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ENG

L-128

ENGINE ASSEMBLY AND ADJUSTMENTS

4-56

Cylinder head Installation

1. Install

• Dowel Pins ¿

New

• Gasket ( Cylinder Head) À

New

• Guide Stopper#1 Á

4. Install :

• Piston Rings ¿

NOTE :

Offset the Piston Rings end gaps as shown.

ç Top Ring End

è Oil Ring end (lower)

é Oil Ring End (upper)

ê 2nd Ring End

5. Lubricate :

• Piston outer surface

• Piston Rings

• Cylinder Inner Surface

6. Install :

• Cylinder ¿

NOTE :

• Install the Cylinder with one hand while com-

pressing the Piston Rings with the other hand

• Pass the Timing Chain and Guide stopper # 2

through the Timing Chain Cavity.

• Press the Piston down to rest on Piston Base

YSST - 604

Piston Base

YSST - 604

Содержание Libero

Страница 1: ...WORKSHOP MANUAL...

Страница 2: ...anding of mechanical concepts and procedures inherent to Motorcycle repair technology Without such knowledge attempted repairs or service of this model may render it unfit for use and or unsafe Yamaha...

Страница 3: ...ge 2nd title 2 This title indicates the Section of the chapter and only appears on the first page of each section It is located in the centre of the page 3rd title 3 This title indicates a Subsection...

Страница 4: ...on and adjustment 4 Engine 9 Filling fluid 11 Special Tool 15 Resistance Voltage Current 12 Torque 13 Wear Limit Clearance 10 Lubricant 14 Engine speed Illustrated symbols 9 to 15 are used to identify...

Страница 5: ...4 INDEX GENERAL INFORMATION GEN INFO 1 TROUBLE SHOOTING TRBL SHTG 8 ELECTRICAL ELEC 7 CHASSIS CHAS 6 CARBURETION CARB 5 ENGINE ENG 4 PERIODIC INSPECTION AND ADJUSTMENTS INSP ADJ 3 SPECIFICATIONS SPEC...

Страница 6: ...NUMBER 1 1 IMPORTANT INFORMATION PREPARATION FOR DISASSEMBLY 1 2 ALL REPLACEMENT PARTS 1 3 GASKETS OIL SEALS AND O RINGS 1 3 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS...

Страница 7: ...nd sepecifications are subject to change without notice MOTORCYCLE IDENTIFICATION MOTORCYCLE IDENTIFICATION Do not tamper with any of these numbers It may lead to legal action Year of Production 2 Dig...

Страница 8: ...cludes gears Cylinder Piston and other mated parts that have been mated through normal wear Mated parts must be reused as an assem bly or replaced 4 During the Motorcycle disassembly clean all parts a...

Страница 9: ...l lips and O rings contact must be cleaned and Lubricated LOCK WASHERS PLATES AND COTTER PINS 1 All Lock Washers plates and Cotter Pins must be replaced when they are removed Lock tab s should be bent...

Страница 10: ...when re moving or installing the Magneto Securing Nut 1 Magnet o Holder This tool is used to adjust Valve clear ance 5 Valve Clearance Adjusting Tool YSST 606 This tool is used to replace Piston Pin...

Страница 11: ...ew Driver small YSST 609 This tool is used to hold the Driving Sprocket when removing or installing Driving Sprocket Nut 11 Driving Sprocket Holder YSST 605 This tool is used to loosen or tighten the...

Страница 12: ...eedometer Gear Nut YSST 237 This tool is used to adjust spring preload of Rear Shock Absorbers 17 Rear Shock Absorber Adjuster YSST 221 This fixture is used to hold the Engine for its disassembly and...

Страница 13: ...r 0 25 mm 50 75 mm 7 CO Gas Analyser 8 Hydrometer This instrument is used for checking ignition timing This instrument is used for checking the engine compression This instrument is used for checking...

Страница 14: ...tool is used to tighten the Nuts Bolts at a specified torque This instrument is used to check clear ance gaps between parts SPECIAL SERVICE MATERIAL The following Service material are necessary to use...

Страница 15: ...IONS 2 1 MAINTENANCE SPECIFICATIONS ENGINE 2 4 CHASSIS 2 10 ELECTRICAL 2 13 GENERAL TORQUE SPECIFICATIONS 2 15 LUBRICATION POINTS AND LUBRICANT TYPE ENGINE 2 16 CHASSIS 2 17 ENGINE LUBRICATION ROUTE 2...

Страница 16: ...nclined single cylinder Displacement 105 6 cm Bore X Stroke 49 X 56 mm Compression ratio 9 1 Starting system Kick starter Lubrication system Wet sump Max power 7 6 BHP 7500 RPM Torque 8 Nm 6000 rpm Oi...

Страница 17: ...ype Double cradle Caster angle 26 4 Trail 83 mm Tyre Type With tube Size Front 2 50 18 4 PR Rear 2 75 18 6 PR Manufacturer Front LOCAL MADE Rear LOCAL MADE Type Front RIB TYPE Rear RIB LUG TYPE Tyre p...

Страница 18: ...ring Oil damper Wheel travel Front wheel travel 110 mm Rear wheel travel 70 mm Electrical Ignition system CDI Digital Generator system Flywheel magneto Battery type LOCAL MADE Battery capacity 12V 2 5...

Страница 19: ...p ring Type Barrel Dimensions B x T 1 0 x 1 95 mm End gap installed 0 10 0 25 mm Limit 0 35mm Side clearance installed 0 030 0 065 mm Limit 0 115m 2nd ring Type Taper Dimensions B x T 1 0 x 1 9 mm End...

Страница 20: ...t Inside diameter Rocker Arm 10 000 10 015 mm Limit 10 03 mm Outside diameter Rocker Armshaft 9 981 9 991 mm Limit 9 95 mm Cam chain Cam chain type No of links BUSH CHAIN 90 Cam chain adjustment metho...

Страница 21: ...Valve spring Free length IN 39 62 mm EX 39 62 mm Limit IN 38 17 mm EX 38 17 mm Set length valve closed IN 25 6 mm EX 25 6 mm Tilt limit IN 2 5 1 7 mm EX 2 5 1 7 mm Compression pressure installed IN 1...

Страница 22: ...DP19 2 Needle jet N J E OM 860 Cut away C A 3 0 Pilot outlet P O 1 1 Pilot jet P J 12 5 Valve seat size V S 1 5 Starter jet G S 1 30 Fuel level with special tool F L 2 5 0 5 mm Above the Joint Line of...

Страница 23: ...3 6 Intake Manifold Bolt M6 2 10 1 0 7 2 Carburetor Joint Manifold Bolt M6 2 10 7 2 7 2 Carburetor Joint Air filter Screw M4 1 2 0 2 1 5 Air filter Case Bolt M6 2 7 0 7 5 1 Muffler Cylinder Head Bolt...

Страница 24: ...hand t TIGHTENING TORQUE ENGINE Part to be tightened Parts name Thread size Q ty Tightening torque Remark Nm m kg ft lb Shift Pedal Bolt M6 1 10 1 0 7 2 Segment Screw M6 1 12 1 2 9 Torx Bolt Stopper l...

Страница 25: ...grade Special YAMAHA oil Rear suspension Shock Absorber travel 70 mm Spring free length 205 4 mm Fitting length 197 4 mm Spring rate K1 18 6 N mm K2 27 8 N mm Stroke K1 0 40 mm K2 40 70 mm Swingarm Fr...

Страница 26: ...ng free length 36 5mm Rear drum brake Type Leading Trailing Brake Drum inside diameter 130mm Wear limit 131 Lining Thickness 4 0 mm Wear limit 2 mm Shoe spring free length 36 5 mm Free Plays Brake Lev...

Страница 27: ...QUE CHASSIS MAINTENANCE SPECIFICATIONS Note 1 First tighten the Ring Nut approximately 45 5 Nm 4 55 m kg 32 3 ft lb by using the torque wrench then loosen the Ring Nut one turn 2 Retighten the Ring Nu...

Страница 28: ...Model Manufacturer 5KA DENSO Charging Voltage 14 15V 5000 RPM Charging Coil Resistance 0 82 20 68 F Lighting Lighting Voltage Min 12V 3 000 r min Max 15V 8 000 r min Lighting Coil Resistance 0 62 20 6...

Страница 29: ...SPEC L 28 MAINTENANCE SPECIFICATIONS Circuit Breaker Type Fuse Amperage for individual circuit X quantity Main 10A X 1pc Reserve 10A X 1pc 2 14...

Страница 30: ...semblied in a criss cross fashion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Components should be at room temperatur...

Страница 31: ...Valve Stem End Rocker Arm Shaft and Rocker Arm Cam and Bearing Camshaft Push Rod Primary Driven Gear and Main Axle Push Lever Axle Rotary Filter and Oil Pump Sliding Gear Transmission Kick Axle Shaft...

Страница 32: ...l Seal Lips all Pivot Shaft Swingarm Pivoting Points Brake Pedal Shaft and Frame Ball and Ball Race Steering Head Tube Guide Right Grip Pivoting points Brake Lever and Clutch Lever Pivoting Point Brak...

Страница 33: ...SPEC L 32 ENGINE LUBRICATION ROUTE Engine Lubrication route 2 18 WARNING CAUTION DO NOT DAMAGE CRANK CASE SURFACES OTHERWISE OIL LEAKAGE WILL START...

Страница 34: ...SPEC R 33 ENGINE LUBRICATION ROUTE Engine Lubrication route 2 19 WARNING CAUTION FOR IMPROVED PERFORMANCE ALWAYS USE YAMALUBE OIL...

Страница 35: ...SPEC L 34 ENGINE BEARINGS ENGINE BEARINGS 2 20...

Страница 36: ...ING Flasher light lead left Horn Flasher light lead right A Pass the Clutch Cable and the Handle bar Switch Lead through the cable guide of the left side B Pass the Throttle Cable and the Brake Cable...

Страница 37: ...Align the white marking of wireharness with the frame clamp D Tighten the battery negative lead and th ground lead of the wireharness together E Pass the battery breather hose through the hole of the...

Страница 38: ...utch cable Breather hose A Pass the high tension cord through the cable guide to the inside of throttle cable and the clutch cable B Tighten the ground lead and ignition coil to gether C Pass the thro...

Страница 39: ...ING Clamp Rectifier regulator Flasher relay Flasher light lead A Clamp the battery positive lead to the batterybox B Insert hose Air Bent to holder of frame B A Stop tail light lead Wireharness Batter...

Страница 40: ...3 13 ENGINE OIL LEVEL INSPECTION 3 14 ENGINE OIL REPLACEMENT 3 14 AIR FILTER CLEANING 3 16 CLUTCH CABLE ADJUSTMENT 3 17 CHASSIS FRONT BRAKE ADJUSTMENT 3 18 REAR BRAKE ADJUSTMENT 3 18 BRAKE SHOE INSPE...

Страница 41: ...d Choke Lever operation Tune if necessary Clean inspect lubricate replace if necessary Check Fuel Hose for cracks or damage Replace if necessary FRONT FORKS STEERING RACE BALL WHEEL BEARING WHEELS REA...

Страница 42: ...if necessary Clean and lubricate Check all Chassis fittings and fasteners for looseness Tighten as per specification Check operation and lubricate if necessary Check electrolyte level and top it up w...

Страница 43: ...over towards the rear end of the Motorcycle for removing the Lug from the Chassis SIDE COVERS SEAT AND FUEL TANK SIDE COVERS SEAT AND FUEL TANK 3 3 1 2 3 1 2 3 REMOVAL SIDE COVER RH 1 Remove Side Cove...

Страница 44: ...ion the Fuel Cock to the OFF dis connect the Fuel Hose Place a rag under the Fuel Line to absorb any spilt fuel REMOVAL SEAT 1 Remove Side Cover LH and RH Bolts 2 Nos Seat Removal steps Open bolts and...

Страница 45: ...OTE Keep the projection on plate downward 2 Install Seat Bolts and NOTE Insert the projection on the rear of the seat into the receptacles on the Chassis then push down front of the seat and tighten t...

Страница 46: ...on Cam Sprocket should be aligned with the marking on Cylinder Head ENGINE 3 6 1 Remove Side Covers Seat Fuel Tank Refer to SIDE COVERS SEAT AND FUEL TANK section Page no 3 3 2 Remove Spark Plug Bolt...

Страница 47: ...nce 5 Adjust Valve clearance Adjustment steps Loosen the Locknut Turn the Adjuster in or out with the Valve adjusting tool until specified clearance is obtained Hold the Adjuster to prevent it from mo...

Страница 48: ...Engine idle RPM always check throttle cable free movement and free play 4 Insert Sampling probe CO tester to the exhaust pipe Out of specification Adjust 3 8 Turning IN Increasing in rpm Turning OUT D...

Страница 49: ...djusting CO concentration as specified remove the CO tester make sure that the Engine idling speed has not changed THROTTLE CABLE ADJUSTMENT NOTE Prior to adjusting the Throttle Cable free play the En...

Страница 50: ...rmal color is medium to light tan color 4 Clean Spark Plug with Spark Plug cleaner or wire brush 5 Measure Spark Plug gap with a wire gauge Out of specification Adjust gap 3 10 Turning IN Free play is...

Страница 51: ...orque is to finger tighten the Spark Plug and then tighten it another 1 4 to 1 2 turn to using Box Spanner IGNITION TIMING CHECKING PROCEDURE NOTE Prior to checking the ignition timing check all elect...

Страница 52: ...e 4 Check Auto advance mechanism Checking steps Increase the Engine speed from 1400 r min to 2250 r min Check the stationery pointer should be within the ignition timing range marked on the Rotor Asse...

Страница 53: ...s and Piston Crown for carbon deposits If it is below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again Follow the table Measurement steps Crank the Engine wi...

Страница 54: ...Dip Stick Oil Level Gauge 5 Inspect Engine oil level Oil level should be between maximum and minumim marks Oil level is below the minimum mark Add oil up to the proper level RECOMMENDED ENGINE OIL NO...

Страница 55: ...se Damage Tighten replace Gasket Exhaust Pipe Exhaust gas leaks Tighten replace 2 Inspect Bolt Muffler Loose Damage Tighten replace 3 Inspect Screw Muffler Protector Loose damage Tighten replace AIR F...

Страница 56: ...t Guide 6 Install Air Filter Element Assy Spring Wire Air Filter Case Cap Side Cover R H 3 16 WARNING CAUTION Never operate the Engine without the Air Filter element installed Unfiltered air will caus...

Страница 57: ...utch Lever end then adjust it by using Adjuster below the Fuel Tank Below the Fuel Tank Remove Side Covers Seat and Fuel Tank Detach Clutch Cable from Push Lever Loosen the Locknut Turn the adjuster i...

Страница 58: ...ith Adjuster on the Wheel end of the Front Brake Cable Wheel side Loosen the Locknut Turn the Adjuster in or out until the speci fied free play is obtained Tighten the Locknut CHASSIS 3 18 Turning in...

Страница 59: ...al 2 Inspect Brake shoes Wear indicator reaches the wear limit line Replace the brake shoes as a set Refer to FRONT WHEEL and REAR WHEEL in CHAPTER 6 page no 6 6 BRAKE LIGHT SWITCH ADJUSTMENT NOTE The...

Страница 60: ...ormal noise and will affect the life of chain sprock ets and low fuel efficiency 1 Stand the Motorcycle on its center stand 2 Check Drive chain slack a Out of specification Adjust 3 Remove Cotter pin...

Страница 61: ...here are marks on swing arm and mark on chain adjuster Ensure that left hand and right hand chain alignment marks are equally matched Use them when adjusting the slack for proper alignment Before tigh...

Страница 62: ...the lower Front Fork tubes and gently rock the Fork Assembly Looseness Adjust the Steering Head 4 Remove Bands Bolts Handlebar Upper holders Handlebar upper holders Handlebar lower holders Handlebar H...

Страница 63: ...ligned Install the Lock Washer NOTE Make sure the lock washer tab is placed in the slots 6 Install Handle crown with Spacer Handle Crown bolt Handlebar Lower Holder Handlebar Handlebar upper holder Bo...

Страница 64: ...on Repair Refer to FRONT FORK in Chapter 6 Page no 6 21 REAR SHOCK ABSORBER ADJUSTMENT 1 Adjust Spring preload Turn the adjuster ring to direction or using Shocker Adjuster or a plain rod as applicabl...

Страница 65: ...NING Tyre inflation pressure should only be checked and adjusted when the Tyre tem perature equals the ambient air tempera ture Tyre inflation pressure and suspen sion must be adjusted according to th...

Страница 66: ...der passenger and accessories WARNING It is dangerous to ride with a worn out tyre When the tyre tread begins to show signs of wear replace the tyre immediately Patching a punctured tube is not recom...

Страница 67: ...ON 1 Inspect Wheels Damage Bends Replace NOTE Always balance the wheel when a tyre or wheel has been changed or replaced SPOKES INSPECTION AND TIGHTENING 1 Inspect Spokes Bending damage Replace Loose...

Страница 68: ...stilled water only for top up Tap water con tains minerals which are harmful to a Battery BATTERY INSPECTION 1 Remove Side Cover L H Refer to SEAT SIDE COVERS AND FUEL TANK section Page no 3 3 Battery...

Страница 69: ...letely before installing it to ensure maximum performance WARNING Battery electrolyte is dangerous It contains sulfuric acid which is poisonous and highly caustic Always follow these preventive measur...

Страница 70: ...r current rat ing Turn on switches to verify operation of related electrical deveces If the fuse blows again immediately check the electrical circuit 4 Install Fuse holder Side cover left Refer to SEA...

Страница 71: ...re the new Bulb with the Bulb spring 3 31 Push down Headlight beam moves lower Pull up Headlight beam moves higher WARNING Keep flammable products and your hands away from the Bulb while it is on it w...

Страница 72: ...4 9 C D I MAGNETO 4 10 GUIDE STOPPER AND TIMIMG CHAIN 4 10 CRANKCASE 4 11 TRANSMISSION AND SHIFTER 4 12 CRANKSHAFT 4 12 CYLINDER HEAD ROCKER ARMS CAMSHAFT VALVES 4 13 INSPECTION AND REPAIRS CYLINDER...

Страница 73: ...NT 4 32 CRANKSHAFT 4 35 TRANSMISSION 4 37 SHIFTER 4 38 CRANKCASE 4 40 CDI MAGNETO 4 42 SHIFT SHAFT AND KICK STARTER 4 44 CLUTCH PRIMARY DRIVE GEAR AND OIL PUMP 4 47 CYLINDER AND PISTON 4 52 CYLINDER H...

Страница 74: ...Refer to the ENGINE OIL REPLACEMENT section in Chapter 3 Page no 3 14 BATTERY 1 Remove Fuse Negative terminal Black Battery Breather Hose Battery CARBURETOR 1 Loosen Air cleaner case mounting bolts H...

Страница 75: ...ection in Chapter 3 Page no 3 20 3 Remove Bolt Holder Sprocket Holder Sprocket Sprocket Drive Remove with the Drive Chain EXHAUST MUFFLER 1 Remove Bolt exhaust pipe Bolt muffler Refer to EXHAUST SYSTE...

Страница 76: ...er 2 Remove Spark Plug Cap ENGINE REMOVAL 1 Remove Engine Mount Bolt front upper Bolt Engine Mount stay front upper Bolt Engine Mount stay front lower Engine Mount Bolt front upper Engine Mount Bolt f...

Страница 77: ...ntre Plug with o ring 3 Align Piston to TDC position NOTE Turn the Crankshaft anticlockwise with a Socket Spanner 17 mm TDC alignment steps Turn the Crankshaft anticlockwise until the slit cut mark on...

Страница 78: ...the Crankcase 8 Remove Guide Stopper 1 Dowel Pins Gasket Cylinder Head Cylinder 5 Remove Tensioner Cap Bolt Retract completely the Tensioner Rod by Screw in clockwise direction Bolts timing chain tens...

Страница 79: ...he Crankcase cavity 9 Remove Dowel Pins Gasket Cylinder 1 Remove Bolts Crankcase Cover 1 L H 7 nos Crankcase Cover 1 L H Neutral Light wire from Neutral Switch NOTE Loosen the Bolts in criss cross pat...

Страница 80: ...Motorcycle by remov ing the following parts and draining the Engine oil Kick Crank Assy 1 Remove Nut kick Crank assy Kick Crank Assy Bolts Crankcase Cover 2 R H 9 nos Crankcase Cover RH NOTE Hold Kick...

Страница 81: ...ssembly Gasket oil pump Oil strainer 8 Remove Nut Plate Washer Primary Drive Gear Key Rotary Filter OIL PUMP NOTE The oil pump can be removed while the engine is mounted by removing the following part...

Страница 82: ...ollowing parts Shift Pedal Kick Crank Assy Crankcase Cover 2 RH Clutch 1 Remove Shift Shaft Torsion Spring Bolt stopper lever Stopper Lever 2 Remove Torsion spring Kick axle assembly KICK STARTER NOTE...

Страница 83: ...h Bush NOTE Place the Bush on the Crankshaft threaded end before using the Magneto Puller to avoid thread damage 3 Remove CDI magneto using magneto puller Key wood ruff 4 Remove Bolt Guide Stopper 2 B...

Страница 84: ...rew driver ex cept at the separating slot Separate the Crankcase after first check ing that the shift cam segments and the Drive Axle Circlip can be removed Do not damage the Crankcase mating sur face...

Страница 85: ...Push Rod 2 Washer Push Lever Assembly Lock Oil Seal 3 Remove Neutral switch Gasket CRANKSHAFT 1 Attach Crankshaft Removal Tool 2 Remove Crankshaft using Crankshaft removal tool NOTE Fully tighten the...

Страница 86: ...t 5 Remove Camshaft Assy with spacer NOTE Before the Valves Valve Springs Valve Stem Seals etc are removed from the Cylinder Head the Valve sealing should be checked 6 Check Valve sealing Leakage at t...

Страница 87: ...is to be attached between the Valve Spring retainer and the Valve face Inlet and Exhaust one at a time 9 Remove Valve Spring Retainer Valve Spring Valve Valve Stem Seal Valve Spring Seat NOTE Identif...

Страница 88: ...ure Cylinder Head warpage Out of specification resurface replace Warpage measurement and resurfacement steps Place a straightedge and a feeler gauge across the Cylinder Head Measure the warpage If the...

Страница 89: ...d onto the valve seat to make a clear pattern Measure the Valve Seat width Where the Valve Seat and Valve Face made contact blueing will have been removed If the Valve Seat is too wide too narrow or t...

Страница 90: ...at while rotating the Valve Apply a fine lapping compound to the Valve face and repeat the above steps NOTE Make sure to clean off all compound from the Valve face and Valve seat after every lapping o...

Страница 91: ...e Spring free length Out of specification Replace 3 Check Spring contact face Wear pitting scratches Replace 5 Measure Valve stem diameter 4 Measure Valve guide inside diameter Valve spring free lengt...

Страница 92: ...Stem to guide clearance Valve guide inside diameter Valve stem diameter 3 Inspect Camshaft oil passage Chocked Blow out oil passage with compressed air CAMSHAFT INSPECTION 1 Inspect Cam lobes Pitting...

Страница 93: ...ocker Arm Shaft hole Cam lobe contact surface Excessive wear Replace Inspect the surface condition of the Rocker Arm Shafts Pitting scratches blue discoloration Re place and check lubrication route Me...

Страница 94: ...ct Tooth Profile Roller Sprocket 3 Inspect Guide Stopper 1 Guide Stopper 2 and Bush Wear damage Replace TIMING CHAIN TENSIONER 1 Check One way Cam operation If Unsmooth operation Replace Checking step...

Страница 95: ...ure the Piston Skirt diameter P with a Micrometer 4 5 mm from the Piston bottom edge If out of specification replace the Piston and the Piston Rings as a set 3rd step Calculate the Piston to Cylinder...

Страница 96: ...re NOTE Push the Ring with the Piston Crown so that the Ring will be at right angles to the Cylinder Bore 5 mm from the bottom side 3 Measure End gap using a feeler gauge Out of specification Replace...

Страница 97: ...of specification re place the Piston Pin Measure the Piston Pin hole inside diameter using a Internal Micrometer Calculate the Piston Pin to Piston clearance using the following formula Out of specifi...

Страница 98: ...re Crank width Out of specification Replace Crankshaft 2 Measure Big end side clearance using a Feeler Gauge Out of specification Replace big end Bearing Crank Pin and Connecting Rod CRANKSHAFT 1 Meas...

Страница 99: ...2 Measure Friction Plate thickness using a Vernier Calliper at four points Out of specification Replace the Friction Plates as a set 3 Inspect Clutch Plates for damage Clutch Plate Warpage Using a Su...

Страница 100: ...e Bend Replace 2 Inspect Push Rod 2 Wear damage Bend Replace 6 Inspect Dogs on the Primary Driven Gear Scoring wear damage Deburr or replace Clutch Boss Splines Scoring wear damage Replace NOTE Scorin...

Страница 101: ...ace Shift Cam Segment Wear damage Replace 3 Check Shift Fork movement on the Guide Bar Unsmooth operation Replace the Shift Fork and the Guide Bar 4 Inspect The assembly for proper working Shift Fork...

Страница 102: ...ce Mated Dogs Rounded edges cracks missing portions Replace 7 Inspect Shift Shaft Damage bent wear Replace Return spring shift shaft Return Spring stopper lever Wear damage Replace KICK STARTER INSPEC...

Страница 103: ...y Housing and Rotor clearance between the Pump Housing and the Rotors and Out of specification Replace the Oil Pump Assembly Damage Replace Contamination Clean with flushing oil 3 Inspect Oil strainer...

Страница 104: ...Roughness noise Replace 2 Inspect Oil Seals Damage wear Replace CRANKCASE 1 Thoroughly wash the crankcase L H R H in mild solvent 2 Thoroughly clean all the Gasket Mating surfaces and Crankcase Matin...

Страница 105: ...NGINEASSEMBLYANDADJUSTMENTS 4 32 VALVES ROCKER ARM AND CAMSHAFT Valve Cotters Valve Spring Retainer Valve Springs Valve Stem Seal Valve Spring seat Valve intake Valve exhaust Lock Nut Adjuster Valve R...

Страница 106: ...moothing 2 Apply Molybdenum disulfide oil on the Valve Stem and Oil Seal 4 Install Valve Cotters NOTE Install the Valve Cotters while compressing the valve spring with Valve Spring compressor 3 Instal...

Страница 107: ...ide oil on the rocker arm and Rocker Arm Shaft CAMSHAFT AND ROCKER ARM INSTALLATION 1 Lubricate Camshaft 5 Secure the Valve Cotters onto the Valve Stem by tapping lightly with a mallet WARNING CAUTION...

Страница 108: ...ENG R 107 ENGINEASSEMBLYANDADJUSTMENTS 4 35 CRANKSHAFT Crank Pin Crank Shaft Connecting Rod Big end Bearing Crankshaft Bearing Wood ruff Key Bearing Spacer...

Страница 109: ...to ease the Installation procedure apply Engine Oil onto each Bearing and crankcase LH 4 Install Neutral Switch 3 Install Crankshaft by tightening the Nut NOTE Hold the Connecting Rod at Top End with...

Страница 110: ...LYANDADJUSTMENTS 4 37 TRANSMISSION Drive Sprocket Oil Seal Bearing 4th Wheel Gear Drive Axle 2nd Wheel gear 3rd Wheel Gear Clutch Dog Bearing Bearing 4th Pinion Gear 3rd Pinion Gear 2nd Pinion Gear Ma...

Страница 111: ...ENG L 110 ENGINEASSEMBLYANDADJUSTMENTS 4 38 SHIFTER Shift Fork Guide Bar long Shift Fork R Shift Fork L Shift Cam Segment Shift Fork Guide Bar short Shift fork C Torx Screw Pin Shaft Cam...

Страница 112: ...ift Forks for smooth operation by turning the Shift cam with your hand 3 Install The following parts in Crankcase LH in following sequence Shift Fork L left face the L side for the Clutch side Shift F...

Страница 113: ...ENG L 112 ENGINEASSEMBLYANDADJUSTMENTS 4 40 CRANKCASE Crankcase 1 LH Dowel Pins Crankcase Breather Hose Crankcase 2 RH Holder Clutch Cable Tightening Sequence...

Страница 114: ...ll Crankcase RH with the Crankcasse LH Tap lightly on the Case with mallet NOTE Tighten the Engine Mounting Nuts 2 nos for holding the Engine on the engine stand 4 Tighten Bolts 2 nos Crankcase RH Bol...

Страница 115: ...ENG L 114 ENGINEASSEMBLYANDADJUSTMENTS 4 42 CDI MAGNETO Timing Chain Guide Stopper 1 and 2 CDI Rotor Assy Wood Ruff Key Stator Assy Gasket Dowel Pin Cover Crankcase 1...

Страница 116: ...tall Guide stopper 2 with spacer Tighten the bolt C D I MAGNETO INSTALLATION 1 Install Woodruff Key 2 Install C D I Magneto Washer Nut NOTE When installing the Magneto Rotor make sure that the Woodruf...

Страница 117: ...NGINEASSEMBLYANDADJUSTMENTS 4 44 SHIFT SHAFT AND KICK STARTER Shift Shaft Torsion Spring Stopper Lever Return Spring Segment Kick Starter Assembly Circlip Washer Kick Idle Gear Kick Shaft Assy Cover C...

Страница 118: ...r lever NOTE Hook the Spring ends on the Stopper Lever and the Crankcase Pin Mesh the Stopper Lever with the Cam Shifter Stopper 2 Install Segment using Torx Bit Tool NOTE Fit the Dowel Pins on the Ca...

Страница 119: ...mbly Kick Gear Clip Torsion Spring NOTE Turn the Torsion Spring clockwise and hook into the proper hole in the Crankcase 2 Install Following parts on the Axle Drive Circlip Washer Kick Idle gear Washe...

Страница 120: ...Plate Push Plate Push Rod 1 Friction Plate Clutch Plate Clutch Boss Thrust Washer Primary Driven Gear Ball Push Rod 2 Push lever Axle Primary Drive Gear Rotary Filter CLUTCH PRIMARY DRIVE GEAR AND OIL...

Страница 121: ...4 Install Rotary Filter NOTE Align the Rotary Filter Dog with groove of the Crankshaft and make sure to keep TOP marking facing upside 2 Install Drive gear Oil Pump Gasket Oil Pump Assy 3 Tighten Scr...

Страница 122: ...Clutch Plate with Projec tion Mark offset approximately 90 from pre vious plates projection continue this procedure in clockwise direction until all Clutch Plates are installed 3 Tighten Nut Clutch Bo...

Страница 123: ...on Clutch Boss while in stalling the Pressure Plate Tighten the Clutch Spring Bolts in stage using a crisscross pattern 9 Check Push Lever position Push the Push Lever Assembly in the arrow direction...

Страница 124: ...e Bolts in decreasing numerical order see number on the illustration 13 Install Kick Crank Nut Kick Crank 14 Install Dowel Pins Gasket Crankcase Cover 1 New Crankcase Cover 1 L H NOTE Tighten the Bolt...

Страница 125: ...ENG L 124 ENGINEASSEMBLYANDADJUSTMENTS 4 52 Cylinder Gasket Cylinder Dowel Pins Piston Rings Piston Pin Circlips Piston Pin Piston CYLINDER AND PISTON...

Страница 126: ...ENGINEASSEMBLYANDADJUSTMENTS 4 53 Bolt Flange Washer Bolt Valve Cover intake O Ring Valve Cover exhaust Cylinder Head Dowel Pin Gasket Cylinder Head O Ring Cover Cylinder Head Side 3 Spark Plug CYLIN...

Страница 127: ...ENG L 126 ENGINEASSEMBLYANDADJUSTMENTS 4 54 CAM SPROCKET AND TIMING CHAIN Gasket Timing Chain Tensioner Assembly Guide Stopper 2 Cam Sprocket Timing Chain Guide Stopper 1...

Страница 128: ...so that the GTP TOP1 GTP TOP 2 marks are lo cated on the upper side of the 2nd Ring Top Ring Lubricate the Piston and Piston Rings with En gine Oil 2 Install Piston Piston Pin using Piston Pin Replace...

Страница 129: ...hown Top Ring End Oil Ring end lower Oil Ring End upper 2nd Ring End 5 Lubricate Piston outer surface Piston Rings Cylinder Inner Surface 6 Install Cylinder NOTE Install the Cylinder with one hand whi...

Страница 130: ...ark on the Cam Sprocket with the stationary pointer on the Cylinder Head Fit the Timing Chain on Cam Sprocket and install the Cam Sprocket on the Camshaft NOTE When installing the Cam Sprocket keep in...

Страница 131: ...ner Timing Chain Tensioner Installation steps Remove the Tensioner Cap Bolt While Pressing the Tensioner Rod lightly with fingers use a Flat Head Screwdriver and retract the Tensioner Rod up fully clo...

Страница 132: ...s with O Ring Cylinder Head Side Cover with O Ring Bolts 8 Check Valve clearance specifications Out of specification Adjust Refer to the VALVE CLEARANCE ADJUST MENT section in Chapter 3 Page no 3 8 9...

Страница 133: ...est Assy 3 Install Engine Mount Bolt Rear Lower Engine Mount stay upper Engine Mount bolt Front upper Mounting Bolt Engine mount stay upper Mounting Bolt upper Engine Mount Stay front Bolt Engine Moun...

Страница 134: ...section in Chapter 3 Page no 3 20 Bolt Engine Mount stay front lower 38 Nm 3 8 m kg 27 5 ft lb Engine Mount Bolt Front lower 38 Nm 3 8 m kg 27 5 ft lb Engine Mount bolt from upper 38 Nm 3 8 m kg 27 5...

Страница 135: ...Page no 3 14 17 Adjust Idle Speed Refer to IDLING CO MEASUREMENT AND ADJUSTMENT in Chapter 3 Page no 3 8 18 Adjust Throttle cable Free play Refer to THROTTLE CABLE ADJUSTMENT in Chapter 3 Page no 3 9...

Страница 136: ...CARB R 135 CHAPTER 5 CARBURETION CARBURETOR VIEW 5 1 REMOVAL 5 2 DISASSEMBLY 5 3 INSPECTION 5 4 ASSEMBLY 5 6 INSTALLATION 5 7 TUNING 5 8 CARBURETION...

Страница 137: ...Throttle Valve Plug Drain Float Chamber Body O Ring Main Chamber Body Float Pin Float Needle Valve Assembly Jet Main Throttle valve Nozzle Main Screw Pilot Assembly Jet Pilot Starter Lever Plunger St...

Страница 138: ...fuel CARBURETOR 5 2 7 Remove Throttle Cable Remove with Carburetor Chamber Top and Throttle Valve 5 Remove Bolts Intake Manifold 2 nos Joint with O ring 6 Remove Carburetor Assembly with O ring 3 Dis...

Страница 139: ...and inspected without Carburetor Disassembly Throttle Valve Assembly Starter lever Starter Plunger Assembly Before disassembly of Carburetor clean the outer surface of Carburtor and Check the Starter...

Страница 140: ...p plunger Starter Lever Assembly by opening Cap Plunger Starter Plunger Assembly 9 Remove Throttle Stop Screw Set Spring Washer and O ring INSPECTION Carburetor Float Chamber Body 1 Inspect Cracks dam...

Страница 141: ...Spring Plunger Starter Plunger for seat and free movement Throttle Valve 1 Check Free movement Insert the Throttle Valve in the Carburetor body and check for free movement Hinderance Clean Replace Fl...

Страница 142: ...stall Pilot jet Pilot screw assembly ASSEMBLY 7 Install Seal Float Chamber New Float Chamber Screw with Spring Washer 4 nos 6 Measure Float Height Incorrect Adjust 5 Install Float Float Pin 3 Install...

Страница 143: ...tion on the Carburetor Body 3 Install Carburetor Assembly and Joint together on the intake manifold NOTE While installing Joint A keep its lug side downword and L H S of Engine 4 Tighten Bolts Intake...

Страница 144: ...ter to the Spark Plug lead 3 Check Engine idling speed If out of sepecification adjust Engine Idling Speed 1300 1500 R P M Adjustment Steps Turn the Throttle Stop Screw in or out until specified idlin...

Страница 145: ...t of Main Chamber Body and Float Chamber Body Fuel Level Gauge 6 Adjust Idling speed by Throttle Stop Screw FUEL LEVEL ADJUSTMENT 1 Measure Fuel Level Out of specification Adjust Measurement and adjus...

Страница 146: ...own Float Height increase By Lifting Up Float Height Decrease Otherwise adjust Float level by bending the Float Tang on the Float slightly up or down as required Install the Carburetor Recheck the fue...

Страница 147: ...ATION 6 15 DRIVE CHAIN AND SPROCKETS 6 16 REMOVAL 6 17 DRIVE CHAIN INSPECTION 6 18 CLUTCH HUB INSPECTION 6 19 DRIVEN SPROCKET ASSEMBLY 6 19 DRIVEN SPROCKET AND DRIVE CHAIN INSTALLATION 6 19 FRONT FORK...

Страница 148: ...CHAS R 147 FRONT WHEEL Cotter Pin Axle Nut Speedometer Cable Assy Wheel Axle Spacer Brake Shoe Plate Assy Dust Seal Collar Front Wheel FRONT WHEEL AND FRONT BRAKES 6 1...

Страница 149: ...CHAS L 148 FRONT BRAKE Brake Shoe Assy Oil Seal Clutch Meter Gear Drive Lever Camshaft Indicator Plate FRONT WHEEL AND FRONT BRAKES 6 2 Camshaft Bush Plate Washer Gear Meter O Ring Oil Seal...

Страница 150: ...ter Cable by removing the clip 4 Remove Cotter Pin Nut 5 Lift Front Wheel NOTE Place a suitable stand under the Engine 5 Remove Front Wheel Axle Brake Shoe Plate Assembly Dust Seal Collar Front Wheel...

Страница 151: ...ECTION in Chapter 3 Page no 3 27 3 Check Spokes Bends damage Replace Loose Spokes Tighten Turn the Wheel and tap the Spokes with a Screwdriver NOTE A tight Spoke will emit a clear ringing tone a loose...

Страница 152: ...Oil Seals Wear damage Replace 7 Inspect Collar Grooved Wear Replace the Collar and the Oil Seal as a set BRAKE SHOE PLATE DIASSEMBLY 1 Remove Bush Meter Gear Remove the bush using a Meter Gear Bush T...

Страница 153: ...ake Shoes as a set if either is worn to the limit 3 Measure Brake Drum inside diameter Out of specification Replace the Wheel Drum 4 Inspect Brake Drum inner surface Oil Scratches Repair Oil Use a Rag...

Страница 154: ...ter Gear Bush Install the Bush using the Spanner Speedom eter Gear Nut 2 Install Cam Lever Bolt Cam Lever BRAKE SHOE PLATE ASSEMBLY 1 Install Camshaft Indicator Plate Installation steps Align the proj...

Страница 155: ...ation WARNING Always use a new Cotter Pin 4 Install Cotter Pin New and bend its ends 3 Tighten Front Wheel Axle Axle Nut Front Wheel NOTE Do not loosen the Axle Nut after Torque tight ening If Axle Nu...

Страница 156: ...e for proper operation Improper operation Recheck or disassemble 7 Adjust Brake Lever free play Refer to FRONT BRAKE ADJUSTMENT section in Chapter 3 Page no 3 18 FRONT WHEEL AND FRONT BRAKES 6 9 WARNI...

Страница 157: ...WHEEL Adjuster Pin CompressionSpring Cotter Pin Tension Bar Axle Nut Chain Puller Driven Sprocket Axle Rear Wheel Assembly Brake Shoe Plate Assembly Damper Bearing Spacer Collar Bearing REAR WHEEL AND...

Страница 158: ...CHAS R 157 REAR BRAKE Brake Shoe Kit Cam Lever Indicator Plate Camshaft REAR WHEEL AND REAR BRAKE 6 11...

Страница 159: ...ace REMOVAL 1 Remove Chain Cover upper and lower 2 Loosen Chain Adjuster 3 Remove Adjuster Rear Brake Pin Nut with Bolt Tension Rod Compression Spring Brake Rod 4 Remove Cotter Pin Nut Wheel Axle Whee...

Страница 160: ...r to FRONT WHEEL INSPECTION Page no 6 4 3 Inspect Clutch Hub Damper Wear damage Replace REAR BRAKE INSPECTION 1 Inspect Brake Lining surface 2 Measure Brake Lining thickness 3 Inspect Brake Drum inner...

Страница 161: ...Hub as sembly 2 Adjust Drive Chain Slack Refer to DRIVE CHAIN ADJUSTMENT section in Chapter 3 Page no 3 20 3 Tighten Nut Rear Wheel Axle NOTE Do not loosen the Axle Nut after torque tighten ing If Axl...

Страница 162: ...AND SPROCKETS Chain Case Crankcase Cover 3 Drive Sprocket Clip Chain Joint Link Plate Chain Joint Drive Chain Nut Driven Sprocket Axle Driven Sprocket Assembly Chain Tensioner Circlip Oil Seal DRIVE C...

Страница 163: ...Chain Joint Drive Chain WARNING Securely support the Motorcycle on Centre stand so that there is no danger of it falling over REMOVAL 1 Stand the Motorcycle on a level surface 2 Remove Chain Case uppe...

Страница 164: ...Measure 10 link length Drive Chain Out of specification Replace the Drive Chain NOTE Tighten the Drive Chain with a fingers before measuring 10 link length is the distance between the inside edge of R...

Страница 165: ...e Sprocket Assembly NOTE Align the slot on the Swingarm with the flat face of the Driven Sprocket Axle 2 Tighten Nut Driven Sprocket Axle DRIVEN SPROCKET ASSEMBLY 1 Install Driven Sprocket on Clutch H...

Страница 166: ...19 3 Install Drive Sprocket Drive Chain Chain Joint Plate 4 Install Clip New 5 Install Chain Case upper Chain Case lower Shift Pedal Refer to ENGINE REMOVAL section in Chapter 4 Page no 4 1 6 Adjust...

Страница 167: ...T FORK 6 20 FRONT FORK Front Fender Cap Bolt Holder Cable O Ring Collar Spring Seat Fork Spring Seal Dust Ring Snap Washer Bolt Gasket Spindle Taper Cylinder Comp Front Fork Inner Tube Sub Spring Oil...

Страница 168: ...eat Upper Spring Front Fork 3 Remove Front Wheel Front Fender Refer to FRONT WHEEL REMOVAL Section Page no 6 3 Handlebar Refer to HANDLEBAR REMOVAL Section Page no 6 30 4 Remove Cap Bolts Inner Tube 2...

Страница 169: ...ing snap Washer Oil Seal using Oil Seal Remover 4 Remove Bolt Damper Rod Washer Cylinder complete Fornt Fork Spindle Taper Spring Sub 3 Loosen Bolt Allen Damper Rod Loosen the Bolt Damper Rod while ho...

Страница 170: ...s damage Replace Spring Sub Spindle Taper Bends damage Replace Contamination Blow out all Oil Passages with Compressed Air 6 23 WARNING Do not attempt to straighten a bent Inner Tube as this may dange...

Страница 171: ...Tube Outer Tube FRONT FORK ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points NOTE When assembling the Front Fork be sure to replace the following parts Oil Seal Seal Dust Snap Ring...

Страница 172: ...a T Handle 6 Install Oil Seal New Using TFF Oil Seal Installation Tool NOTE Before installing the Oil Seal apply lithium soap base grease onto the Oil Seal lips Adjust the Ring Snap so that it fits in...

Страница 173: ...bracket Cap Bolts Pinch Bolt Underbracket 28Nm 2 8 m kg 20 ft lb Bolt Cap Bolt 23Nm 2 3 m kg 17 ft lb FRONT FORK 6 26 9 Fill Fork Oil 10 After filling up slowly Pump the Fork up and down to distribute...

Страница 174: ...ssembly right Handle Crown Lock Washer Ring Nut upper Damper Rubber Ring Nut lower Ball Race Cover Under Bracket Ball Race upper Ball upper Ball lower Ball Race center Ball Race lower Bush Tightening...

Страница 175: ...Clutch Cable Speedometer Cable 2 Remove Switch Handle 3 Remove Bolts 4 Nos Handlebar Upper Holder Handlebar Throttle Grip Lever Holder Front Brake 4 Remove Front Wheel Refer to FRONT WHEEL Section Pag...

Страница 176: ...n the Handlebar Ring Nut Wrench YSST 621 HANDLEBAR INSPECTION 1 Inspect Handlebar Bends Cracks damage Replace HANDLEBAR REMOVAL 1 Remove Grip left Removal Steps Blow with compressed air between the Ha...

Страница 177: ...hown Install the new Dust Seal and Races NOTE Always replace Bearing races as a set STEERING INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Lubricate Balls upper and lower Ball...

Страница 178: ...Holders should be in stalled with the longer side to the forward then tighten the Front Bolt as shown 2 Install Front Brake Lever Assembly Handlebar Switch left Grip Assembly Throttle Cable Housing Th...

Страница 179: ...CHAS L 178 REAR SHOCK ABSORBER AND SWING ARM REAR SHOCK ABSORBER AND SWINGARM Rear Shock Absorber Axle Nut Swing arm Tension Bar Seal Guard 6 32...

Страница 180: ...OVERS SEAT AND FUEL TANK section in Chapter 3 Page no 3 3 3 Remove Rear Wheel Driven Sprocket Assembly Refer to DRIVE CHAIN AND SPROCKETS section Page no 6 16 4 Remove Nut Rear Shocker upper and lower...

Страница 181: ...pect Swingarm looseness Looseness exists Tighten the Pivot Shaft nut or replace Bushes Swingarm up and down movement Unsmooth movement bending rough spots Replace Bushes 2 Inspect Rear Shock Absorber...

Страница 182: ...OF CONNECTIONS 7 3 IGNITION SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 7 4 TROUBLESHOOTING 7 4 CHARGING SYSTEM TROUBLESHOOTING 7 9 LIGHTING SYSTEM CIRCUIT DIAGRAM 7 10 TROUBLESHOOTING 7 10 LIGHTING SYSTE...

Страница 183: ...ELEC L 182 CIRCUIT DIAGRAM CIRCUIT DIAGRAM 7 1...

Страница 184: ...h Flasher Relay Assy C D I Unit Assy Battery Fuse Stop Switch Rear Neutral Switch Assy Rectifier Regulator Assy Ignition Coil Assy Spark Plug Cap Horn Spark Plug LOCATION OF ELECTRICAL COMPONENTS ELEC...

Страница 185: ...two or three times 4 Pull the lead to check that it will not come off CHECKING OF CONNECTIONS 5 If the terminal comes off bend up the pin and reinsert the terminal in to the con nector 6 Check for co...

Страница 186: ...ug Cap resistance 3 Ignition coil 4 Main switch 5 Sensor coil resistance 6 Charging Coil resistance 7 Rectifier cum Regulator Unit 8 Wiring connections entire ignition system 9 CDI Note Remove the req...

Страница 187: ...PLUG CAP RESISTANCE Remove the Spark Plug Cap Connect the Multimeter X1k to the Spark Plug Cap NOTE When removing the Spark Plug Cap turn out the Spark Plug Cap from high tension Cord Remove Turn ant...

Страница 188: ...Connect the Multimeter to the Ignition Coil Check the secondary coil resistance Multimeter lead High Tension lead Multimeter lead Orange Terminal Replace the Ignition Coil OUT OF SPECIFICATION Ignitio...

Страница 189: ...UT OF SPECIFICATION MEETS SPECIFICATION Sensor coil is OK 6 CHARGING COIL RESISTANCE Remove the Charging Coil coupler from the Wire Harness Connect the Multimeter to the charging coil Measure the char...

Страница 190: ...ge Charging voltage 14 15 V at 5000RPM Multimeter lead Battery terminal Multimeter lead Battery terminal MEETS SPECIFICATIONS Charging Circuit and Rectifier cum Regula tor are OK Rectifier cum Regulat...

Страница 191: ...lled water Clean the Battery terminals Recharge or Replace the Battery INCORRECT 3 CHARGING VOLTAGE Refer to Rectifier cum Regulator unit in spection method in the Ignition System section in this Chap...

Страница 192: ...il resistance 2 Light Switch 3 Dimmer Switch 4 Lighting Voltage 5 Wiring connections entire lighting system 6 Check individual lighting circuits Note Remove the following parts before trouble shooting...

Страница 193: ...LH Coupler from Wireharness Connect the Multimeter X 1 to Handle bar Switch LH Terminals Check the switch connections for continu ity between Blue and Yellow Red NO CONTINUITY CONTINUITY Repair or Rep...

Страница 194: ...individual Lighting System Circuits 4 LIGHTING VOLTAGE Connect the Tachometer to Spark Plug lead Disconnect the Taillight coupler from wire harness Connect the Multimeter AC 20 V to tail light wire S...

Страница 195: ...Bulb and Bulb socket for conti nuity 6 INDIVIDUAL LIGHTING CIRCUITS A If the Headlight and Highbeam Indicator Light do not work Replace Bulb and or Bulb Socket NO CONTINUITY 2 LIGHTING VOLTAGE Refer...

Страница 196: ...NDICATOR LIGHTS DO NOT WORK IF THE HORN DOES NOT WORK PROCEDURE CHECK 1 Fuse 2 Battery 3 Main Switch 4 Wiring connections entire lighting system 5 Check individual lighting circuits Note Remove the fo...

Страница 197: ...coupler from wireharness Check the continuity between Brown and Red wires Top up the Battery fluid Clean Battery terminal Recharge or replace the Battery INCORRECT CORRECT NO CONTINUITY CONTINUITY Re...

Страница 198: ...ONTINUITY 5 INDIVIDUAL SIGNAL SYSTEMS The wiring circuit from the Main Switch to the Horn is faulty Repair Replace wireharness OUT OF SPECIFICATION MEETS SPECIFICATION 3 HORN Disconnect the Pink termi...

Страница 199: ...heck The voltage 12V between the Yel low and Black terminal NO CONTINUITY CONTINUITY MEETS SPECIFICATIONS Brake Light circuit is OK 7 17 4 WIRING CONNECTION Wiring circuit from Main Switch to the Bulb...

Страница 200: ...White and Darkgreen and Brown White and Chocolate Replace the left Handlebar Switch CONTINUITY CONTINUITY MEETS SPECIFICATION NO CONTINUITY NO CONTINUITY OUT OF SPECIFICATION The wiring circuit from M...

Страница 201: ...ark Green Terminal Multimeter lead Body earth MEETS SPECIFICATIONS Wiring connection Wiring circuit from the Turn Switch to Bulb Socket connector is faulty Repair Replace Refer to CIRCUIT DIAGRAM OUT...

Страница 202: ...l indicator lights fails to operate Replace the Bulb and or Bulb Socket NO CONTINUITY CONTINUITY Replace the Neutral switch NO CONTINUITY 3 VOLTAGE Connect the Multimeter DC20 V to the neutral switch...

Страница 203: ...SPEED PERFORMANCE 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 POOR SPEED PERFORMANCE 8 3 CLUTCH SLIPPING DRAGGING 8 3 FAULTY GEAR SHIFTING 8 4 OVER HEATING 8 4 FAULTY BRAKE 8 4 FRONT FORK MALFUNCTI...

Страница 204: ...operly adjusted Valve clearance Improperly sealed Valve Improperly contacted Valve and Valve seat Improper Valve timing Broken Valve Spring Seized Valve FUEL SYSTEM Fuel Tank Empty Clogged Fuel Tank C...

Страница 205: ...ned Starter Plunger Loose or clogged Pilot jet Damaged Carburetor Joint Improperly tightened Carburetor Joint Clamp hose Improperly adjusted idle speed Pilot Screw Throttle stop Screw Improperly adjus...

Страница 206: ...GING section Page no 8 3 Engine Oil Improper oil level low or over oil level Improper quality low oil viscosity Deterioration Clogged oil passage Brakes Dragging brake POOR SPEED PERFORMANCE CLUTCH SL...

Страница 207: ...dog OVER HEATING Ignition system Improper Spark Plug gap Improper Spark Plug heat range Faulty C D I unit Fuel system Improper Carburetor setting Improper fuel level adjustment Clogged air Filter ele...

Страница 208: ...ed Steering Nut Loose or overtightened Steering Nut Bent Under Bracket Improperly installed Steering Shaft improp erly tightened Ring Nut Damaged Bearing or Ball Race Front forks Uneven oil levels on...

Страница 209: ...LINK Improperly grounded Insufficient battery capacity Faulty Fuse Faulty Turn Switch Faulty Flasher Relay Broken wireharness incorrect coupler con nection Bulb burnt out FLASHER KEEPS ON Faulty Flash...

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