link body 3 5 Remove 9drive chain 1 2 6 Remove 9sprocket holder bolt 9drive sprocket holder 1 9drive sprocket ...

Page 287: ...uter 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 9drive chain a Wipe the ...

Page 288: ...eth 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 bolt Recommende...

Page 289: ... chain onto worn drive chain sprockets this will dramatically shorten the drive chains life 7 Adjust 9drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 cC Adrive 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 chain slack within the speci fied limits...

Page 290: ...CHAS http www motorcycle in th ...

Page 291: ...OOTING 8 16 STARTER MOTOR T135SE 8 18 REMOVING THE STARTER MOTOR 8 19 DISASSEMBLING THE STARTER MOTOR 8 19 CHECKING THE STARTER MOTOR 8 19 ASSEMBLING THE STARTER MOTOR 8 21 INSTALLING THE STARTER MOTOR 8 21 CHARGING SYSTEM 8 22 CIRCUITDIAGRAM 8 22 TROUBLESHOOTING 8 23 LIGHTING SYSTEM 8 25 CIRCUITDIAGRAM 8 25 TROUBLESHOOTING 8 26 CHECKING THE LIGHTING SYSTEM 8 27 SIGNALING SYSTEM 8 30 CIRCUITDIAGRA...

Page 292: ...ELEC http www motorcycle in th ...

Page 293: ... 1 Ignition coil 2 Main switch 3 Rear brake light switch 4 Negative battery lead 5 Battery 6 Positive battery lead T135SE 7 Positive battery lead T135S 8 Fuse 9 Wire harness 1 2 3 4 5 6 7 8 9 ELEC ELECTRICALCOMPONENTS 8 1 http www motorcycle in th ...

Page 294: ...RICALCOMPONENTS 8 2 1 Horn 2 Turn signal relay 3 Starter relay T135SE 4 Fuel gauge 5 Rectifier regulator 6 Fan motor relay 7 Neutral switch 8 Thermo sensor 9 C D I unit 2 1 3 4 5 6 7 8 9 http www motorcycle in th ...

Page 295: ...ter 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 illustration NOTE 1 ...

Page 296: ...ELEC CHECKING SWITCH CONTINUITY 8 4 http www motorcycle in th ...

Page 297: ...7 8 9 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 8 5 http www motorcycle in th ...

Page 298: ... 6 CHECKING THE 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 Front brake light switch 9 Main switch http www motorcycle in th ...

Page 299: ... 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 pushing and turni...

Page 300: ...ncy 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 probe to termi ...

Page 301: ...uity 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 03112 http www ...

Page 302: ...W B L G R G R G W B Br G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH B r W Ch B Dg L B W Y Y P B Y R B r W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L L Br Br 1 2 3 4 5 6 ...

Page 303: ...mittent spark EAS00738 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...

Page 304: ...resistance 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 specification YES N...

Page 305: ...Negative tester probe terminal 11 Positive tester probe spark plug lead 22 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 11 Negative te...

Page 306: ...9Check the entire ignition system wiring Refer to CIRCUITDIAGRAM 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 http www motorcycle in th ...

Page 307: ... G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH B r W Ch B Dg L B W Y Y P B Y R B r W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L L Br Br L W R Br R W L W R Br R W 1 2 3 4 ...

Page 308: ...itch 6 start switch 7 wiring connections of the entire starting system NOTE 9Before troubleshooting remove the following part s 1 side cowlings left and right 2 front cowling 3 center panels upper and lower 4 rear cowlings left and right 5 inner panel 9Troubleshoot with the following special tool s EAS00739 2 Battery 9Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in...

Page 309: ...Replace the starter relay R R W 3 4 2 1 L W R Br R W L W R Br 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 CIRCUITDIAGRAM 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 CHECKING THE S...

Page 310: ...ELEC STARTER MOTOR T135SE 8 18 EASF0061 STARTER MOTOR T135SE 1 Starter motor yoke 2 Armature 3 Brush set 4 Starter motor lead 5 Starter motor front cover 1 2 3 5 4 http www motorcycle in th ...

Page 311: ...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 9O ring 2 9armature 3 EAS00769 CHECKING THE STARTER MOTOR 1 Check 9commutator Dirt Clean with 600 grit sandpaper 1 http www motorcycle in th ...

Page 312: ...e 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 Armature coil Co...

Page 313: ...00772 ASSEMBLING THE STARTER MOTOR 1 Install 9O ring 9armature in start motor front cover 1 9O ring 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 in Brush spring f...

Page 314: ...Br L W B B L W L W B L G R G R G W B Br G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH B r W Ch B Dg L B W Y Y P B Y R B r W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L L B...

Page 315: ...r panel 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 the battery OK YES NO 9Clean the battery terminals 9Recharge or replace the bat tery 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 ...

Page 316: ... 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 11 Negative tester probe black 22 9Measure the charging coil resistances 9Is the charging coil OK YES NO W B Y RW 1 2 EAS00779 5 Wiring 9Check the wiring connections of the entire charging system ...

Page 317: ... Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH B r W Ch B Dg L B W Y Y P B Y R B r W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L L Br Br 1 2 3 4 5 6 7 8 9 0 q w e r y t u i p o ...

Page 318: ... coil resistance 9Disconnect the stator coil coupler from the wire harness 9Connect the pocket tester Ω 1 to the lighting coil terminals as shown Positive tester probe yellow 11 Negative tester probe black 22 9Measure the lighting coil resistances 9Is the lighting coil OK YES NO W B Y RW 1 2 EAS00787 2 Wiring 9Check the entire lighting system wiring Refer to CIRCUITDIAGRAM 9Is the lighting system ...

Page 319: ...socket or both 3 Voltage 9Connect the pocket tester AC 20 V to the headlight and high beam indicator light con nectors as shown å When the dimmer switch is set to When the dimmer switch is set to Headlight Positive tester probe green 11or yellow 22 Negative tester probe black 33 High beam indicator light Positive tester probe yellow 44 Negative tester probe black 55 9Set the main switch to ON 9Sta...

Page 320: ...light coupler wire harness side as shown Positive tester probe blue 11 Negative tester probe black 22 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 9Connect the po...

Page 321: ...ket or both 2 Voltage 9Connect the pocket tester AC 20 V to the auxiliary light coupler wire harness side as shown Positive tester probe blue 11 Negative tester probe black 22 9Set the main switch to ON 9Start the engine 9Measure the voltage AC 12 V of blue lead terminal 1 on the auxiliary light coupler wire harness side 9Is the voltage within specification B Dg Dg B L L Ch Ch B B L L 1 1 L R YES ...

Page 322: ...R O O W Y R B Y B W Br L W Br L W B B L W L W B L G R G R G W B Br G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH B r W Ch B Dg L B W Y Y P B Y R B r W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G ...

Page 323: ... f Turn signal switch g Tail brake light h Rear turn signal light j Front turn signal light z Fuel gauge x Fuel sender c Neutral switch n Turn signal indicator light m Neutral indicator light 1st gear position indicator light 2nd gear position indicator light 3rd gear position indicator light 4th gear position indicator light http www motorcycle in th ...

Page 324: ...3 9Is the battery OK YES NO 9Clean the battery terminals 9Recharge or replace the bat tery Pocket tester 90890 03112 Minimum open circuit voltage 12 8 V or more at 20 C 68 F 99 Any of the following fail to light turn sig nal light brake light or an indicator light 99 The horn fails to sound Replace the main switch EAS00783 3 Main switch 9Check the main switch for continuity Refer to CHECKING THE S...

Page 325: ... 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 11 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 wiring circuit f...

Page 326: ... 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 brake light bulb...

Page 327: ...G 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 11 Negative tester probe ground 9Set the main switch to ON 9Measure the voltage DC 12 V on brown lead terminal 1 at the turn signal relay co...

Page 328: ...obe ground Positive tester probe dark green 44 Negative tester probe ground B Ch L Dg Y L Dg B G Y Ch 21 4 Voltage 9Connect the pocket tester DC 20 V to the turn signal relay coupler as shown Positive tester probe brown white 11 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 coupler 9Is the voltage withi...

Page 329: ... 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 lead terminal ...

Page 330: ...Shift the transmission into each gear 9Measure the 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 ELEC 8 38 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 EAS00804 5 The f...

Page 331: ...GB Ch Dg B Br Ch L G 1 ELEC 8 39 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 least three min...

Page 332: ... Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH B r W Ch B Dg L B W Y Y P B Y R B r W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L L B B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L L Br Br 1 2 3 4 5 6 7 8 9 0 q w e r y t u i p o a ...

Page 333: ...ity 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 bat tery Pocket tester 90890 03112 Digital circuit tester 90890 03174 Minimum open circuit voltage 12 8 V or more at 20 C 68 ...

Page 334: ...aced B L 2 1 5 Radiator fan motor relay 9Disconnect the radiator fan motor relay cou pler 9Connect the pocket tester to the radiator fan motor relay coupler relay side as shown Battery positive lead brown 11 Battery negative lead white yellow 22 Positive tester probe brown 33 Negative tester probe blue 44 9Check the radiator fan motor relay blue and brown for continuity 9Does the coupler is OK YES...

Page 335: ...ensor with special care 99 Never subject the thermo sensor to strong shocks If the thermo sensor is dropped replace it 9Does the thermo sensor operate properly as described above 1 3 2 YES NO Replace the thermo sensor Tighten the thermo sensor to specified torque EAS00795 7 Wiring 9Check the entire signaling system wiring Refer to CIRCUITDIAGRAM 9Is the signaling system wiring properly con nected ...

Page 336: ...s run ning or not Item Condition Response Display condition code 9Enables the vehicle to run so that the ignition timing is fixed when the throttle is fully opened 9Displays the condition code on the coolant temperature warning indicator light 9Enables the vehicle to run so that the ignition timing is fixed 9Displays the condition code on the coolant temperature warning indicator light Throttle po...

Page 337: ... 2 å Repetition 1 3 4 1 3 seconds 2 1 second 3 1 5 seconds 4 0 5 seconds 5 0 5 seconds å Light on Light off When more than one item is being monitored 2 3 4 5 1 å Repetition 2 3 4 5 2 Light on seconds 1 scond 3 Light off seconds 1 5 sconds 4 Light on seconds 0 5 sconds 5 Light off seconds 0 5 sconds 6 1 cycle Fault code 1 7 1 cycle Fault code 2 1 1 Light off seconds 3 sconds 7 6 Fault code http ww...

Page 338: ...2 The coolant temperature warning indicator light starts to display the self diagnosis sequence 1 Throttle position sensor CIRCUITDIAGRAM 0 C D I unit e Throttle position sensor BLACK BLACK BLACK Br Br L Y W B B B O O B L G R G R G W B W Y Y B L B L LY L P W Br B O W W B L B L R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R Br Br 9 0 w e r y t 2 Throttle position sensor 9Check the throttle p...

Page 339: ...L R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R Br Br 9 0 e r y t 1 Wireharness 9Check the wireharness for continuity Refer to CIRCUITDIAGRAM 9Is the wireharness OK YES NO Repair or replace the wireharness 2 Thermo sensor 9Check the thermo sensor Refer to COOLING SYSTEM 9Is the thermo sensor OK YES NO Replace the thermo sensor Replace the C D I unit http www motorcycle in th ...

Page 340: ...ELEC http www motorcycle in th ...

Page 341: ...TRBL SHTG CHAPTER 9 TROUBLESHOOTING TROUBLESHOOTING 9 1 ELECTRICALSYSTEM 9 1 COMPRESSION SYSTEM 9 2 INTAKE AND EXHAUSTSYSTEM 9 3 http www motorcycle in th ...

Page 342: ...TRBL SHTG http www motorcycle in th ...

Page 343: ...aulty 8 Spark plug cap is faulty C D I unit 8 C D I unit is broken CHARGING COIL see page 8 24 PICKUPCOIL see page 8 13 8 Windings are broken SPARK PLUG 8 Wet carbon deposits 8 Electrodes 8 Improper gap 8 Broken EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICALSYSTEM STARTER MOTOR see page 8 18 8 Starter motor is broken or faulty 8 Starter relay is broken 8 Starter switch is broken http www moto...

Page 344: ...COMPRESSION SYSTEM WEAR SCRATCH DAMAGE WEAR STUCK BROKEN DAMAGE DAMAGE WEAR SCRATCHES INSUFFICIENT TIGHTENING TORQUE INSUFFICIENT TIGHTENING TORQUE WEAR CARBON DEPOSITS DAMAGE INSUFFICIENT TIGHTENING TORQUE http www motorcycle in th ...

Page 345: ... idling and starting NEEDLE VALVE ASSEMBLY 8 Wear PILOT JET 8 Clogged low speed FLOAT CHAMBER 8 Accumulated dust and or water FLOAT 8 Incorrect fuel level adjustment 8 Puncture MAIN JET 8 Incorrect size 8 Clogged high speed PILOT AIR SCREW 8 Improperly adjusted idling and starting EXHAUST PIPE 8 Cracked or broken 8 Carbon deposits SILENCER 8 Clogged NEEDLE SET 8 Improperly adjusted medium speed ht...

Page 346: ...TRBL SHTG http www motorcycle in th ...

Page 347: ...http www motorcycle in th ...

Page 348: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN http www motorcycle in th ...

Page 349: ...R B Y B W Br L W Br L W B B L W L W B L G R G R G W B Br G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg LG Y P B Y G G Y Y P HI LO OFF PUSH Br W Ch B Dg L B W Y Y P B Y R Br W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L BL Y Ch Dg G Y Dg B L Ch R W W R B L B L LY G B L P W Br B O Y R Y R Y R W W R R W Br R B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L...

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