Specifications

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WORKSHOP

MANUAL

Summary of content (209 pages)

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WORKSHOP MANUAL
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R-1 FOREWORD This Workshop Manual has been prepared for use by the Yamaha Motor India Private Ltd. Authorised Dealerships and their service personnel to attend to servicing of Crux Motorcycles. It is not possible to include entire service education into this Manual. It is assumed that persons using this book to perform maintenance and repairs on Crux Motorcycles have a basic understanding of mechanical concepts and procedures inherent to Motorcycle repair technology.
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L-2 HOW TO USE THIS MANUAL MANUAL ORGANISATION This manual consists of chapters for the main categories of subjects. (See Illustrated symbols) 1st title 1 : This is the Title of the Chapter with its symbol on the upper right corner of each page. 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.
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R-3 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapters number and content. 1. General Information 3. Periodic inspection and adjustment GEN INFO 2. Specifications SPEC INSP ADJ 4. Engine ENG 5. Carburetion CARB 6. Chassis CHAS 7. Electrical ELEC 8. Troubleshooting TRBL SHTG Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text. 9. Filling fluid 10.Lubricant 11.Special Tool 12.Torque 13.
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L-4 INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE CARBURETION CHASSIS ELECTRICAL TROUBLE SHOOTING GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 CARB 5 CHAS 6 ELEC 7 TRBL SHTG 8
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R-5 CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER ....................................................... 1-1 ENGINE SERIAL 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 .............
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L-6 MOTORCYCLE IDENTIFICATION GEN INFO MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The Frame Serial Number ¿ is stamped into the right side of the Steering Head Pipe. ENGINE SERIAL NUMBER The Engine Serial Number À is stamped on the top portion of RH Crankcase.
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R-7 IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR DISASSEMBLY 1. Remove all dirt, mud, dust and foreign material before disassembly. 2. Use proper Tools and Cleaning Equipment. Refer to “SPECIAL SERVICE TOOLS”. 3. When disassembling the Motorcycle, keep mated parts together. This includes gears, Cylinder, Piston and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced. 4.
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L-8 IMPORTANT INFORMATION GEN INFO ALL REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use Yamalube Oil and Grease recommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality. GASKETS, OIL SEALS, AND O-RINGS 1. All Gaskets, Seals and O-rings should be replaced when the Engine is overhauled. 2. All surfaces where Gasket, Oil Seal lips and O-rings contact must be cleaned and Lubricated.
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R-9 SPECIAL SERVICE TOOLS GEN INFO SPECIAL TOOLS SPECIAL SERVICE TOOLS The appropriate Special Service Tools are necessary for proper maintenance of the Motorcycle. Using the correct Special Service Tool will help to prevent damage caused by the use of improper tools or improvised techniques. The following is the detailed list of all Special Service Tools with their application. Refer to the list provided to avoid errors when placing an order for Special service tools. 5. Valve Clearance Adjusting Tool.
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L-10 SPECIAL SERVICE TOOLS 9. Crank Shaft Removal Tool. YSST - 265 GEN INFO 13. Torx Bit (T - 30) YSST - 611 This tool is used to loosen or tighten the Cam Shifter Segment Screw. This tool is used to remove the Crank Shaft from the Crank Case. 10. Crank Shaft Installing Tool with spacer (a) YSST - 266 è ç (b) YSST - 267 14. Scraper YSST - 612 These tools are used for installation of Crank Shaft. This tool is used for scraping the sealent from Crankcase surface. 11.
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R-11 SPECIAL SERVICE TOOLS GEN INFO 22. Engine Stand 17. Rear Shock Absorber Adjuster YSST 221 This fixture is used to hold the Engine for its disassembly and assembly. This tool is used to adjust spring preload of Rear Shock Absorbers. 18. T -Handle YSST - 213 23. Oil Seal Installing Tool. YSST - 622 This tool is used to hold the TFF plunger for loosening and tightening of Hex Socket Head Bolt This tool is used to install Oil Seal in Crank Case Cover#2. 24. Bearing Puller YSST - 623 19. T.F.F.
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L-12 SERVICE INSTRUMENTS GEN INFO SERVICE INSTRUMENTS The following Service Instruments are necessary for complete and accurate tune up of Motorcycle 5. Vernier Calliper (150 mm) 1. Tachometer YSST - 613 This Instrument is used for checking the Engine RPM This instrument is used for measuring length, width & thickness of components 2. Timing light (SKC S14-121) 6.
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R-13 SERVICE INSTRUMENTS 9. Tyre pressure gauge GEN INFO 11. Torque Wrench (10-50 Ft-Lb) (20-100 Ft-Lb) This tool is used to tighten the Nuts/Bolts at a specified torque. This instrument is used for checking the Tyre Pressure 10. Vaccum Gauge 12. Feeler gauge This instrument is used for checking intake vaccum. This instrument is used to check clearance/ gaps between parts. SPECIAL SERVICE MATERIAL The following Service material are necessary to use at the time of assembly of various parts. 1.
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CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ....................................................2-1 MAINTENANCE SPECIFICATIONS ENGINE ...................................................................................... 2-4 CHASSIS .................................................................................... 2-10 ELECTRICAL .............................................................................. 2-13 GENERAL TORQUE SPECIFICATIONS ...................................
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R-15 GENERAL SPECIFICATIONS SPEC GENERAL SPECIFICATIONS DESCRIPTION Model : Model Code : Engine model code: DIMENSIONS: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Dry weight : Basic weight : (With Oil and full Fuel Tank) ENGINE : Engine type Cylinder arrangement Displacement Bore X Stroke Compression ratio Starting system Lubrication system Max power Torque Oil type or grade : Engine oil SPECIFICATION CRUX 5KA1 5KA 1997 735 1055 780
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L-16 GENERAL SPECIFICATIONS DESCRIPTION Clutch type : Transmission : Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio SPECIFICATION Wet, Multiple disc Helical gear 68/18 (3.778 : 1) Chain drive 42/14 (3.00 : 1) Constant mesh 4-speed Left foot operation 33/11 (3.000) 27/16 (1.688) 24/20 (1.200) 21/23 (0.
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R-17 GENERAL SPECIFICATIONS DESCRIPTION Brake : Front brake Rear brake SPEC SPECIFICATION Type Operation Type Operation Drum Brake (Dia 130 mm) Right hand operation Drum brake (Dia 130 mm) Right foot operation Suspension : Front suspension Rear suspension Shock absorbser : Front shock absorber Rear shock absorber Wheel travel : Front wheel travel Rear wheel travel Electrical : Ignition system Generator system Battery type Battery capacity Headlight type : Headlight bulb type Bulb (voltage - wattage x q
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L-18 MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE DESCRIPTION Cylinder : Bore size SPECIFICATION 49.000 ~ 49.020 mm (in five grades) Piston : Piston to Cylinder Clearance Piston size “D” Cylinder Piston Grading 0.017 ~ 0.021 mm <0.12mm> 48.962 ~ 48.
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R-19 MAINTENANCE SPECIFICATIONS DESCRIPTION Cylinder head : SPECIFICATION <0.03 mm (0.0012 in)> * Lines indicate straightedge measurement. Camshaft : Drive method Cam dimensions Intake Chain Drive C B Exhaust SPEC B “A” “B“ “C“ “A“ “B“ “C“ 25.356 ~ 25.456 mm <25.326 mm> 20.989 ~ 21.089 mm <20.959 mm> 4.4055 mm 21.360 ~ 21.460 mm <21.330 mm> 21.001 ~ 21.101 mm <20.971 mm> 4.4114 mm Rocker Arm/ Rocker Arm Shaft : Inside diameter (Rocker Arm) 10.
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L-20 MAINTENANCE SPECIFICATIONS DESCRIPTION Stem outside diameter Guide inside diameter Stem to guide clearance IN EX IN EX IN EX IN EX IN EX IN EX SPECIFICATION 4.975 ~ 4.990 mm 4.960 ~ 4.975 mm <4.950 mm> <4.935 mm> 5.000 ~ 5.012 mm 5.000 ~ 5.012 mm <5.035 mm> <5.035 mm> 0.005 ~0.0325 mm 0.0125 ~ 0.026 mm <0.075 mm> <0.075 mm> 0.010 mm IN EX IN EX 0.9 ~ 1.1 mm 0.9 ~ 1.1 mm <1.6 mm> <1.
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R-21 MAINTENANCE SPECIFICATIONS DESCRIPTION Clutch : Friction plate thickness Quantity Clutch Plate thickness Quantity Clutch Spring free length Quantity Minimum length Clutch release method Carburetor : I. D. Mark Main Jet Main Air Jet size Jet needle Needle jet Cut away Pilot outlet Pilot jet Valve seat size Starter jet Fuel level (with special tool) SPEC SPECIFICATION 2.90 ~ 3.10 mm 5 pcs. <2.80 mm> 1.05 ~ 1.35 mm 4 pcs. 0.
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L-22 MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUE (ENGINE) Part to be tightened Parts name Thread size Q'ty Cylinder Head Bolt M8 4 Tightening torque Nm m.kg ft.lb 22 2.2 17 Bolt M6 2 10 1.0 7.2 Spark Plug - M12 1 17.5 1.75 12.6 Cylinder Head Side Cover Bolt M6 2 10 1.0 7.2 Valve Cover - M45 2 17.5 1.75 13 CDI Magneto Rotor Bolt M6 1 70 7.0 51 Stopper Guide Bolt M6 1 10 1.0 7.2 Adjust Screw Nut M5 2 8 0.8 5.
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R-23 MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUE (ENGINE) Tightening sequence Cylinder Head Part to be tightened Parts name Thread size Q'ty Shift Pedal Bolt M6 Segment Screw Stopper lever Bolt Sensor Assembly Neutral Switch Assembly Crankcase Tightening torque Nm m.kg ft.lb 1 10 1.0 7.2 M6 1 12 1.2 9 M6 1 10 1.0 7.2 Bolt M6 2 10 1.0 7.2 - M10 1 4 0.
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L-24 MAINTENANCE SPECIFICATIONS SPEC CHASSIS DESCRIPTION Steering system : (as applicable) Steering Bearing type No.
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R-25 MAINTENANCE SPECIFICATIONS DESCRIPTION Front Drum Brake : Type Brake Drum inside diameter Lining Thickness Shoe Spring free length Rear drum brake : Type Brake Drum inside diameter Lining Thickness Shoe spring free length Free Plays : Brake Lever free play (At lever end) Brake Pedal free play Clutch Lever free play (at lever end) Throttle Grip free play SPECIFICATION Leading, Trailing 130mm <131> 4.0 mm <2 mm> 36.5mm Leading, Trailing 130mm <131> 4.
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L-26 MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUE (CHASSIS) * 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.
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R-27 MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL DESCRIPTION Voltage : Ignition system : Ignition timing (B.T. D.
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L-28 MAINTENANCE SPECIFICATIONS Circuit Breaker : Type Amperage for individual circuit X quantity : Main Reserve Fuse 10A X 1pc. 10A X 1pc.
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R-29 GENERAL TORQUE SPECIFICATION SPEC GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specification for special components or assemblies are included in applicable section of this book. To avoid warpage, tighten multi-fastener assemblied in a criss-cross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads.
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L-30 LUBRICATION POINTS AND LUBRICANT TYPE SPEC LUBRICATION POINTS AND LUBRICANT TYPE ENGINE Lubrication points (part name) Lubricant type Oil Seal lips (all) Bearing Retainer (all) Bolt (Cylinder Head) O-ring (Cylinder Head Side Cover and Valve Cover) Crank Pin Connecting Rod (big end) Piston Pin Valve Stem and Valve Guide Oil Seal (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 Ge
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R-31 LUBRICATION POINTS AND LUBRICANT TYPE SPEC CHASSIS Lubrication points (part name) Lubricant type Gear Unit (Gear Meter and Drive) Oil 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 (Brake Shoe Plate) Cable End (Front Brake and Clutch) Pivoting Points (Sidestand Mainstand and Rear Footrest) Brake Camshaft (Cam and Shaft) 2-17
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L-32 ENGINE LUBRICATION ROUTE SPEC Engine Lubrication route CAUTION: WARNING DO NOT DAMAGE CRANK CASE SURFACES, OTHERWISE OIL LEAKAGE WILL START 2-18
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R-33 ENGINE LUBRICATION ROUTE Engine Lubrication route CAUTION: WARNING FOR IMPROVED PERFORMANCE, ALWAYS USE YAMALUBE OIL 2-19 SPEC
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L-34 ENGINE BEARINGS ENGINE BEARINGS 2-20 SPEC
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R-35 CABLE ROUTING CABLE ROUTING SPEC É Flasher light lead (left) of the right side. Ê Horn C Pass the Meter Cable Ç and the Brake Cable through the Ë Flasher light lead (right) A Pass the Clutch Cable À, cable guide. and the Handle-bar Switch D Pass the Main Harness È through the wire Guide. Lead Á through the cable guide of the left side.
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L-36 CABLE ROUTING ¿ Headlight assembly À Handlebar switch lead Á Speedometer cable Â Cable guide Ã Clutch cable Ä Air vent hose Å Fuse Æ CDI unit Ç Clamp È Stop/tail light É Flasher light lead (right) Ê Flasher light Ë Battery Ì Battery breather hose Í Neutral switch lead Î Over flow hose Ï Crankcase breather hose Ð Brake cable A Pass the wireharness through the cable guide. B Inser the air vent hose to the hole of the flap. C Align the white marking of wireharness with the frame clamp.
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R-37 SPEC CABLE ROUTING ¿ Throttle cable À High tension cord Á Ignition Coil Â Band Ã Brake cable front Ä Speedometer Å Brake switch lead Æ Clutch cable Ç Breather hose A Pass the high tension cord À through the cable guide to the inside of throttle cable ¿ and the clutch cable Æ. B Tighten the ground lead and ignition coil together C Pass the throttle cable ¿ through the headlight stay. D Pass breather hose through upper right side hole of frame bracket engine.
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L-38 SPEC CABLE ROUTING ¿ Clamp Ã Stop/tail light lead À Rectifier regulator Ä Wireharness Á Flasher relay Å Battery Â Flasher light lead Æ CDI unit assy. A Clamp the battery positive (+) lead to the batterybox. B Insert hose Air Bent to holder of frame.
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R-39 CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENTS PERIODIC MAINTENANCE / LUBRICATION INTERVALS .......3-1 SIDE COVER, SEAT AND FUEL TANK REMOVAL ...................................................................................3-3 INSTALLATION ...........................................................................3-5 ENGINE VALVE CLEARANCE CHECKING ADJUSTMENT ....................3-6 IDLING CO MEASUREMENT, AND ADJUSTMENT .................
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L-40 INSP ADJ INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable Motorcycle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to Motorcycles already in service as well as to new Motorcycles that are being prepared for sale.
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R-41 PERIODIC MAINTENANCE/LUBRICATION INTERVALS INSP ADJ SERVICES SNO ITEM OPERATION 17 REAR SHOCK 18 DRIVE CHAIN 19 NUTS, BOLTS Check all Chassis fittings and fasteners for AND FASTENERS looseness. Tighten as per specification. CENTERSTAND Check operation and lubricate if necessary 20 FREE I PAID II III IV V VI EVERY 2000km Check operation/oil leakage, Replace if necessary. ABSORBER Check Chain slack, alignment. Adjust if necessary. Clean and lubricate.
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L-42 SIDE COVERS, SEAT AND FUEL TANK INSP ADJ SIDE COVERS, SEAT AND FUEL TANK REMOVAL SIDE COVER (LH) 2 1. Remove • Side Cover (LH) 3 1 3 2 3 2 ææææææææææææææææææææææææææææææææææ Removal steps : • Open the Lock ¿ using Main Switch Key. • Pull the Lug À towards you to remove it from the Fuel Tank. • Slide the Side Cover towards the rear end of the Motorcycle for removing the Lug Á from the Chassis. ææææææææææææææææææææææææææææææææææ REMOVAL SIDE COVER (RH) 1.
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R-43 SIDE COVERS, SEAT AND FUEL TANK 1 2 INSP ADJ REMOVAL SEAT 1. Remove • Side Cover LH and RH • Bolts 2 Nos • Seat ææææææææææææææææææææææææææææææææææ Removal steps : • Open bolts ¿ and À inside the side covers. • Lift the front of the Seat and slide it forward. REMOVAL FUEL TANK 1. Disconnect • Fuel Hose NOTE : • Position the Fuel Cock ¿ to the ‘OFF’, disconnect the Fuel Hose. • Place a rag under the Fuel Line to absorb any spilt fuel. WARNING • Gasoline is highly flammable.
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L-44 SIDE COVERS, SEAT AND FUEL TANK INSP ADJ INSTALLATION Reverse the REMOVAL procedure. Note the following points. 1. Install • Fuel Tank ¿ • Damper Rubber À • Plate Á • Bolt Â • Fuel Hose Ã Bolt (fuel tank) 20 Nm (2.0 mkg; 14.4 ft.lb) NOTE : • Keep the projection on plate Á downward. 2. Install • Seat • Bolts ¿ and À a 2 b NOTE : • Insert the projection ç on the rear of the seat into the receptacles è on the Chassis, then push down front of the seat and tighten the bolts. 1 Bolt (Seat) 3.
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R-45 VALVE CLEARANCE CHECKING AND ADJUSTMENT INSP ADJ ENGINE VALVE CLEARANCE CHECKING AND ADJUSTMENT NOTE : Valve clearance checking and adjustment should be made with the Engine in cold condition, at room temperature. When the Valve clearance is to be measured or adjusted, the Piston must be at Top Dead Center (T.D.C.) on the compression stroke and marking on Cam Sprocket should be aligned with the marking on Cylinder Head. 1.
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L-46 VALVE CLEARANCE CHECKING AND ADJUSTMENT INSP ADJ ææææææææææææææææææææææææææææææææææ Checking steps : Measurement steps : • Rotate the Crankshaft anticlockwise to align the slit ç third mark on the rotor with the stationary pointer è on the Crankcase Cover LH when the Piston is at Top Dead Center (T.D.C.) and in compression stroke. • Measure the Valve clearance by using a feeler gauge. Feeler Gauge YSST 615 Out of specification Ÿ Adjust clearance. ææææææææææææææææææææææææææææææææææ 5.
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R-47 IDLING CO. MEASUREMENT AND ADJUSTMENT INSP ADJ 7. Install • Valve Covers (with O-ring) ¿ • Spark Plug • Cylinder Head Side Cover À Valve cover (intake and exhaust) : 17.5 Nm (1.75 m kg, 13 ft-lb) Bolts (cylinder head side cover) : 10 Nm (1.0 m kg, 7.2 ft-lb) 8. Install • Seat • Side Covers • Fuel Tank Refer to the “SIDE COVERS, SEAT AND FUEL TANK” section Page no 3-3 IDLING CO. MEASUREMENT ADJUSTMENT AND 1. Start the Engine and let it warm up by running the Motorcycle approx. 4 kms. 2.
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L-48 IDLING ‘CO’ MEASUREMENT AND ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT INSP ADJ 5. Adjust : • ‘CO’ concentration ææææææææææææææææææææææææææææææææææ Adjustment steps : • Turn the pilot screw ¿ in or out until the specified ‘CO’ concentration is obtained. Turning in ‘CO’ concentratin decreases Turning out ‘CO’ concentration increases 2 1 NOTE : For adjusting the Engine idling speed use the throttle stop screw À .
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R-49 THROTTLE CABLE ADJUSTMENT/ SPARK PLUG INSPECTION INSP ADJ • Loosen the Locknut ¿ on the Throttle Cable. • Turn the Adjuster À in or out until the specified free play is obtained. Turning IN ç Ÿ Free play is increased. Turning OUT è Ÿ Free play is decreased. • Tighten the locknut ¿. WARNING After adjusting, turn the Handlebar to the right and to the left to ensure that this does not cause the Engine idling speed to change. SPARK PLUG INSPECTION 1.
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L-50 SPARK PLUG INSPECTION/ IGNITION TIMING CHECKING PROCEDURE INSP ADJ 6. Install : • Spark Plug Spark Plug : 17.5 Nm (1.75 mkg, 12.6 ftlb) NOTE : • Before installing a Spark Plug, clean the Gasket surface and Plug surface.
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R-51 IGNITION TIMING CHECKING PROCEDURE INSP ADJ 3. Check : • Ignition timing ********************************************* Checking steps : • Start the Engine and let it warm up for several minutes or run the Motorcycle for approx. 4 kms. • Maintain the Engine idling speed Engine idling speed : 1,300 ~ 1,500 r/min • Confirm that the stationary pointer on LH Crankcase Cover ç falls within the ignition timing range è marked on Rotor Assembly. NOTE : Ignition timing is not adjustable. B.T.D.C. D 28 + 1.
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L-52 COMPRESSION PRESSURE MEASUREMENT INSP ADJ COMPRESSION PRESSURE MEASUREMENT NOTE : Insufficient compression pressure will result in performance loss. 1. Check : • Valve clearance Out of specification Ÿ Adjust. Refer to “VALVE CLEARANCE ADJUSTMENT” section. Page no 3-6 2. Start the Engine and let it warm up for several minutes. 3. Turn off the engine. 4. Remove : • Spark Plug 5.
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R-53 ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT INSP ADJ 8. Install : • Fuel tank • Seat • Side covers Refer to “SIDE COVERS, SEAT AND FUEL TANK” section Page no 3-3 ENGINE OIL LEVEL INSPECTION 1. Stand the Motorcycle on a level surface using the Center Stand. NOTE: Make sure the Motorcycle is upright when inspecting the oil level. 2. Start the Engine and let it warm up for a few minutes. 3. Turn off the Engine. 4. Remove the Dip Stick ¿ (oil level gauge).
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L-54 ENGINE OIL REPLACEMENT/ EXHAUST SYSTEM INSPECTION INSP ADJ 4. Install : • Drain plug ¿ with Washer Drain plug : 20 Nm (2.0 m.Kg, 14.5 ft. lb) 5. Fill : • Oil in Crankcase 1 Oil quantity : 1.0 L 6. Check : • Engine oil level Refer to “ENGINE OIL LEVEL INSPECTION” section Page no 3-14 7. Install • Dip Stick (Oil Level Gauge) EXHAUST SYSTEM INSPECTION 1. Inspect : • Bolt ¿ (Exhaust Pipe) Loose/ Damage Ÿ Tighten / replace. • Gasket (Exhaust Pipe) Exhaust gas leaks Ÿ Tighten /replace. Bolt : 10 Nm, 1.
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R-55 AIR FILTER CLEANING INSP ADJ 1. Remove: • Side Cover (R.H.) • Air Filter Case Cap ¿ • Spring Wire À • Air Filter Element Á • Element guide Â CAUTION: WARNING Never operate the Engine without the Air Filter element installed. Unfiltered air will cause rapid wear of Engine parts and may damage the Engine. Operating the Engine without the Air Filter Element will also affect the Carburetor tuning, leading to poor Engine performance and possible overheating. 2.
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L-56 CLUTCH CABLE ADJUSTMENT INSP ADJ CLUTCH CABLE ADJUSTMENT 1. Check : • Clutch Cable free play ç Out of specification Ÿ Adjust, Free play (clutch lever) : 10 ~ 15 mm at lever end 2. Adjust: • Clutch Cable free play ææææææææææææææææææææææææææææææææææ Adjustment steps: Lever side • Loosen the Locknut ¿ • Turn the Adjuster À in or out until the specified free play is obtained. Turning in ç Ÿ Free play is increased. Turning out è Ÿ Free play is decreased.
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R-57 FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT INSP ADJ CHASSIS FRONT BRAKE ADJUSTMENT 1. Check : • Brake Lever free play a Out of specification Ÿ Adjust. Free play (Brake Lever): 10 ~ 15 mm at Brake Lever end 2. Adjust : • Brake Lever free play ææææææææææææææææææææææææææææææææææ Adjustment steps : Lever Side • Loosen the Locknut ¿. • Turn the Adjuster À in or out until the specified free play is obtained. Turning in ç Ÿ Free play is increased. Turning out è Ÿ Free play is decreased.
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L-58 REAR BRAKE ADJUSTMENT/ BRAKE SHOE INSPECTION INSP ADJ ææææææææææææææææææææææææææææææææææ Adjustment steps : • Turn the Adjuster ¿ in or until the specified free play is obtained. Turning out ç Ÿ Free play is increased. Turning in è Ÿ Free play is decreased. CAUTION: WARNING Make sure that the Brake does not drag after adjusting it. ææææææææææææææææææææææææææææææææææ 3. Adjust : • Brake light switch Refer to “BRAKE LIGHT SWITCH ADJUSTMENT”. as given below BRAKE SHOE INSPECTION 1.
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R-59 DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ DRIVE CHAIN SLACK ADJUSTMENT NOTE: • Before checking and adjusting, rotate the Rear Wheel several revolutions and check the slack at several points to find the tightest point. • Check and if necessary adjust the Drive Chain slack with the Rear Wheel in this “tightest” position. CAUTION: WARNING Too little chain slack will overload the engine and other vital parts; keep the slack within the specified limits.
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L-60 DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ ææææææææææææææææææææææææææææææææææ Adjustment steps : • Loosen both the Locknuts Â. • Turn the Adjuster Ã in or out until the specified Drive Chain slack is obtained. Turning in ç Ÿ Drive Chain slack is decreased. Turning out è Ÿ Drive Chain slack is increased. NOTE : • Turn each Chain Adjuster exactly the same amount to maintain correct Axle alignment.
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R-61 STEERING HEAD INSPECTION INSP ADJ STEERING HEAD INSPECTION WARNING Securely support the Motorcycle so that there is no danger of it falling over. 1. Stand the Motorcycle on a level surface. NOTE : Stand the Motorcycle on its Center Stand. 2. Elevate the Front wheel by placing a suitable stand under the Engine. 3. Check: • Handlebar assembly Grasp the Handle Bar and gently rock the Steering. Looseness Ÿ Adjust the Handlebar.
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L-62 STEERING HEAD INSPECTION INSP ADJ NOTE : Set the Torque Wrench to the Ring Nut Wrench so that they form a right angle. Ring nut-lower (final tightening) : 15.5 Nm (1.55 m.kg, 11.2 ft. lb) WARNING Avoid over torquing. • Check the Steering Stem by Turning it Lock to Lock. If there is any binding, remove the Steering Stem Assembly and inspect the Steering Bearings.
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R-63 FRONT FORK INSPECTION INSP ADJ FRONT FORK INSPECTION WARNING Securely support the motocycle so that there is no danger of it falling over. 1. Stand the Motorcycle on a level surface. 2. Check: • Inner tube Scratches/damage Replace. • Oil seal Excessive oil leakage Replace 1. Hold the Mitorcycle upright on level surface and apply the Front Brake 2. Check: • Operarion Push down hard on the Handlebar several times. Unsmooth operation Repair.
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L-64 INSP ADJ REAR SHOCK ABSORBER ADJUSTMENT ææææææææææææææææææææææææææææææææææ Adjustment steps: • Turn the Adjuster Ring in or out. Turning toward ç Ÿ Turning toward è Ÿ Spring preload is increased. Spring preload is decreased. Adjustment numbers: Standard 3 Minimum 1 Maximum 5 WARNING CAUTION: • Never turn the Adjuster beyond the maximum or minimum setting. • Always adjust each Shock Absorber to the same setting. ææææææææææææææææææææææææææææææææææ TYRE INSPECTION 1.
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R-65 TYRE INSPECTION INSP ADJ 2. Inspect : • Tyre surfaces Wear/damage Ÿ Replace Minimum Tyre tread Depth : (Front and rear) 1.6 mm ¿ Tread Depth À Side wall Á Wear indicator WARNING Basic weight : With oil and full fuel tank 113 kg Maximum load* 172 kg Cold tyre pressure Front Rear Up to 90 kg load* 24 psi 28psi 24psi 32psi 90 kg ~ maximum load* *Load is the total weight of the cargo, rider, passenger and accessories. • It is dangerous to ride with a worn out tyre.
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L-66 SPOKE INSPECTION AND TIGHTENEING INSP ADJ SPOKES INSPECTION AND TIGHTENING 1. Inspect : • Spokes ¿ Bending/damage Ÿ Replace. Loose spoke Ÿ Retighten 2. Tighten : • Spokes NOTE : Be sure to tighten the Spokes before and after break-in. Nipple : 2 Nm (0.2 m.kg, 0.3 ft.lb) WHEEL INSPECTION 1. Inspect : • Wheels Damage/Bends Ÿ Replace. NOTE : Always balance the wheel when a tyre or wheel has been changed or replaced. WARNING Never attempt to make any repairs to the wheel rim.
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R-67 BATTERY INSPECTION INSP ADJ ELECTRICAL BATTERY INSPECTION 1. Remove: • Side Cover (L.H.) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section. Page no 3-3 • Battery 2. Inspect : • Electrolyte level Electrotyte level should be between the Upper ¿ and Lower À level marks. Electrolyte level is too low Ÿ add distilled water to proper level. 1 MAX MIN 2 CAUTION: WARNING Use distilled water only for top up. Tap water contains minerals which are harmful to a Battery. 3.
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L-68 BATTERY INSTALLATION INSP ADJ Replace the battery if: • Battery voltage does not rise to a specific value or bubbles fail to rise during charging. • Sulphation of one or more cells occurs, (as indicated by the plates turning white, or material accumulating in the bottom of the cell ). • Specific gravity readings after a long, slow charge indicate that one cell is charged lower than the rest. • Warpage or buckling of plates or insulators is evident.
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R-69 FUSE INSPECTION INSP ADJ FUSE INSPECTION 1 WARNING CAUTION: 2 MAX MIN Always turn off the Main Switch when checking or replacing the Fuse. Otherwise, a short circuit may occur. 1. Remove: • Side cover (left) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section Page no 3-3 • Fuse holder ¿ 2. Inspect : • Fuse ææææææææææææææææææææææææææææææææææ Inspection steps : • Connect the Multimeter to the fuse and check it for continuity. NOTE : Set the multimeter selector to “Ohm x 1 resistance ” position.
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L-70 HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT INSP ADJ HEADLIGHT BEAM ADJUSTMENT 1. Adjust : • Headlight beam (vertical) Push down Ÿ Headlight beam moves lower. Pull up Ÿ Headlight beam moves higher. HEADLIGHT BULB REPLACEMENT 1. Remove: • Cowling (as applicable) • Headlight Assy. 2. Disconnect : • Headlight beam leads • Bulb cover 3. Remove : • Bulb NOTE : Unhook the Bulb spring. WARNING Keep flammable products and your hands away from the Bulb while it is on, it will be hot.
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R-71 CHAPTER 4 ENGINE OVERHAUL ENGINE REMOVAL SIDE COVERS, SEAT AND FUEL TANK REMOVAL ................4-1 ENGINE OIL DRAIN ...................................................................4-1 BATTERY ....................................................................................4-1 CARBURETOR ...........................................................................4-1 CLUTCH CABLE ........................................................................4-1 DRIVE CHAIN ..............................
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L-72 MAINTENANCE SPECIFICATIONS ENG BEARINGS AND OIL SEALS .....................................................4-31 CIRCLIPS AND WASHERS .......................................................4-31 ENGINE ASSEMBLY AND ADJUSTMENT ................................4-32 CRANKSHAFT ...........................................................................4-35 TRANSMISSION ........................................................................4-37 SHIFTER.......................................................
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R-73 ENGINE REMOVAL ENG ENGINE REMOVAL It is not necessary to remove the Engine in order to remove the following parts. • • • • • Cylinder Head Cylinder Piston Clutch CDI Magneto SIDE COVERS, SEAT AND FUEL TANK REMOVAL 1. Remove : • Side covers (LH and RH) • Seat • Fuel tank Refer to the “SIDE COVERS, SEAT AND FUEL TANK” section in Chapter 3, Page no 3-3 ENGINE OIL 1. Drain : • Engine oil Refer to the “ENGINE OIL REPLACEMENT” section in Chapter 3, Page no 3-14 BATTERY 1.
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L-74 ENGINE REMOVAL ENG CLUTCH CABLE 1. Remove : • Clutch cable ææææææææææææææææææææææææææææææææææ Removal steps : • Loosen the locknut ¿ of the Clutch Lever. • Turn in the Adjuster À to enough to free the inner Clutch Cable • Unhook the Cable End from Push Lever Á on the Crankcase L.H. ææææææææææææææææææææææææææææææææææ 3 DRIVE CHAIN 1. Remove : • Crankcase Cover#1 (L.H.) ¿ • Drive Chain Case upper À and lower Á 2.
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R-75 ENGINE REMOVAL ENG SHIFT PEDAL 1. Remove • Bolt (Shift Pedal) ¿ • Shift Pedal À BATTERY BOX 1. Remove • Bolt (Battery Box) ¿ 2 nos • Battery Box À 1 2 LEADS 1. Disconnect: • Stator Coil Lead Coupler ¿ • Sensor Coil Lead Coupler À 2. Remove : • Spark Plug Cap ENGINE REMOVAL 1.
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L-76 ENGINE DISASSEMBLY ENG ENGINE DISASSEMBLY CYLINDER HEAD, CYLINDER AND PISTON NOTE: With Engine mounted on Motorcycle, the Cylinder Head, Camshaft and Cylinder can be maintained by removing the following parts. • Side Covers • Spark Plug Lead • Seat • Engine Mount Stay • Chain Tensioner (upper) (Retract ) • Timing Check Plug • Center Plug • Exhaust Pipe • Carburetor WARNING CAUTION: Before Engine disassembly clean the outer body of Engine properly 1.
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R-77 ENGINE DISASSEMBLY ENG 5. Remove : • Tensioner Cap Bolt ¿ • Retract completely the Tensioner Rod by Screw in (clockwise) direction. • Bolts (timing chain tensioner ) À 2 Nos • Timing Chain Tensioner Assembly Á • Gasket 6. Remove : • Bolt (cam sprocket) ¿ • Plate washer (cam sprocket) À • Cam sprocket Á NOTE : Hold the Nut Rotor with socket spanner for opening Cam Sprocket Bolt. Fasten a safety wire Â to the Timing Chain to prevent it from falling in the Crankcase. 7.
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L-78 MAINTENANCE SPECIFICATIONS ENG 9. Remove : • Dowel Pins ¿ • Gasket (Cylinder) À 10. Remove : • Piston Pin Circlip ¿ 2 nos • Piston Pin À , using Piston Pin Replacer • Piston Á NOTE : Before removing the Piston Pin Circlip, cover the Crankcase with a clean cloth to prevent the Circlip from falling into the Crankcase cavity. Piston Pin Replacer : YSST - 207 C. D. I.
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R-79 ENGINE DISASSEMBLY ENG CLUTCH NOTE : The Clutch Assembly can be removed while the Engine is mounted on the Motorcycle by removing 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 Crank Assy. at extreme down position for opening the Nut Kick Crank Assy. • Loosen the Bolts of Crankcase Cover #2 (RH) in a crisscross pattern. 2.
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L-80 ENGINE DISASSEMBLY ENG 6. Remove : • Clutch Boss Nut ¿ • Lock Washer À • Clutch Boss Á • Thrust Washer Â • Clutch Housing Ã • Spacer Ä • Washer Å 7. Loosen : • Nut ¿ (Primary Drive Gear) NOTE : • Open the Nut (Primary Drive Gear) by holding the Magneto with Magneto Holder. Magneto Holder YSST - 601 A 8.
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R-81 ENGINE DISASSEMBLY ENG KICK STARTER NOTE : The kick starter can be removed while the engine is mounted by removing the following part. • Kick Crank Assy • Crankcase Cover 2 (RH) • Clutch Drum Assy 1. Remove : • Circlip ¿ • Plate washer À • Gear Kick idle Á • Plate washer Â • Circlip Ã 2. Remove : • Torsion spring ¿ • Kick axle assembly À Kick Starter disassembly 1.
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L-82 ENGINE DISASSEMBLY ENG CDI MAGNETO REMOVAL 1. Remove : • Nut (magneto) • Plain washer NOTE : • Loosen the Nut Magneto while holding the Magneto À with Magneto Holder ¿ Magneto Holder : YSST - 601 A 2. Attach • 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 À • Key wood-ruff Magneto Puller : YSST - 602 4. Remove • Bolt ¿ • Guide Stopper# 2 À • Bush • Timing chain Á 5.
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R-83 ENGINE DISASSEMBLY ENG CRANKCASE 1. Remove : • Bolts (Crankcase RH-2 nos) ¿ 2. Remove : • Bolts (Crankcase LH-8 nos) NOTE : • Loosen the Bolts in a crisscross pattern. • Loosen each Bolts 1/4 turn at a time and remove them after all are loose. 1. Remove : • Right crankcase half NOTE : Open the Engine stand mounting Nuts 2 nos . Then separate the Crankcase by using the flat head screw driver in the separating slit ç.
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L-84 ENGINE DISASSEMBLY: TRANSMISSION AND SHIFTER ENG TRANSMISSION AND SHIFTER 1. Remove : • Shift Fork Guide Bar ¿ (short) • Shift Fork Guide Bar À (long) • Shift Cam Á • Shift Fork -C Â • Shift Fork -R Ã • Shift Fork - L Ä 2. Remove : • Axle Drive assembly À • Axle Main assembly ¿ • Push Rod # 2 • Washer • Push Lever Assembly Á • Lock • Oil Seal 3. Remove : • Neutral switch ¿ • Gasket CRANKSHAFT 1. Attach • Crankshaft Removal Tool À Crankshaft Removal Tool : YSST - 265 2.
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R-85 ENGINE DISASSEMBLY ENG DISASSEMBLY OF CYLINDER HEAD, ROCKER ARMS, CAMSHAFT AND VALVES 1. Loosen : • Valve Adjuster Locknuts ¿ • Valve Adjusters À 2. Remove : • Stopper Plate Á by opening allen bolt Â 3. Attach • Rocker arm shaft puller ¿ Rocker Arm Shaft Puller YSST - 608A 4. Remove : • Rocker Arm Shafts by tightening the Puller nut À • Rocker Arms (intake/exhaust) 5. Remove : • Camshaft Assy ¿ with spacer À NOTE : Before the Valves, Valve Springs, Valve Stem Seals, etc.
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L-86 ENGINE DISASSEMBLY ENG 7. Attach Valve Spring compression Tool ¿ Valve Spring Compressor : YSST - 603 8. Remove : • Valve Cotters À NOTE : Valve Spring compressor tool 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 À • Valve Á • Valve Stem Seal Â • Valve Spring Seat Ã NOTE : Identify the position of each part very carefully so that it can be reinstalled in its original place.
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R-87 INSPECTION AND REPAIR: CYLINDER HEAD ENG INSPECTION AND REPAIR CYLINDER HEAD 1. Remove : • Carbon deposits from combustion chambers using a rounded scraper. NOTE : Do not use a sharp instrument to avoid damaging or scratching : • Spark Plug threads • Valve seats 2. Inspect : • Cylinder Head Scratches/damage Ÿ Replace 3. Measure : • Cylinder Head warpage Out of specification Ÿ resurface/ replace. Cylinder Head warpage : Less than 0.
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L-88 INSPECTION AND REPAIR:VALVE SEATS ENG VALVE SEATS 1. Remove : • Carbon deposits from the Valve Face and Valve Seat. 2. Inspect : • Valve Seats Pitting/wear Ÿ reface the valve seat. 3. Measure : • Valve Seat width ç Out of specification Ÿ Reface the Valve Seat. Valve seat width : Intake : 0.9 ~ 1.1 mm Exhaust : 0.9 ~ 1.1 mm ææææææææææææææææææææææææææææææææææ Measurement steps : • Apply Mechanic’s blueing dye (Dykem) è to the valve face.
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R-89 INSPECTION AND REPAIRS ENG ææææææææææææææææææææææææææææææææææ Lapping steps : • Apply coarse lapping compound ç to the Valve Face WARNING CAUTION: Do not let compound enter the gap between the Valve Stem and the Guide. • Apply molybdenum disulfide oil to the Valve Stem. • Install the Valve into the Cylinder Head. • Turn the Valve in one Direction using the Valve lapping tool until the Valve Face and Valve Seat are evenly polished, then clean off all compound.
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L-90 INSPECTION AND REPAIR : VALVE SPRINGS AND VALVES ENG VALVE SPRINGS AND VALVES 1. Measure : • Valve Spring free length ç Out of specification Ÿ Replace. Valve spring free length : 39.62 mm 2. Measure : • Spring tilt ç Out of specification Ÿ Replace Spring Tilt Limit : 1.7 mm 3. Check • Spring contact face Wear/pitting/scratches Ÿ Replace 4. Measure : • Valve guide inside diameter Valve guide inside diameter : Intake : 5.000 ~ 5.012 mm Exhaust : 5.000 ~ 5.
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R-91 ENGINE INSPECTION AND REPAIR ENG 6. Calculate : Stem Guide Clearance Stem-to-guide clearance = Valve guide inside diameter – Valve stem diameter Stem-to-guide clearance limit : Intake : 0.005 ~ 0.0325 mm Exhaust : 0.0125 ~ 0.026 mm Out of specification Ÿ Replace the Cylinder Head 7. Measure : • Runout (valve stem) Out of specification Ÿ Replace Runout Limit : 0.01 mm CAMSHAFT INSPECTION 1. Inspect : • Cam lobes Pitting/scratches/blue discoloration Ÿ Replace 2.
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L-92 ENGINE INSPECTION AND REPAIR ENG ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 1. Inspect : • Cam lobe contact surface ¿ • Adjuster surface À Wear/pitting/scratches/blue discoloration Ÿ Replace ææææææææææææææææææææææææææææææææææ Inspection steps : • Inspect the two contact areas on the Rocker Arms for signs of unusual wear.
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R-93 ENGINE INSPECTION AND REPAIR ENG TIMING CHAIN, SPROCKETS AND CHAIN GUIDES 1. Inspect : • Timing Chain Wear out/Stiffness/damage Ÿ Replace the Chain and the Sprockets as a set. 2. Inspect : • Cam Sprocket Wear/damage Ÿ Replace the Cam Sprocket and the timing chain as a set. ¿ 1/4 tooth gap À Correct Tooth Profile Á Roller Â Sprocket 3. Inspect : • Guide Stopper #1 ¿ • Guide Stopper # 2 À and Bush Wear/damage Ÿ Replace TIMING CHAIN TENSIONER 1.
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L-94 ENGINE INSPECTION AND REPAIR ENG CYLINDER AND PISTONS 1. Inspect : • Cylinder and Piston walls Vertical scratches Ÿ Rebore or replace the Cylinder and the Piston 2. Measure : • Piston-to-Cylinder clearance ææææææææææææææææææææææææææææææææææ Measurement steps : 1st step : • Measure the Cylinder Bore “C” with a Cylinder Bore Gauge. NOTE : Measure the Cylinder Bore “C” in parallel to and at right angles to the Crankshaft. Then, find the average of the measurements. Cylinder Bore “C” 49.000 ~ 49.
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R-95 ENGINE INSPECTION AND REPAIR ENG PISTON RING INSPECTION 1. Measure : • Side clearance Out of specification Ÿ Replace the Piston and the Piston Rings as a set NOTE : Remove the carbon deposits from the Piston Ring Grooves and Rings before measuring the side clearance. Side clearance : Top Ring : 0.030 ~ 0.065 mm 2nd Ring : 0.020 ~ 0.065 mm 5mm 2.
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L-96 ENGINE INSPECTION AND REPAIR ENG PISTON PIN INSPECTION 1. Inspect : • Piston Pin Blue discoloration/grooves Ÿ Replace and inspect the lubrication system 2. Measure : • Piston Pin-to-Piston clearance ææææææææææææææææææææææææææææææææææ Measurement steps. • Measure the Piston Pin outside diameter ç using a micrometer. If out of specification, replace the Piston Pin. Outside diameter (Piston Pin): 12.996 ~ 13.000 mm : 12.
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R-97 ENGINE INSPECTION AND REPAIR ENG CRANKSHAFT 1. Measure : • Crankshaft runout, using a Surface plate and Dial gauge. Keep the Crankshaft on V blocks and rotate slowly while measuring. Out of spescification Ÿ Replace Runout : 0.01 mm : <0.03 mm> 2. Measure : • Big end side clearance ç using a Feeler Gauge Out of specification Ÿ Replace big end Bearing , Crank Pin and Connecting Rod Big end side clearance : 0.15 ~ 0.45 mm 3. Measure : • Crank width ç Out of specification Ÿ Replace Crankshaft.
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L-98 ENGINE INSPECTION AND REPAIR 2 1 ENG PRIMARY DRIVE GEAR INSPECTION 1. Inspect : • Primary Drive Gear teeth ¿ • Primary Driven Gear teeth À Wear/damage Ÿ Replace both Gears as a set. NOTE : Refer the general specification for grading. Excessive noise during operation Ÿ Replace both Gears as a set. CLUTCH INSPECTION 1. Inspect : • Friction Plates Wear/damage Ÿ Replace the Friction Plates as a set 2. Measure : • Friction Plate thickness ç using a Vernier Calliper at four points.
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R-99 ENGINE INSPECTION AND REPAIR ENG 6. Inspect : • Dogs on the Primary Driven Gear ¿ Scoring/wear/damage Ÿ Deburr or replace • Clutch Boss Splines À Scoring/wear/damage Ÿ Replace NOTE : Scoring on the Clutch Housing Dogs and the Clutch Boss Splines will cause erratic operation of the clutch. PUSH ROD INSPECTION 1. Inspect : • Ball ¿ • Push Rod #1 À Wear/damage/Bend Ÿ Replace 2.
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L-100 ENGINE INSPECTION AND REPAIR ENG SHIFT FORK SHIFT CAM INSPECTION 1. Inspect : • Shift Fork follower ¿ • Shift Fork Pawl À Scoring/bends/wear/damage Ÿ Replace 2. Inspect : • Shift Cam grooves ¿ Wear/damage/scratches Ÿ Replace • Shift Cam Segment À Wear/damage Ÿ Replace 3. Check : • Shift Fork movement (on the Guide Bar ) Unsmooth operation Ÿ Replace the Shift Fork and the Guide Bar 4.
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R-101 ENGINE INSPECTION AND REPAIR ENG 5. Measure : • Axle runout (Main and Drive) Use a centering device and a dial gauge ¿ Out of specifications Ÿ Replace the bent Axle Runout : 0.01 mm : 0.03 mm 6. Inspect : • Gear teeth Blue discoloration/pitting/wear Ÿ Replace • Mated Dogs Rounded edges/cracks/missing portions Ÿ Replace 7. Inspect : • Shift Shaft ¿ Damage/bent/wear Ÿ Replace • Return spring (shift shaft) À • Return Spring (stopper lever) Á Wear/damage Ÿ Replace KICK STARTER INSPECTION 1.
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L-102 ENGINE INSPECTION AND REPAIR ENG OIL PUMP INSPECTION 1. Measure : • Tip clearance ç (between the inner rotor ¿ and the outer rotor À) using feeler gauge. • Side clearance è (between the outer rotor À and the Pump Housing Á) using feeler gauge Out of specification Ÿ Replace the Oil Pump Assembly • Housing and Rotor clearance é (between the Pump Housing Á and the Rotors ¿ and À ) Out of specification Ÿ Replace the Oil • Pump Assembly Damage Ÿ Replace Contamination Ÿ Clean with flushing oil.
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R-103 ENGINE INSPECTION AND REPAIR ENG DELIVERY PASSAGE INSPECTION CRANK CASE RH 1. Check : • Oil delivery passage Blockage Ÿ Blow the passage with compressed air. CRANKCASE 1. Thoroughly wash the crankcase L.H. & R.H. in mild solvent. 2. Thoroughly clean all the Gasket Mating surfaces and Crankcase Mating surfaces using solvent. 3. Inspect : • Crankcase Cracks/damage Ÿ Replace • Oil delivery passages Blockage Ÿ Blow the passages with compressed air BEARINGS AND OIL SEALS 2 1.
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L-104 ENGINE ASSEMBLY AND ADJUSTMENTS ENGINE ASSEMBLY AND ADJUSTMENTS VALVES, ROCKER ARM AND CAMSHAFT ¿ Valve Cotters À Valve Spring Retainer Á Valve Springs Â Valve Stem Seal Ã Valve Spring seat Ä Valve (intake) Å Valve (exhaust) Æ Lock Nut Ç Adjuster È Valve Rocker Arm É Rocker Arm Shaft Ê Camshaft Ë Plate 4-32 ENG
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R-105 ENGINE ASSEMBLY AND ADJUSTMENTS ENG WARNING For Engine Assembly, replace the following parts with new ones : • O-Rings • Gaskets • Oil Seals • Copper Washers • Lock Washers • Circlips VALVES AND INSTALLATION VALVE SPRINGS 1. Deburr : • Valve Stem end ¿ Using an Oil Stone for smoothing. 2. Apply : • Molybdenum disulfide oil on the Valve Stem and Oil Seal Molybdenum Disulfide Oil 3.
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L-106 ENGINE ASSEMBLY AND ADJUSTMENTS ENG 5. Secure the Valve Cotters onto the Valve Stem by tapping lightly with a mallet CAUTION: WARNING Do not hit so much as to damage the Valve CAMSHAFT AND ROCKER ARM INSTALLATION 1. Lubricate : • Camshaft ¿ Camshaft and Camshaft bearing : Multrigrade engine oil. 2. Apply : • Molybdenum disulfide oil on the rocker arm and Rocker Arm Shaft Molybdenum disulfide oil 3. Install : • Rocker Arm • Rocker Arm Shaft ¿ by pushing it in completely 4.
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R-107 ENGINE ASSEMBLY AND ADJUSTMENTS CRANKSHAFT ¿ À Á Â Ã Ä Å Æ Crank Pin Crank Shaft Connecting Rod Big end Bearing 4-35 Crankshaft Bearing Wood-ruff Key Bearing Spacer ENG
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L-108 ENGINE ASSEMBLY AND ADJUSTMENTS ENG CRANKSHAFT 1. Insert : • CrankShaft in the Crankcase (L.H.) 2. Attach : • Crankshaft Installing Tool on Crankshaft Crankshaft Installing Tool YSST - 266 Spacer YSST - 267 3. Install : • Crankshaft by tightening the Nut ¿ NOTE : Hold the Connecting Rod at Top End with one hand while turning the Nut of the Installing Tool with the other. Operate the Installing Tool until the Crankshaft is seated against the Bearing.
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R-109 ENGINE ASSEMBLY AND ADJUSTMENTS TRANSMISSION ¿ À Á Â Ã Ã Å Æ È É Ê Ë Ì Í Î Ï Drive Sprocket Oil Seal Bearing 4th Wheel Gear Drive Axle 2nd Wheel gear 3rd Wheel Gear Clutch Dog 4-37 Bearing Bearing 4th Pinion Gear 3rd Pinion Gear 2nd Pinion Gear Main axle Plate Bearing ENG
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L-110 ENGINE ASSEMBLY AND ADJUSTMENTS ENG SHIFTER ¿ À Á Â Ã Ä Å Æ Ç Shift Fork Guide Bar (long) Shift Fork # R Shift Fork # L Shift Cam Segment 4-38 Shift Fork Guide Bar (short) Shift fork # C Torx Screw Pin Shaft Cam
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R-111 ENGINE ASSEMBLY AND ADJUSTMENTS ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK INSTALLATION 1. Measure : • Axle Main Assembled length ç Assembled length (Axle Main): 82.25 ~ 83.45 mm 2. Install : • Push rod # 2 ¿ in the Axle Main. 3. Install : The following parts in Crankcase LH in following sequence. • Shift Fork “L” (left) ¿ (face the “L” side for the Clutch side.
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L-112 ENGINE ASSEMBLY AND ADJUSTMENTS Tightening Sequence CRANKCASE ¿ À Á Â Ã Crankcase #1 (LH) Dowel Pins Crankcase Breather Hose Crankcase #2 (RH) Holder Clutch Cable 4-40 ENG
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R-113 ENGINE ASSEMBLY AND ADJUSTMENTS ENG CRANKCASE LH 1. Apply : • Sealant on the Crankcase Mating surfaces Sealant Yamaha bond No. 1215: 90890-85505 2. Install : • Dowel Pins ¿ NOTE : Do not allow any sealant to come in contact with the Oil Galleries ç and è as shown in the figure. 3. Install: • 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.
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L-114 ENGINE ASSEMBLY AND ADJUSTMENTS ENG CDI MAGNETO ¿ À Á Â Ã Ä Å Æ Timing Chain Guide Stopper # 1 and # 2 CDI Rotor Assy Wood-Ruff Key 4-42 Stator Assy.
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R-115 ENGINE ASSEMBLY AND ADJUSTMENTS ENG TIMING CHAIN AND GUIDE STOPPER#2 1. Install • Timing Chain ¿ 2. Install • Guide stopper#2 À with spacer • Tighten the bolt Á C.D.I. MAGNETO INSTALLATION 1. Install : • Woodruff Key ¿ 2. Install : • C.D.I. Magneto À • Washer • Nut NOTE : When installing the Magneto Rotor, make sure that the Woodruff Key is properly seated in the Keyway of the Crankshaft. 3. Tighten : • Nut (CDI Magneto) using the Magneto Holder À Nut (CDI Magneto): 70 Nm (7.0 m.kg, 51 ft.
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L-116 ENGINE ASSEMBLY AND ADJUSTMENTS SHIFT SHAFT AND KICK STARTER ¿ À Á Â Ã Ä Shift Shaft Torsion Spring Stopper Lever Return Spring Segment Kick Starter Assembly Å Æ Ç È É 4-44 Circlip Washer Kick Idle Gear Kick Shaft Assy.
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R-117 ENGINE ASSEMBLY AND ADJUSTMENTS ENG SEGMENT AND SHIFT SHAFT 1. Install • Dowel Pins ¿ on the Cam Shifter À 2. Install : • Segment ¿ using Torx Bit Tool Torx Bit Tool YSST - 611 NOTE : Fit the Dowel Pins on the Cam Shifter to the locating hole ç on the Cam Shifter and install the Segment ¿ 3. Install : • Stopper Lever ¿ • Spring À 4. Tighten • Bolt stopper lever Á Bolt (Stopper Lever) : 10 Nm (1.0 m.kg, 7.2 ft.
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L-118 ENGINE ASSEMBLY AND ADJUSTMENTS ENG KICK STARTER INSTALLATION 1. Install : • Kick Axle Assembly ¿ • Kick Gear Clip À • Torsion Spring Á NOTE : Turn the Torsion Spring clockwise and hook into the proper hole ç in the Crankcase. 2.
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R-119 ENGINE ASSEMBLY AND ADJUSTMENTS ENG CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP ¿ À Á Â Ã Ä Å Clutch Spring Pressure Plate Push Plate Push Rod #1 Friction Plate Clutch Plate Clutch Boss Æ Ç È É Ê Ë Ì Thrust Washer Primary Driven Gear Ball Push Rod # 2 Push lever Axle Primary Drive Gear Rotary Filter 4-47 Í Î Ï Ð Ñ Key Oil Pump Drive Gear Oil Pump Driven Gear Oil Pump Gasket
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L-120 ENGINE ASSEMBLY AND ADJUSTMENTS ENG OIL PUMP INSTALLATION 1. Lubricate : • Oil delivery passage (Crankcase RH) • Oil Pump Assembly ¿ Recommended Lubricant: 4- Stroke Engine Oil 2. Install : • Drive gear (Oil Pump) ¿ • Gasket • Oil Pump Assy Á 3. Tighten • Screw (2 nos) À 4. Install • Rotary Filter NOTE : Align the Rotary Filter Dog ç with groove of the Crankshaft è and make sure to keep ‘TOP’ marking facing upside. PRIMARY DRIVE GEAR INSTALLATION 1.
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R-121 ENGINE ASSEMBLY AND ADJUSTMENTS ENG CLUTCH INSTALLATION 1. Install : • Oil Seal ¿ New • Circlip New • Push Lever Axle À NOTE : Install longer side ç of the Spring on Push Lever and smaller side è on the Crankcase Notch. 2. Install : • Washer ¿ • Spacer À • Primary Driven Gear Á • Thrust Washer Â • Clutch Boss Ã • Lock Washer Ä New • Clutch Boss Nut Å 3. Tighten : • Nut Clutch Boss ¿ while holding the Clutch Boss with Clutch Hub Holder À Clutch Hub Holder YSST - 233 Nut (Clutch Boss ): 60 Nm (6.0 m.
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L-122 ENGINE ASSEMBLY AND ADJUSTMENTS ENG 6. Install : • Ball 7. Install : • Push Rod # 1 ¿ • Push Plate À • Plate Washer Á • Nut Â (Push Rod # 1) 8. Install : • Pressure Plate ¿ • Compression Springs À • Bolts Á (Clutch Spring) Bolts (Clutch Spring) : 6 Nm (0.6 m.kg, 4.3 ft. lb) a ALIGNED b NOTE : Match arrow mark ç on the Pressure Plate with the Punch mark on Clutch Boss è while installing the Pressure Plate. Tighten the Clutch Spring Bolts in stage, using a crisscross pattern. 9.
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R-123 ENGINE ASSEMBLY AND ADJUSTMENTS ENG • Hold the Adjuster to prevent it from moving and tighten the Locknut to specification CAUTION: WARNING Take care not to overtighten the Adjuster À and remove the freeplay between both Push Rods. • Tighten the Locknut ¿ ææææææææææææææææææææææææææææææææææ 11. Install • Strainer NOTE : Always keep its wider side, outside of Crankcase 12. Install : • Dowel Pins • Gasket (Crankcase #2) New • Crankcase Cover #2 (RH) Bolts (Crankcase Cover): 10 Nm (1.0 m.kg, 7.2 ft.
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L-124 ENGINE ASSEMBLY AND ADJUSTMENTS CYLINDER AND PISTON ¿ À Á Â Cylinder Gasket Cylinder Dowel Pins Piston Rings Ã Piston Pin Circlips Ä Piston Å Pin Piston 4-52 ENG
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R-125 ENGINE ASSEMBLY AND ADJUSTMENTS ENG CYLINDER HEAD ¿ À Á Â Ã Ä Bolt Flange Washer Bolt Valve Cover (intake) O-Ring Valve Cover (exhaust) Å Æ Ç È É Ê 4-53 Cylinder Head Dowel Pin Gasket Cylinder Head O-Ring Cover Cylinder Head Side # 3 Spark Plug
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L-126 ENGINE ASSEMBLY AND ADJUSTMENTS CAM SPROCKET AND TIMING CHAIN Â Cam Sprocket Ã Timing Chain Ä Guide Stopper # 1 ¿ Gasket À Timing Chain Tensioner Assembly Á Guide Stopper # 2 4-54 ENG
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R-127 ENGINE ASSEMBLY AND ADJUSTMENTS ENG PISTON RING, PISTON AND CYLINDER INSTALLATION 1. Install in following sequence • Expander Spacer (Oil Ring) ¿ • Side Rails (Oil Ring) À • 2nd Ring Á • Top Ring Â NOTE : • Make sure to install the Piston Rings so that the “GTP TOP1” / “GTP-TOP 2” marks are located on the upper side of the 2nd Ring/Top Ring • Lubricate the Piston and Piston Rings with Engine Oil. 2.
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L-128 ENGINE ASSEMBLY AND ADJUSTMENTS ENG 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 compressing the Piston Rings with the other hand • Pass the Timing Chain and Guide stopper # 2 through the Timing Chain Cavity.
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R-129 ENGINE ASSEMBLY AND ADJUSTMENTS ENG 2. Install : • Cylinder Head • Bolt with Washer (Cylinder Head) Bolts (Cylinder Head ): M8 (1-4) : 22 Nm (2.2 m.kg, 17 ft.lb) M6(5-6) : 10 Nm (1.0 m.kg., 7.2 ft. lb) NOTE : • Apply Engine Oil onto the Bolt thread • Tighten the Bolts starting with the lowest numbered one. 3.
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L-130 ENGINE ASSEMBLY AND ADJUSTMENTS ENG 4. Install : • Plate Washer 5. Tighten • Bolt Sprocket ¿ Bolt (Timing Chain Sprocket) : 20 Nm (2. 0 m.kg, 14.5 ft. lb) NOTE : Install the Bolt while holding the Magneto Mounting nut with a Wrench. 6. Check : • Magneto Rotor Slit ç Third mark in Anticlockwise direction. Align with stationary pointer è in the Crankcase Cover #1 (LH) • Cam Sprocket “I” mark é Align with stationary pointer ê on the Cylinder head Out of alignment Ÿ Adjust 7.
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R-131 ENGINE ASSEMBLY AND ADJUSTMENTS ENG 8. Check : • Valve clearance specifications Out of specification Ÿ Adjust. Refer to the “VALVE CLEARANCE ADJUSTMENT” section in Chapter 3, Page no 3-8 9. Lubricate : • 4 Stroke Engine Oil Recommended Lubricant : Engine Oil - YAMALUBE 10.Install : • Valve Covers (with O-Ring) ¿ • Cylinder Head Side Cover (with O-Ring) À • Bolts Á Valve Cover : 17.5 Nm (1.75 m.kg, 13 ft.lb) Bolts (Cylinder Head Side Cover) 10 Nm (1.0 m.kg, 7.2 ft.lb) 11.
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L-132 ENGINE ASSEMBLY AND ADJUSTMENTS ENG 14. Install : • Spark Plug Spark Plug : 17.5 Nm (1.75 m.kg, 12.6 ft. lb) 15. Install : • Plug Drain Plug Drain : 20 Nm (2.0 m.kg, 2.0 ft.lb) 1 ENGINE MOUNTING When remounting the Engine, reverse the removal procedure. Note the following points : 1. Install : • Engine Assembly (from the Left side of the Motorcycle) 2. Install • Footrest Assy 3.
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R-133 ENGINE ASSEMBLY AND ADJUSTMENTS Engine Mount Bolt (Rear) : 38 Nm (3.8 m.Kg.27.5 ft. lb) Bolt (Engine mount Stay) : 38 Nm (3.8 m..kg, 27. 5 ft.lt) Engine mount bolt (upper) 38 Nm (3.8 m..kg, 27. 5 ft.lt) Bolt (Engine Mount Stay front upper) 38 Nm (3.8 m.kg., 27.5 ft.lb) ENG 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 ft.lb) 5.
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L-134 ENGINE ASSEMBLY AND ADJUSTMENTS ENG 11. Install: • Carburetor Refer to “CARBURETOR “ section in Chapter 5 page no 5-7 12. Tighten: • Air Filter Case Screws ¿ Bolts (Air Filter Case ): 7 Nm (0.7 m.kg, 5.1 ft.lb) 13. Install • Battery Box • Battery • Battery Flap Bolts (Battery Box) 3.8 Nm (0.38 mkg), 3 ft lb 14. Connect • Battery Leads • Sensor Coil Lead Coupler WARNING CAUTION: Connect the positive lead ¿ First and then the negative lead À 15. Install Spark Plug Cap 16.
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R-135 CARBURETION CARB CHAPTER 5 CARBURETION CARBURETOR VIEW ................................................................5-1 REMOVAL ...................................................................................5-2 DISASSEMBLY ...........................................................................5-3 INSPECTION .............................................................................. 5-4 ASSEMBLY .................................................................................
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L-136 CARBURETOR CARB CARBURETOR ¿ À Á Â Ã Ä Å Æ Ç È É Throttle Cable Jet Needle Assembly Spring Throttle Valve Plug Drain Float Chamber Body O-Ring Main Chamber Body Float Pin Float Needle Valve Assembly Jet Main Ê Throttle valve Ë Nozzle Main Ì Screw Pilot Assembly Í Jet Pilot Î Starter Lever Ï Plunger Starter Assy Ð Throttle stop Screw Ñ Pipe Drain Ò Cable Adjust Screw Set Ó Seal (F.C.B.
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R-137 CARBURETOR CARB REMOVAL 1. Remove : • Side Covers (LH & RH) Refer to the “SIDE COVER, SEAT AND FUEL TANK” section in Chapter 3, Page no 3-3 2. Drain : • Fuel (Float Chamber) NOTE : Place a rag under the over flow hose to absorb the spilt fuel. WARNING Petrol is highly flammable. Avoid spilling fuel on the hot Engine. 3. Disconnect : • Air Vent Hose ¿ • Fuel Hose À • Over Flow Hose Á 4.
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L-138 DISASSEMBLY CARB DISASSEMBLY NOTE: The following parts can be cleaned 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 Lever Opeartion. 1. Open • Screws (Float chamber) ¿ 4 Nos 2. Remove : • Float Chamber À • Seal Float Chamber Á 3. Remove : • Float Pin ¿ • Float À 4. Remove : • Needle Valve ¿ 5.
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R-139 DISASSEMBLY/INSPECTION CARB 7. Remove : • Pilot Screw Assembly ¿ (Spring, Washer and ‘O’ ring) • Pilot Jet À 8. Remove : • Cap plunger ¿ • Starter Lever Assembly À by opening Cap Plunger Ã • Starter Plunger Assembly Á 9. Remove • Throttle Stop Screw Set Â (Spring, Washer and ‘O’ ring INSPECTION Carburetor Body 1. Inspect : • Cracks/damage Ÿ Replace • Fuel Passages Blockage Ÿ Clean with petrol and Compressed air. • Contamination in jet housings Ÿ Clean Carburetor Float Chamber Body 1.
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L-140 INSPECTION CARB Float 1. Inspect : • Damage Ÿ Replace Needle Valve and Valve Seat 1. Inspect • Needle Valve ¿ • valve seat À • O-Ring Á Damage/wear /blockage Ÿ Clean/Replace as a set Jets and Screws 1. Inspect : • Jet Needle ¿ • Needle Jet À (Main Nozle) • Main Jet Á • Pilot screw Â • Pilot jet Ã • Throttle Stop Screw Ä • Bends/wear/damage Replace Blockage Ÿ Blow the Jets compressed air with Throttle Valve 1.
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R-141 ASSEMBLY CARB ASSEMBLY Reverse the disassembly procedure. 1. Wash • All the parts in clean petroleum based solvent • Always use new ‘o’ rings 2. Install : • Pilot jet ¿ • Pilot screw assembly À 3. Install : • Needle Jet ¿ (Main Nozzle) • Main Jet À 4. Install : • Valve Seat ¿ • Valve seat stopper À • Valve seat Stopper screw Á • Needle Valve Â 5. Install : • Float ¿ • Float Pin À 6. Measure • Float Height ç Incorrect Ÿ Adjust Float Height : 9.3 ± 1mm 7.
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L-142 INSTALLATION CARB 8. Install • Throttle Stop Screw set ¿ 9. Install • Starter Plunger Assembly À with Starter Lever Á INSTALLATION Reverse the “REMOVAL” procedure 1. Install : • Spring, Throttle Valve with the Throttle Cable 2. Install : • Throttle Valve Assembly With Carburetor Chamber Top NOTE : Align the slot ç on the Throttle Valve ¿ with the projection è on the Carburetor Body. 3. Install : • Carburetor Assembly and Joint together on the intake manifold.
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R-143 CARBURETOR TUNING CARB 8. Adjust : • Idling speed by Throttle Stop Screw ¿ 1 Engine Idling Speed : 1300 - 1500 R.P.M. 9. Adjust : • Throttle Cable free play Refer to “THROTTLE CABLE ADJUSTMENT” in Chapter 3, Page no 3-9 Carburetor Tuning ‘CO MEASUREMENT AND ADJUSTMENT” 1. Start the Engine and let it worm up by running approximately 4 kms. 2. Attach : • Tachometer to the Spark Plug lead 3. Check : • Engine idling speed If out of sepecification Ÿ adjust Engine Idling Speed : 1300 - 1500 R.P.M.
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L-144 CARBURETOR TUNING CARB CAUTION: WARNING Do not disturb settings of the Carburetor if the Engine performance is O.K. • If required, must record the existing setting (No. of turns) of the Pilot Screw. • To counter check the setting of the Pilot Screw, follow the ‘CO’ adjustement procedure. • Ensure proper clamping of the blind plug 6. Adjust : • Idling speed by Throttle Stop Screw ¿ 1 Engine Idling R.P.M. 1300 to 1500 RPM ææææææææææææææææææææææææææææææææææ FUEL LEVEL ADJUSTMENT 1.
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R-145 CARBURETOR TUNING CARB • Otherwise adjust Float level by bending the Float Tang Â on the Float slightly up or down as required.
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L-146 FRONT WHEEL AND FRONT BRAKES CHAS CHAPTER 6 CHASSIS FRONT WHEEL AND FRONT BRAKE ...................................... 6-1 FRONT WHEEL .........................................................................6-1 FRONT BRAKE ..........................................................................6-2 REMOVAL ...................................................................................6-3 FRONT WHEEL INSPECTION ..................................................
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R-147 FRONT WHEEL AND FRONT BRAKES FRONT WHEEL ¿ À Á Â Ã Ä Å Æ Cotter Pin Axle Nut Speedometer Cable Assy. Wheel Axle Spacer Brake Shoe Plate Assy.
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L-148 FRONT WHEEL AND FRONT BRAKES FRONT BRAKE ¿ À Á Â Ã Ä Å Æ Ç È É Ê Brake Shoe Assy.
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R-149 FRONT WHEEL AND FRONT BRAKES CHAS REMOVAL WARNING • Securely support the Motorcycle on the centre stand so that there is no danger of it falling over. • Park the Motorcycle on a level surface 1. Loosen : • Lock nut ¿ and screw in the adjuster À fully to loosen the Brake Cable 2. Remove : • Front Brake Cable Á by slacking and removing it first from the Handlebar end and then from the Front Wheel end. 3. Disconnect • Speedometer Cable ¿ by removing the clip À 4. Remove • Cotter Pin ¿ • Nut À 5.
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L-150 FRONT WHEEL AND FRONT BRAKES CHAS Front Wheel Inspection : 1. Inspect • Front Wheel Axle (by rolling it on a flat surface) Bends Ÿ Replace Wheel Axle Bending Limit : 0.25 mm WARNING Do not attempt to straighten a bent Axle 2. Inspect : • Front Tyre Wear/damage Ÿ Replace Refer to “TYRE INSPECTION” in Chapter 3, Page no 3-26 • Front Wheel Refer to “WHEEL INSPECTION” in Chapter 3, Page no 3-27 3.
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R-151 FRONT WHEEL AND FRONT BRAKES CHAS 5. Measure : • Front Wheel runout using a height gauge Over the specified limits Ÿ Correct/Replace Front Wheel runout limits : Radial ç : 0.5 mm Lateral è : 0.8 mm 6. Inspect : • Front Wheel Bearings Bearings allow free play in the Wheel Hub or the Wheel does not turn smoothly Ÿ Replace • Oil Seals Wear/damage Ÿ Replace 7. Inspect : • Collar Grooved Wear Ÿ Replace the Collar and the Oil Seal as a set BRAKE SHOE PLATE DIASSEMBLY 1.
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L-152 FRONT WHEEL AND FRONT BRAKES CHAS FRONT BRAKE INSPECTION 1. Inspect : • Brake Lining surface Glazed areas Ÿ Replace Use Coarse Sand Paper for polishing of Brake Lining NOTE: After polishing , wipe the polished particles with a cloth. 2. Measure : • Brake Lining thickness ç Out of specification Ÿ Replace Brake Lining thickness: Standard : 4 mm Limit : 2 mm NOTE : Replace the Brake Shoes as a set if either is worn to the limit. 3.
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R-153 FRONT WHEEL AND FRONT BRAKES CHAS BRAKE SHOE PLATE ASSEMBLY 1. Install : • Camshaft ¿ • Indicator Plate À ææææææææææææææææææææææææææææææææææ Installation steps : • Align the projection ç on the Indicator Plate À with the Camshaft notch è ææææææææææææææææææææææææææææææææææ 2. Install : • Cam Lever ¿ • Bolt Cam Lever À Cam Lever Nut : 10 Nm (1.0m.kg, 7.2 ft.lb) 3.
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L-154 FRONT WHEEL AND FRONT BRAKES CHAS FRONT WHEEL INSTALLATION Reverse the “REMOVAL” procedure Note the following points 1. Lubricate : • Axle Front Wheel • Bearings • Oil Seal (lips) • Drive/Driven Gear (Speedometer) Recommended lubricant : Lithium Soap base grease 2. Install : • Front Wheel NOTE: Make sure that the slot ç in the Shoe Plate fits over the Stopper è on the Front Fork Outer Tube LH 3.
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R-155 FRONT WHEEL AND FRONT BRAKES CHAS 5 Install : • Meter Cable ¿ • Clip À • Brake Cable Á WARNING Make sure that the Brake Cable and Meter Cable is routed properly. 6. Check : • Front Brake for proper operation Improper operation Ÿ Recheck or disassemble. 7.
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L-156 REAR WHEEL AND REAR BRAKE CHAS REAR WHEEL ¿ À Á Â Ã Ä Å Æ Ç È É Ê Ë Ì Adjuster Pin CompressionSpring Cotter Pin Tension Bar Axle Nut Chain Puller 6-10 Driven Sprocket Axle Rear Wheel Assembly Brake Shoe Plate Assembly Damper Bearing Spacer/Collar Bearing
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R-157 REAR WHEEL AND REAR BRAKE REAR BRAKE ¿ À Á Â Brake Shoe Kit Cam Lever Indicator Plate Camshaft 6-11 CHAS
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L-158 REAR WHEEL AND REAR BRAKE CHAS REMOVAL WARNING • Securely support the Motorcycle on centre stand so that there is no danger of it falling over • Stand the Motorcycle on a level surface 1. Remove : • Chain Cover (upper ¿ and lower À) 2. Loosen • Chain Adjuster Á 3. Remove : • Adjuster (Rear Brake) ¿ • Pin À • Nut Á with Bolt • Tension Rod Â • Compression Spring Ã • Brake Rod Ä 4.
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R-159 REAR WHEEL AND REAR BRAKE CHAS REAR WHEEL INSPECTION 1. Inspect : • Axle Rear Wheel • Rear Wheel • Bearings Rear Wheel • Oil Seals Refer to “FRONT WHEEL INSPECTION” Page no 6-4 2. Measure : • Rear Wheel runout Refer to “FRONT WHEEL INSPECTION ” Page no 6-4 3. Inspect : • Clutch Hub Damper Wear/damage Ÿ Replace REAR BRAKE INSPECTION 1. Inspect : • Brake Lining surface 2. Measure : • Brake Lining thickness 3.
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L-160 REAR WHEEL AND REAR BRAKE CHAS REAR WHEEL INSTALLATION Reverse the “REMOVAL” procedure 1. Install : • Rear Wheel Assembly • Brake Shoe Plate Assembly • Spacer with Chain Adjuster • Axle Rear Wheel NOTE : Make sure that the slots in the Rear Wheel Hub Damper fits over the tabs on the Clutch Hub assembly 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 tightening.
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R-161 DRIVE CHAIN AND SPROCKETS CHAS DRIVE CHAIN AND SPROCKETS ¿ À Á Â Ã Ä Chain Case Crankcase Cover 3 Drive Sprocket Clip Chain Joint Link Plate Chain Joint Å Æ Ç È É Ê 6-15 Drive Chain Nut Driven Sprocket Axle Driven Sprocket Assembly Chain Tensioner Circlip Oil Seal
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L-162 DRIVE CHAIN AND SPROCKETS CHAS REMOVAL 1. Stand the Motorcycle on a level surface. WARNING Securely support the Motorcycle on Centre stand so that there is no danger of it falling over. 2. Remove : • Chain Case (upper and lower) ¿ • Shift pedal À • Crankcase Cover 3 Á • Drive Sprocket Refer to “ENGINE REMOVAL” Section in Chapter 4, Page No 4-1 1 3 2 3. Remove • Rear Wheel Refer to “REAR WHEEL” Section Page no 6-12 4.
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R-163 DRIVE CHAIN AND SPROCKETS CHAS DRIVE CHAIN INSPECTION 1. Inspect : • Drive Chain stiffness Stiffness Ÿ Clean and Lubricate or replace 2. Inspect : • Drive Chain ¿ • Driven Sprocket À More than 1/2 tooth wear ç Ÿ Replace the Drive Chain and both the Sprockets as a set. 3. Measure : • 10 link length è (Drive Chain) Out of specification Ÿ Replace the Drive Chain 10 link length limit : 119.
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L-164 DRIVE CHAIN AND SPROCKETS CHAS CLUTCH HUB INSPECTION 1. Inspect : Clutch Hub Wear/damage/cracks Ÿ Replace DRIVEN SPROCKET ASSEMBLY 1. Install • Driven Sprocket ¿ on Clutch Hub • Lock Washer À New • Nut Á Nut (Driven Sprocket ): 26 Nm (2.6 m.kg, 19 ft.lb) NOTE : Tighten the Nuts in a crisscross pattern 2. Bend : Lock Washer Tab ¿ (along a flat side of the end) DRIVEN SPROCKET AND DRIVE CHAIN INSTALLATION 1.
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R-165 DRIVE CHAIN AND SPROCKETS CHAS 3. Install : • Drive Sprocket • Drive Chain ¿ • Chain Joint À • Plate Á 4. Install : Clip ¿ New CAUTION: WARNING Be sure to install the Chain Joint Clip to the direction as shown 5. Install : • Chain Case (upper) • Chain Case (lower) • Shift Pedal Refer to “ENGINE REMOVAL” section in Chapter 4 Page no 4-1 6. Adjust : • Drive Chain Slack Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in Chapter 3, Page no 3-20 7.
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L-166 FRONT FORK CHAS FRONT FORK ¿ À Á Â Ã Ä Front Fender Cap Bolt Holder Cable O Ring Collar Spring Seat Å Æ Ç È É Ê Fork Spring Seal Dust Ring Snap Washer Bolt Gasket 6-20 Ë Ì Í Î Ï Ð Spindle Taper Cylinder Comp Front Fork Inner Tube Sub Spring Oil seal Outer Tube
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R-167 FRONT FORK CHAS FRONT FORK REMOVAL WARNING Securely support the Motorcycle so there is no danger of it falling over 1. Stand the Motorcycle on a level surface 2. Elevate the Front Wheel by placing a suitable stand under the Engine 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 Nos ¿ • Cap Bolt Under Bracket (1No) À FRONT FORK DISASSEMBLY 1.
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L-168 FRONT FORK CHAS 3. Loosen : • Bolt Allen (Damper Rod) ¿ Loosen the Bolt (Damper Rod) ¿ while holding the Damper Rod with T-Handle À T-Handle YSST - 213 4. Remove : • Bolt (Damper Rod) ¿ • Washer À • Cylinder complete Fornt Fork • Spindle Taper • Spring Sub 5.
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R-169 FRONT FORK CHAS FRONT FORK INSPECTION 1. Inspect : • Inner Tube bending Inner Tube bending limit : 0.2 mm Scratches/bends/damage Ÿ Replace WARNING Do not attempt to straighten a bent Inner Tube as this may dangerously weaken the Tube 2. Measure : • Fork Spring length ç Front Fork Spring free length : 320.9 mm 315.9 Over the specified limit Ÿ Replace 3.
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L-170 FRONT FORK CHAS 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 • Before assembling the Fork, make sure that all the components are clean. 1. Install : • Spring Sub ¿ • Cylinder Complete À WARNING Allow the Cylinder Complete to slide slowly down the Inner Fork Tube until it protrudes from the bottom, being careful not to damage the Inner Fork Tube 2.
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R-171 FRONT FORK CHAS 5. Tighten : • Bolt (Cylinder Complete) ¿ holding the Cylinder Complete with a T-Handle À Bolt (Cylinder Complete) : 23 Nm (2.3 m.kg, 17 ft.lb) T-Handle YSST - 213 6. Install : • Oil Seal ¿ New Using TFF Oil Seal Installation Tool TFF Oil Seal Installation Tool YSST - 275 NOTE : • Before installing the Oil Seal ¿ apply lithium soap base grease onto the Oil Seal lips.
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L-172 FRONT FORK CHAS 9. Fill : • Fork Oil ¿ Oil Quantity : Overhauling - 165 ± 3 ml Refilling - 153 ± 4 ml Recommended Oil : Teleshocab Oil 10. After filling up, slowly Pump the Fork up and down to distribute the Fork Oil 11. Install : • Front Fork Spring ¿ • Seat Upper • Spacer 12. Install : • Cap Bolt Temporarily to avoid oil drain. NOTE : • Install the Fork Spring with its smaller Pitch upward. • Before installing the Cap Bolt, apply grease to the O-Ring.
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R-173 STEERING HEAD AND HANDLEBAR CHAS STEERING HEAD AND HANDLEBAR ¿ À Á Â Ã Ä Å Æ Ç È É Ê Ë Ì Í Î Ï Holder Handle Bar Lower Holder Handlebar Upper Handlebar Grip Assembly (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 Steps • Tighten the ring nut Lower 45.5 Nm (4.55 m.kg, 32.3 ft.lb) • Loosen One turn • Retighten The ring nut Lower 15.
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L-174 STEERING HEAD AND HANDLEBAR CHAS REMOVAL WARNING 2 3 Securely support the motorcycle so that there is no danger of it falling over Stand the motorcycle on a level surface 1 1. Remove : • Band ¿ • Brake Cable (front) À • Clutch Cable Á • Speedometer Cable Â 2. Remove : Switch Handle ¿ 1 4 3. Remove : • Bolts (4 Nos) ¿ • Handlebar Upper Holder À • Handlebar Á • Throttle Grip • Lever Holder (Front Brake) 4.
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R-175 STEERING HEAD AND HANDLEBAR CHAS 7. Remove : Lock Washer ¿ Ring Nut (upper) À Damper Rubber Á 8. Remove : • Ring Nut (lower) ¿ Use a Ring Nut Wrench À Ring Nut Wrench : YSST - 621 WARNING Securely support the Steering Shaft so that there is no danger of it falling down 9. Remove : • Bearing Cover ¿ • Bearing Race À • Balls (upper) Á • Lower Bracket Â • Balls (lower) Ã HANDLEBAR REMOVAL 1.
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L-176 STEERING HEAD AND HANDLEBAR CHAS STEERING INSPECTION 2 1 1. Wash the Bearing and Ball Races with a solvent 2.
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R-177 STEERING HEAD AND HANDLEBAR CHAS 4. Install : • Front Fork Refer to “FRONT FORK” Section, Page no 6-27 • Front Fender • Front Wheel Refer to “FRONT WHEEL” Section, Page no 6-8 HANDLEBAR INSTALLATION 1. Install : • Holder Handelbar Lower ¿ • Handlebar ¿ • Upper Handlebar Holder À Bolt (Handlebar Upper Holder): 7.5 ~ 12 Nm (2.3 m.kg, 17 ft.
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L-178 REAR SHOCK ABSORBER AND SWING ARM REAR SHOCK ABSORBER AND SWINGARM ¿ À Á Â Ã Rear Shock Absorber Axle Nut Swing arm Tension Bar Seal Guard 6-32 CHAS
PAGE 180
R-179 REAR SHOCK ABSORBER AND SWING ARM CHAS REMOVAL 1. Stand the Motorcycle on a level surface. WARNING Securely support the Motorcycle on a level surface 2. Remove : • Side Covers (left and right) • Seat • Cover Chaincase • Chain Case (upper and lower) Refer to “SIDE COVERS, 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.
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L-180 REAR SHOCK ABSORBER AND SWING ARM CHAS INSPECTION 1. Inspect : • Swingarm looseness Looseness exists Ÿ Tighten the Pivot Shaft nut or replace Bushes • Swingarm up and down movement Unsmooth movement/bending/rough spots Ÿ Replace Bushes 2.
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R-181 CHAPTER 7 ELECTRICAL CIRCUIT DIAGRAM ................................................................... 7-1 LOCATION OF ELECTRICAL COMPONENTS .........................7-2 CHECKING OF CONNECTIONS ............................................... 7-3 IGNITION SYSTEM/CHARGING SYSTEM CIRCUIT DIAGRAM .............................................................7-4 TROUBLESHOOTING .........................................................7-4 CHARGING SYSTEM TROUBLESHOOTING ...................................
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L-182 CIRCUIT DIAGRAM CIRCUIT DIAGRAM 7-1 ELEC
PAGE 184
R-183 ELECTRICAL COMPONENTS ELEC LOCATION OF ELECTRICAL COMPONENTS ¿ À Á Â Ã Ä Main Switch Flasher Relay Assy C.D.I.
PAGE 185
L-184 CHECKING OF CONNECTIONS ELEC CHECKING OF CONNECTIONS Dealing with wire pressed stains, rust, moisture etc. on the connector. 1. Disconnect • Connector ¿ 2. Dry each terminal with an air blower 3. Connect and disconnect the Connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin ¿ and reinsert the terminal in to the connector. 6. Check for continuity with a tester.
PAGE 186
R-185 IGNITION SYSTEM/ CHARGING SYSTEM ELEC IGNITION SYSTEM AND CHARGING SYSTEM CIRCUIT DIAGRAM TROUBLE SHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE. (NO SPARK OR INTERMITTENT SPARK) PROCEDURE CHECK 1. Spark Plug 2. Spark Plug 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 required parts before trouble shooting.
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L-186 IGNITION SYSTEM / CHARGING SYSTEM ELEC PROCEDURE STEPS • • • • 1. SPARK PLUG Check the spark plug condition Check the Spark Plug type Check the Spark Plug gap Refer to “SPARK PLUG INSPECTION“ section in Chapter 3, Page 3-10 Standard Spark Plug DPR7EA (NGK) Spark Plug Gap : 0.7 mm OUT OF SPECIFICATION Adjust or replace the Spark Plug 2. SPARK PLUG CAP RESISTANCE • Remove the Spark Plug Cap • Connect the Multimeter (ΩX1k) to the Spark Plug Cap.
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R-187 IGNITION SYSTEM / CHARGING SYSTEM ELEC æ Multimeter (+) lead Ÿ Orange Terminal ¿ Multimeter (-) lead Ÿ Earth À 3A. IGNITION COIL RESISTANCE (Primary) • Disconnect the Ignition Coil Connector From the Wire harness • Connect the Multimeter to the Ignition Coil. • Check the primary Coil resistance Primary coil resistance : 0.16 Ω ± 15 % ( at 20º C) 3B.
PAGE 189
L-188 IGNITION SYSTEM/ CHARGING SYSTEM ELEC Mutimeter (+) lead Ÿ Blue/Yellow terminal ¿ Multimeter (-) lead Ÿ Green tertminal À 5. SENSOR COIL RESISTANCE • Disconnect the sensor Coil Coupler from the Wiring Harness • Connect the Multimeter (Ω X 100) to the sensor coil coupler • Check the sensor coil resistance Sensor coil resistance : 240 Ω ± 20 % (at 20ºC) OUT OF SPECIFICATION MEETS SPECIFICATION Sensor coil is OK Replace the Sensor Coil Assembly 6.
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R-189 IGNITION SYSTEM / CHARGING SYSTEM ELEC æ Multimeter (+) lead Ÿ Battery (+) terminal ¿ Multimeter (-) lead Ÿ Battery (-) terminal À 7. RECTIFIER CUM REGULATOR UNIT • Check the Charging Voltage Procedure Steps • Connect the Tachometer to Spark plug lead • Connect the Multimeter ( DC 20V) to Battery Red Wire. Measure the Battery Voltage : 12V If less than specifications, charge the Battery • Start the engine and accelearte the Engine up to 5000 RPM .
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L-190 CHARGING SYSTEM ELEC TROUBLE SHOOTING IF THE BATTERY IS NOT CHARGED PROCEDURE CHECK 1. Fuse 2. Battery 3. Charging voltage 4. Charging coil resistance 5. Wiring system (entire charging system) 1. FUSE Refer to “FUSE INSPECTION SECTION” in Chapter 3, Page no 3-30 Note : Remove the following parts before trouble shooting. 1) Side covers (LH ) • Use Service Instruments as specified. Engine Tachometer. Digital Multimeter NO CONTINUITY CONTINUITY Replace the Fuse 2.
PAGE 192
R-191 LIGHTING SYSTEM ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM : AC TROUBLE SHOOTING IF THE HEAD LIGHT, HI BEAM INDICATOR LIGHT, TAILLIGHT AND METER LIGHT DO NOT WORK PROCEDURE CHECK 1. Lighting Coil 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. 1) Side covers (LH and RH) 2) Seat 3) Headlight Assembly 4) Battery 5) Battery Box Engine Tachometer.
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L-192 LIGHTING SYSTEM 1. LIGHTING COIL RESISTANCE ELEC Multimeter (+) lead Ÿ Yellow terminal ¿ Multimeter (-) lead Ÿ Black terminal À • Remove the C.D.I. Magento Coupler from the wiring Harness • Connect the Multimeter (Ω X 1) to the Lighting Coil • Measure the Lighting Coil resistance Lighting Coil resistance 0.62 Ω ± 20 % at 20ºC OUT OF SPECIFICATION MEETS SPECIFICATIONS 2.
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R-193 LIGHTING SYSTEM ELEC æ 4. LIGHTING VOLTAGE Multimeter (+) lead Ÿ Blue terminal ¿ Multimeter (-) lead Ÿ Black terminal À • Connect the Tachometer to Spark Plug lead.
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L-194 LIGHTING SYSTEM ELEC æ 6. INDIVIDUAL LIGHTING CIRCUITS A. If the Headlight and Highbeam Indicator Light do not work 1. BULB AND BULB SOCKET • Check the Bulb and Bulb socket for continuity. NO CONTINUITY CONTINUITY 2. LIGHTING VOLTAGE Replace Bulb and/or Bulb Socket. • Refer the lighting Voltage section Page no 7-12 B. If the meter light does not work 1. BULB AND BULB SOCKET • Check the Bulb and Bulb Socket for continuity. NO CONTINUITY Continuity 2.
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R-195 SIGNAL SYSTEM ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM : DC TROUBLE SHOOTING IF THE FLASHER LIGHT, BRAKE LIGHT AND INDICATOR 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 following parts before trouble shooting.
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L-196 SIGNAL SYSTEM ELEC 1. FUSE Refer to “FUSE INSPECTION SECTION “ in Chapter 3, Page 3-30 NO CONTINUITY CONTINUITY 2. BATTERY Replace fuse • Check the Battery condition Refer to “BATTERY INSPECTION SECTION” in Chapter 3, Page 3-28 INCORRECT CORRECT • Top up the Battery fluid • Clean Battery terminal • Recharge or replace the Battery 3. MAIN SWITCH • Disconnect the main switch coupler from wireharness • Check the continuity between ”Brown” and Red” wires NO CONTINUITY CONTINUITY 4.
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R-197 SIGNAL SYSTEM ELEC 5. INDIVIDUAL SIGNAL SYSTEMS A. If the Horn does not work. 1. HORN SWITCH • Disconnect the Handlebar Switch Coupler from Wireharness. • Check the continuity between the “Pink” and “Black” with switch in Pressed Position. NO CONTINUITY Replace the Switch Handle (LH) CONTINUITY Multimeter (+) lead Ÿ Brown ¿ Terminal Multimeter (-) lead Ÿ Body earth À 2.
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L-198 SIGNAL SYSTEM ELEC B. If the Brake Light does not work. 1. BULB AND BULB SOCKETS • Check the Bulb and Bulb sockets for continuity. NO CONTINUITY CONTINUITY Replace Bulb and/or Bulb socket. 2. BRAKE SWITCH FRONT / REAR • Disconnect the Brake switch Coupler from wire Harness.
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R-199 SIGNAL SYSTEM ELEC C. If the flasher light and/or turn indicator light fails to blink. 1. BULB AND BULB SOCKET • Check the Bulb and Bulb Socket continuity NO CONTINUITY CONTINUITY 2. TURN SWITCH Replace the Bulb and/or Bulb socket • Disconnect the Handlebar Switch (left) coupler from Wireharness. • Check the switch component for the continuity between “Brown/White and Darkgreen” and “Brown/White and Chocolate”. NO CONTINUITY CONTINUITY Replace the left Handlebar Switch. 3.
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L-200 SIGNAL SYSTEM ELEC æ Multimeter (+) lead Ÿ Brown/White Terminal ¿ Multimeter (-) lead Ÿ Black Terminal À 4. FLASHER RELAY • Connect the Multimeter (DC20V) to the flasher relay coupler • Turn Main switch to ‘ON’ • Check for voltage (12V) on “Brown/White” lead at Flasher Relay and (-) terminal body earth OUT OF SPECIFICATION MEETS SPECIFICATION The Flasher Relay is faulty. Replace.
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R-201 SIGNAL SYSTEM ELEC D. If the neutral indicator lights fails to operate. 1. BULB AND BULB SOCKET • Check the bulb and bulb socket for continuity. NO CONTINUITY CONTINUITY Replace the Bulb and/or Bulb Socket 2. NEUTRAL SWITCH • Disconnect the neutral switch lead. • Check the continuity between the switch terminal and ground. NO CONTINUITY CONTINUITY Replace the Neutral switch. Multimeter (+) lead Ÿ Sky Blue Terminal ¿ Multimeter (-) lead Ÿ Body Earth À 3.
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L-202 CHAPTER 8 TROUBLE SHOOTING STARTING FAILURE/ HARD STARTING .................................. 8-1 POOR IDLE 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 ...................................
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R-203 STARTING FAILURE / HARD STARTING TRBL SHTG NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the related procedure in this manual for inspection, adjustment and replacement of parts.
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L-204 POOR IDLE SPEED PERFORMANCE IGNITION SYSTEM TRBL SHTG Ignition system • Faulty C.D.I Unit • Faulty Sensor Coil • Broken Magneto Woodruff Key Spark Plug • Improper Plug gap • Worn Electrodes • Wire between Terminals broken • Improper heat range • Faulty Spark Plug Cap Switch • Faulty Main Switch Wiring • Loose Coupler connection • Improperly grounded • Broken Wireharness R. R. Unit • Faulty R. R.
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R-205 POOR SPEED PERFORMANCE TRBL SHTG POOR SPEED PERFORMANCE Ignition System Compression System • Dirty Spark Plug • Improper heat range • Faulty C.D.I.
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L-206 FAULTY GEAR SHIFTING / OVERHEATING TRBL SHTG FAULTY GEAR SHIFTING HARD SHIFTING JUMPING -OUT OF GEAR Refer to “CLUTCH DRAGGING’’ Page no 8-3 SHIFT PEDAL DOES NOT MOVE Shift Shaft • Improperly returned Stopper Lever Shift Shaft • Bent Shift Shaft Shift Fork • Improper thrust play • Worn Shift Cam groove Shift Cam Shift Fork • Groove jammed with impurities • Seized Shift Fork • Bent Shift Fork Guide Bar Transmission • Worn gear dog Transmission • Seized Transmission Gear • Clogged impurities
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R-207 FRONT FORK MALFUNCTION / UNSTABLE HANDLING TRBL SHTG FRONT FORK MALFUNCTION OIL LEAKAGE MALFUNCTION • Bent damaged or rusty Inner Tube • Damaged or cracked Outer Tube • Damaged oil seal lip.
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L-208 FAULTY SIGNAL AND LIGHTING SYSTEM TRBL SHTG FAULTY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DIM FLASHER BLINKS SLOWER • Improper Bulb • Too many electric accessories • Hard charging • Faulty rectifier/regulator • Faulty Battery • Improperly connected coupler, connector wire harness • Improperly grounded • Faulty main switch or lights (dimmer) switch • Faulty Flasher Relay • Insufficient Battery capacity (nearly discharged) • Improper Bulb • Faulty Main and/or Turn Switch FLASHER BLINKS QUICKER • Im