Manual Clutch and Automatic T135SE T135S T135 SERVICE MANUAL Sniper / Jupiter MX / Spark 135 / Exciter / 135LC 5YP-F8197-E0 http://mototh.
http://mototh.
EAS00000 T135SE/T135S SERVICE MANUAL ©2005 by Yamaha Motor Co., Ltd. First edition, April, 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. http://mototh.
EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EASF0001 HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 :This is a chapter with its symbol on the upper right of each page. 2nd title 2 :This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3 rd title appears.) 3rd title 3 :This is a final title.
http://mototh.
12 SYMBOLS GEN INFO SPEC 34 CHK ADJ ENG 6 5 CARB COOL 7 8 CHAS ELEC 9 0 The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 2 3 4 5 6 7 8 9 General information Specifications Periodic checks and adjustments Engine Cooling system Carburetor Chassis Electrical system Troubleshooting Symbols 0 to u indicate the following.
http://mototh.
EAS00011 TABLE OF CONTENTS GENERALINFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLINGSYSTEM CARBURETOR CHASSIS ELECTRICALSYSTEM TROUBLESHOOTING http://mototh.
http://mototh.
GEN INFO CHAPTER 1 GENERALINFORMATION VEHICLE IDENTIFICATION ...................................................................................1-1 VEHICLE IDENTIFICATION NUMBER .............................................................1-1 ENGINE SERIALNUMBER...............................................................................1-1 IMPORTANT INFORMATION.................................................................................1-2 PREPARATION FOR REMOVALAND DISASSEMBLY.......................
GEN INFO http://mototh.
GEN VEHICLE IDENTIFICATION INFO EAS00014 1 GENERALINFORMATION VEHICLEIDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The number 1 is stamped into the center of the frame. ENGINE SERIALNUMBER The engine serial number 1 is stamped into the crankcase. NOTE: Designs and specifications are subject to change without notice. 1 1-1 http://mototh.
GEN IMPORTANT INFORMATION INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVALAND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIALTOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
GEN IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. 1 300-000 EAS00024 BEARINGS AND OILSEALS 1 Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
GEN CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 9lead 9coupler 9connector 2. Check: 9lead 9coupler 9connector Moisture → Dry with compressed air. Rust/stains → Connect and disconnect several times. 3. Check: 9all connections Loose connection → Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. 1 4.
SPECIALTOOLS GEN INFO EAS00027 SPECIALTOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. Tool No.
SPECIALTOOLS Tool No. Tool name/Usage GEN INFO Illustration Adoptor (M12) 90890-01278 This tool is necessary for installing the crankshaft. Tappet adjusting tool 90890-01311 This tool is necessary for adjusting valve clearance. Radiator cap tester 90890-01325 Radiator cap tester adapter 90890-01352 Radiator cap tester Radiator cap tester adapter These tools are used to check the cooling syatem.
SPECIALTOOLS Tool No. Tool name/Usage GEN INFO Illustration Compression gauge 90890-03081 These tools are used to measure the engine compression. Pocket tester 90890-03112 This instrument is necessary for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for detecting engine rpm.
SPECIALTOOLS Tool No. Tool name/Usage Valve lapper 90890-04101 This tool is used for removeing and installing the lifter and for lapping the valve. Valve guide remover (4.5 mm) 90890-04116 This tool is needed to remove and installing the valve guide. Valve guide installer (4.5 mm) 90890-04117 This tool is needed to install the valve guide. Valve guide reamer (4.5 mm) 90890-04118 This tool is needed rebore the new valve guide.
SPEC CHAPTER 2 SPECIFICATIONS GENERALSPECIFICATIONS ...............................................................................2-1 MAINTENANCE SPECIFICATIONS ......................................................................2-4 ENGINE ............................................................................................................2-4 TIGHTENING TORQUES .................................................................................2-9 CHASSIS..............................................
SPEC http://mototh.
GENERALSPECIFICATIONS SPEC SPECIFICATIONS GENERALSPECIFICATIONS Model Model code T135SE/T135S 5YP1 (T135SE) 5YP2 (T135S) Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 1,945 mm (76.6 in) 705 mm (27.8 in) 1,065mm (41.9 in) 770 mm (30.3 in) 1,245 mm (49.0 in) 140 mm (5.51 in) 1,900 mm (74.
GENERALSPECIFICATIONS Model SPEC T135SE/T135S Carburetor Type/quantity Manufacturer VM22/1 MIKUNI Spark plug Type Manufacturer Spark plug gap CPR8EA-9 NGK 0.8 – 0.9 mm (0.031 – 0.035 in) Clutch type Wet, multiple-disc and centrifugal automatic Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th Chassis Frame type Caster angle Trail Diamond 25.3° 73.0 mm (2.
GENERALSPECIFICATIONS Model Brake Front brake Rear brake SPEC T135SE/T135S type operation type operation Single disc brake Right hand operation Drum brake Right foot operation Suspension Front suspension Rear suspension Telescopic fork Swingarm (monocross) Shock absorber Front shock absorber Rear shock absorber Coil spring/oil damper Coil spring/oil damper Wheel travel Front wheel travel Rear wheel travel 100 mm (3.94 in) 90 mm (3.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Cylinder head Max. warpage “*” ---- Cylinder Bore Limit 0.03 mm (0.0012 in) 54.000 – 54.010 mm (2.1260 – 2.1264 in) 54.1 mm (2.1299 in) ---0.05 mm (0.002 in) Out of round limit Camshaft Drive Method Cam dimensions Intake “A” Chain drive (left) ) “B” * Exhaust “A” “B” Camshaft runout limit 29.643 – 29.743 mm (1.1670 – 1.1710 in) 29.613 mm (1.1659 in) 25.073 – 25.173 mm (0.9871 – 0.9911 in) 25.043 mm (0.9859 in) 29.
SPEC MAINTENANCE SPECIFICATIONS Item Standard Valve, valve seat, valve guide Valve clearance (cold) IN EX Valve dimensions Limit 0.10 – 0.14 mm (0.0039 – 0.0055 in) 0.16 – 0.20 mm (0.0063 – 0.0079 in) B C D A HdDi Diameter Head “A” head diameter “B” face width “C” seat width “D” margin thickness Valve stem outside diameter Guide inside diameter Face Width Seat Width Margin Thickness IN EX IN EX IN 19.40 – 19.60 mm (0.7638 – 0.7717 in) 16.90 – 17.10 mm (0.6654 – 0.6732 in) 1.583 – 2.
MAINTENANCE SPECIFICATIONS Item Standard Valve spring Free length IN/EX 47.33 mm (1.86 in) Installed length (valve closed) IN/EX Compressed spring force IN/EX Tilt limit “*” IN/EX Winding direction IN/EX Piston Piston-to-cylinder clearance H Piston pin outside diameter B T Ring side clearance (installed) 2nd ring Ring type Dimensions (B ⋅ T) End gap (installed) Ring side clearance 35.30 mm (1.39 in) 135.6 – 156.0 N (13.8 – 15.8 kgf) at 35.3 mm (1.39 in) ---- Clockwise 44.96 mm (1.
MAINTENANCE SPECIFICATIONS Item Standard SPEC Limit Crankshaft C C E Crank width “A” Max. runout limit “C” D A Big end side clearance “D” Big end radial clearance “E” Clutch Friction plate #1 Thickness Plate quantity Friction plate #2 Thickness 45.95 – 46.00 mm (1.81-1.81 in) ---0.11 – 0.41 mm (0.0403 – 0.016 in) 0.004 – 0.014 mm (0.10 – 0.11 in) 2.5 – 2.7 mm (0.10 – 0.11 in) 3 2.5 – 2.7 mm (0.10 – 0.11 in) 1 ---0.03 mm (0.0012 in) ------- 2.4 mm (0.09 in) ---2.4 mm (0.
MAINTENANCE SPECIFICATIONS Item Standard Kickstarter Kickstarter type Spring free length Carburetor Type I.D. mark Main jet Main air jet Jet needle Needle jet Pilot outlet Pilot jet Pilot air screw turns out Pilot air jet 1 Valve seat size Throttle valve size Float height SPEC Ratchet type 15.5 mm (0.61 in) ------- VM22 5YP1 00 (M.J) #105 (M.A.J) ø1.2 (J.N) 5 K010 (N.J) N-9M (P.O) ø1 (P.J) #20 1-5/8 #55 ø2 #2.0 9.2 mm (0.
MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUES ENGINE Part to be tightened Cylinder head Cylinder head (timing chain side) Cylinder head (oil check) Spark plug Cylinder head cover Reed valve assembly Water pump assembly Stud bolt (cylinder head) Cylinder (coolant water drain) Generator rotor Timing chain guide (intake side) Valve adjusting screw locknut (intake and exhaust side) Camshaft sprocket Camshaft retainer Timing chain tensioner assembly Thermostat cover Oil pump assembly Element cover Engine
MAINTENANCE SPECIFICATIONS Part to be tightened Drive sprocket Main axle bearing retainer Clutch release adjusting locknut Shift pedal Shift drum segment Shift drum stopper lever Shift lever stopper screw Pickup coil Stator coil Neutral switch Starter motor Thread Part name Q’ty size Bolt Screw Nut Bolt Bolt Bolt Screw Bolt Bolt Screw Bolt 2-10 http://mototh.com M6 M6 M6 M8 M6 M6 M8 M6 M6 M5 M6 1 2 1 1 1 1 1 2 3 2 2 SPEC Tightening torque Remarks Nmm·kgft·lb 10 7 8 18 12 10 10 10 10 4 10 1.0 0.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Standard Limit Steering system Steering bearing type Lock-to-lock angle (left/right) Ball and race bearing 45° ------- Front suspension Front fork travel Fork spring free length 100 mm (3.94 in) 295.3 mm (11.63 in) ---289.4 mm (11.39 in) ------------------------------0.2 mm (0.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Rear wheel Type Rim size Rim material Max. radial wheel runout Spoke wheel 17 ⋅ 1.60 Steel ---- Max. lateral wheel runout ---- Limit ---------1.0 mm (0.04 in) 0.5 mm (0.02 in) Drive chain Type/manufacturer Link quantity Drive chain slack 428/DAIDO 112 25 – 35 mm (0.98 – 1.38 in) ---------- Front brake Disc brake type Disc outside diameter ⋅ thickness Single 220.0 ⋅ 3.5 mm(8.66 ⋅ 0.14 in) ---3.0 mm (0.12 in) 0.8 mm (0.03 in) 0.8 mm (0.
MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUES CHASSIS Part to be tightened Thread size Tightening torque Nmm·kg Handlebar bracket and lower bracket Handlebar and handlebar bracket Brake hose and brake master cylinder Brake hose and brake caliper Brake master cylinder and holder Brake master cylinder and brake lever Rear view mirror (left and right) Front wheel axle nut Brake hose holder Front fork and brake caliper Bleed screw Front fork cap bolt Lower bracket pinch bolt Damper rod bolt Upper ring
MAINTENANCE SPECIFICATIONS Part to be tightened Thread size Tightening torque Nmm·kg Fuel tank and frame Fuel cock and fuel tank Seat and seat bracket M6 M6 M6 SPEC 7 7 7 0.7 0.7 0.7 Remarks ft·lb 5.0 5.0 5.0 NOTE: 1. First tighten the lower ring nut 30 Nm (3.0 m • kg, 22 ft • lb) by using a torque wrench, then loosen the ring nut 1/4 turn. 2. Then, hold the lower ring nut and tighten the upper ring nut 75 Nm (7.5 m • kg, 54 ft • lb) by using a torque wrench. 2-14 http://mototh.
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit System voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) Advanced type 10° at 1,400 r/min Digital ------- DC-C.D.I Pickup coil resistance/color C.D.I. unit model/manufacturer 248 – 372 Ω at 20 ° C (68 ° F)/R–W 5YP/PTMORIC ------- Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance 4ST/PTMORIC 6 mm 0.32 – 0.48 Ω at 20 ° C (68 ° F) 5.68 – 8.
MAINTENANCE SPECIFICATIONS Item Electric starting system (T135SE) Type Starter motor Model/manufacturer Operation voltage Power output Armature coil resistance Brush overall length SPEC Standard Limit Constant mesh ---- 5YP/PTMORIC 12 V 0.20 kW 0.032 – 0.039 Ω at 20 ° C (68 ° F) 7.0 mm (0.28 in) Commutator diameter 3.92 – 5.88 N (400-600 gf, 14.11 – 21.17 oz) 17.6 mm (0.69 in) Mica undercut (depth) 1.35 mm (0.05 in) ------------3.5 mm (0.14 in) 3.92 N (400 gf) 16.6 mm (0.
CONVERSIONTABLE/ GENERALTIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 EAS00029 CONVERSION TABLE GENERALTIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips Bearings O-rings Cylinder head tightening washer and bolt thread Rocker arm inner surfaces Rocker arm shaft Camshaft Valve stem (IN, EX) Valve stem guide (IN, EX) Piston pin Piston outside and ring groove Piston ring Cylinder inner surface Starter clutch gear inner surface Starter idle gear inner surface Kickstarter ratchet wheel and ratchet wheel guide Kickstarter gear inn
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point SPEC Lubricant Transmission side plate inner surface Transmission pinion gears inner surface Generator lead grommet Yamaha bond No.1215 Crankcase mating surface Yamaha bond No.1215 Timing chain tensioner bolts Yamaha bond No.1215 2-19 http://mototh.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC CHASSIS Lubrication point Lubricant Front wheel oil seal lips Speedometer gear unit inner surface Rear wheel oil seal lips Rear brake camshaft Brake torque rod bolt Front wheel axle Rear wheel axle Upper brake caliper retaining bolt Lower brake caliper retaining bolt Throttle grip tube guide inner surface Brake lever pivot bolt Steering head bearing inner race Steering head bearing outer race Steering head upper bearing Steering head lower bearing Sidestand pi
COOLINGSYSTEM DIAGRAMS SPEC COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 8 9 å Align the white paint mark on the clamp with the white paint mark on the radiator. ∫ Band the end of the cover, before install the projection of the reservoir tank. ç Install the hook of the cover end into the slit of the bracket.
CABLE ROUTING SPEC CABLE ROUTING 1 2 3 4 5 6 7 8 å Install the turn signal relay onto the bracket. ∫ Connect the left handlebar switch lead coupler in front of the handlebar left. ç Pass through the choke cable into the wireharness. ∂ Connect the couplers in front of the handlebar left side. ´ Do not pass the brake hose into the bracket.
CABLE ROUTING ˚ Take care not to bend the choke cable when installing. ˆ Pass the wireharness behind the turn signal relay and brake hose, and then connect the front brake switch. ∆ Route the right handlebar switch lead behind the handlebar and connect the coupler with handlebar right side, and then set the turn signal light relay. å 1 2 ∫ ç ˙ 3 C ˆ ∆ 8 C 4 ∂ 5 7 6 ´ 6 7 ƒ 5 4 © A-A D A B-B SPEC B A B D 2-23 http://mototh.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p Front turn signal light lead Fitting tape (red) Throttle cable C.D.I. unit Case Clamp Breather pipe Band Air vent pipe Stopper Negative lead Fuel hose Vacuum hose Overflow pipe SPEC lead in front of the stay. ∂ Check that the connection of the acceleration pump cable from case, after adjusting and clamp the throttle cable and acceleration pump cable. ´ Clamp the breather pipe. ƒ Cover the throttle cable adjusting nut completely.
CABLE ROUTING ˙ Install the negative lead, should be stopped. ˆ Pass through the fuel hose and vacuum hose into the cable guide. ∆ Route the overflow pipe to the left side of the engine and inside of the neutral switch lead. ˚ Route the vacuum hose onto the fuel hose. ¬ Route the fuel hose onto the cable guide. SPEC µ Pass through the turn signal light lead into the guide. e ˚ w¬ 4 ç 3 å A-A ∫ y t B-B µ 5 6 ∂ 9 0 q ˙ 7 2 8 © ´ƒ B 1 A o w B A i p e ˆ r ∆ u y t 2-25 http://mototh.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 q w ∂ Pass through the starter motor lead under the wireharness. (T135SE) ´ Outside of the frame. ƒ Be sure does not over the outside of the frame. © Set in the connected point to the bracket, after behind them. ˙ Pass through the drain hose, battery breather pipe and over flow pipe into the cable guide.
CABLE ROUTING SPEC ˆ Route the overflow pipe in front of the cross pipe frame. ∆ Pass through the drain hose and battery breather pipe into the guide. ˚ Pass through the drain hose into the hole of the protector. 4 9 © 0 ´ 5 5 ƒ B-B A-A 1 å ∫ ç 3 2 8 A A B 7 B 6 5 t 4 ∂ 6 ∆ r ˚ q w e ˆ ˙ C 2-27 http://mototh.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 q w ∂ Pass through the wireharness into the main switch and cable guide. Pass through the hone lead and turn signal light lead under the wireharness. ´ Route the brake hose as shown. ƒ Clamp the bend hose. © To the neutral switch. ˙ Turn the clip inside without contact the vacuum hose.
CABLE ROUTING SPEC ˆ To the A.C. magneto. ∆ Cover the protector completely , after the coupler connected. ˚ Set the connected point below the pipe end. ¬ Pass through the high tension cord, fan motor lead and thermo sensor lead into the cut part on the plate. qw © ˙ˆ e ¬ ∆ 7 ∫ C å 5 B 8 6 ç 4 3 B 2 1 ˚ ∂ C r ´ A A-A A 9 0 ƒ 2-29 http://mototh.
CABLE ROUTING 1 2 3 4 5 Speedometer cable Acceleration pump cable Throttle cable Fuel sender lead Choke cable å Route the acceleration pump cable into the right side of the stay. ∫ Route the throttle cable into the left side of the stay. ç Black plating joint. ∂ Pass through the fuel sender lead in to the side hole of the fuel tank. ´ Clamp the fuel sender lead onto the hook of the box. ƒ White plating joint. 1 2 å 5 3 ∫ ƒ ç 4 ∂ ´ 2-30 http://mototh.
CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ....................................................................................................3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ............................3-1 COVERS .................................................................................................................3-3 REMOVING THE SIDE COWLINGS ................................................................3-3 INSTALLING THE SIDE COWLINGS ..................
CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD ...................................3-35 CHECKING THE FRONTFORK .......................................................................3-37 CHECKING THE TIRES ...................................................................................3-38 CHECKING AND TIGHTENING THE SPOKES ................................................3-40 CHECKING AND LUBRICATING THE CABLES ..............................................3-41 LUBRICATING THE LEVER AND PEDALS .........
INTRODUCTION/ CHK PERIODIC MAINTENANCE AND LUBRICATION INTERVALSADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
CHK PERIODIC MAINTENANCE AND LUBRICATION INTERVALSADJ ODOMETER READING (⋅ 1000 km) NO. ITEM CHECK OR MAINTENANCE JOB 1 9 Check coolant level and vehicle for coolant leakage. 6 12 18 24 ANNUAL CHECK √√√ √√ 22* Cooling system 23* Front and rear brake switches 9 Check operation. 24 Moving parts and cables 9 Lubricate. √√√ √√ 25* Throttle grip housing and cable 9 Check operation and free play. 9 Adjust the throttle cable free play if necessary.
COVERS CHK ADJ EASF0004 COVERS REMOVING THE SIDE COWLINGS 1. Remove: 9screws 9bolts 9side cowlings (left and right) INSTALLING THE SIDE COWLINGS For installation, reverse the removal procedure. REMOVING THE FRONT COWLING 1. Remove: 9screws 9front cowling 2. Disconnect: 9turn signal light couplers INSTALLING THE FRONT COWLING For installation, reverse the removal procedure. 3-3 http://mototh.
COVERS CHK ADJ REMOVING THE CENTER PANELS 1 1. Remove: 9screws 9center panel (lower) 1 9main switch cover 2 9screws 9center panel (upper) 3 NOTE: Remove the main switch cover by turning it in the direction of the arrow shown. 2 1 3 2. Remove: 9screw 9 inner panel 1 INSTALLING THE CENTER PANELS 1 For installation, reverse the removal procedure. REMOVING THE REAR COWLINGS 1. Remove: 9screws 9center panel (lower) 2. Remove: 9screws 9storage compartment 1 1 3.
COVERS CHK ADJ 4. Remove: 9screws 9screw (with washer) 1 9screws 9rear cowlings (left and right) 2 2 1 INSTALLING THE REAR COWLINGS 1 1. Install: 9rear cowlings (left and right) 1 9screws 9screw (with washer) 2 2 NOTE: Before tightening the rear cowling screws, make sure that all projections (left and right) are securely fitted. 2. Install: 9rear panel 1 9storage compartment 2 9screws 1 NOTE: Make sure that all projections are securely fitted. 2 3.
COVERS CHK ADJ REMOVING THE HEADLIGHT ASSEMBLY 1 1. Remove: 9screws 9headlight assembly 1 2. Disconnect: 9headlight connectors 1 1 INSTALLING THE HEADLIGHT ASSEMBLY 1. Connect: 9headlight connectors 1 2. Install: 9headlight assembly 9screws 1 3-6 http://mototh.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: 9Valve clearance adjustment should be made on a cold engine, at room temperature. 9When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: 9side cowlings (left and right) 9front cowling Refer to “REMOVING THE SIDE COWLINGS” AND “REMOVING THE FRONT COWLING”. 2.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 5. Move: 9radiator assembly To swing the radiator assembly toward the front side. 6. Remove: 9water pump assembly 9O-rings 7. Remove: 9cylinder head cover 9gasket 8. Remove: 9timing check plug 1 (with O-ring) 9center plug 2 (with O-ring) 2 9. Measure: 9valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.10–0.14 mm (0.0039–0.0055 in) Exhaust valve 0.16–0.20 mm (0.0063–0.0079 in) 1 b ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a.
ADJUSTING THE VALVE CLEARANCE d CHK ADJ c. Align the TDC mark c on the generator rotor with the stationary pointer d on the crankcase cover. c d. Measure the valve clearance with a thickness gauge 1 Out of specification → Adjust. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ 1 10. Adjust: 9valve clearance ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Loosen the locknut 1 . b. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip. c.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 11. Install: 9O-ring 9timing check plug (with O-ring) 7 Nm (0.7 m•kg, 5.0 ft•lb) 9center plug 7 Nm (0.7 m•kg, 5.0 ft•lb) (with O-ring) 12. Install: 9gasket 1 9cylinder head cover 10Nm (1.0 m•kg, 7.2 ft•lb) 13. Install: 9O-ring 9water pump assembly 10Nm (1.0 m•kg, 7.2 ft•lb) 14. Connect 9water pump inlet hose 9radiator outlet cover 9radiator inlet hose 1 15. Install: 9AIS resonator 9AIS resonator mount bolt 9spark plug 12.5Nm (1.25 m•kg, 9.0 ft•lb) 16.
ADJUSTING THE ENGINE IDLING SPEED CHK ADJ EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Remove: 9side cowlings (left and right) 9front cowling 9rear cowling (left) Refer to “REMOVING THESIDECOWLINGS”, “REMOVING THE FRONTCOWLING” and “REMOVINGTHEREARCOWLINGS”. 2. Start the engine and let it warm up for several minutes. 3.
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 6. Adjust: 9throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3–7 mm (0.12–0.28 in) 7. Install: 9rear cowling (left) 9front cowling 9side cowlings (left and right) Refer to “INSTALLING THE REAR COWLINGS”, “INSTALLING THE FRONTCOWLING” and “INSTALLING THE REAR COWLINGS”.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 3. Adjust: 9throttle cable free play ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Pull back the adjusting nut cover. b. Loosen the locknut 1 c. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. 2 1 a b Direction aa Throttle cable free play Direction bb Throttle cable free play is increased. is decreased. d. Tighten the locknut. e. Slide the adjusting nut cover to its original position.
CHECKING THE SPARK PLUG CHK ADJ EAS00060 CHECKING THE SPARK PLUG 1. Remove: 9side cowling (right) Refer to “REMOVING THE SIDE COWLINGS”. 9AIS resonator cC Be sure to remove the AIS hose, before removing the AIS resonator, otherwise to brake the AIS resonator mount. 2. Disconnect: 9spark plug cap 3. Remove: 9spark plug cC Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 4.
CHECKING THE SPARK PLUG/ MEASURING THE COMPRESSION PRESSURE 8. Install: 9spark plug CHK ADJ 13 Nm (1.3 m•kg, 9.5 ft•lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: 9spark plug cap 10. Install: 9AIS resonator 9center panel (lower) Refer to “INSTALLING THE CENTER PANELS”. EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1.
MEASURING THE COMPRESSION PRESSURE CHK ADJ 6. Install: 9compression gauge 1 1 Compression gauge 90890-03081 7. Measure: 9compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 2 490 kPa (4.9 kg/cm , 70 psi)/at 500 r/min Standard 2 560 kPa (5.6 kg/cm , 80 psi)/at 500 r/min Maximum 2 , 90 psi)/at 500 r/min 630 kPa (6.3 kg/cm ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Set the main switch to “ON”. b.
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OILLEVEL CHK ADJ 8. Install: 9spark plug 13 Nm (1.3 m•kg, 9.5 ft•lb) 9. Connect: 9spark plug cap 10. Install: 9side cowling (right) Refer to “INSTALLING THE SIDE COWLINGS”. EAS00070 CHECKING THE ENGINE OILLEVEL 1. Stand the vehicle on a level surface. NOTE: Make sure the vehicle is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Remove: 9oil level plug 1 4.
CHANGING THE ENGINE OIL CHK ADJ EAS00075 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: 9oil level plug 1 9engine oil drain plug 2 (with O-ring) 9spring 9oil strainer 4. Drain: 9engine oil (completely from the crankcase) 5. Check: 9oil strainer Clog → Clean. Damage → Replace. 6. Install: 9oil strainer 9spring 9O-ring 9engine oil drain plug 1 2 32 Nm (3.2 m•kg, 23 ft•lb) 7.
CHANGING THE ENGINE OIL/ CHECKING THE EXHAUST SYSTEM CHK ADJ CHECKING THE OILFILTER 1. Remove: 9oil filter element cover 9O-ring 9oil filter element 2. Check: 9oil filter element Dirt or clog → Replace. 3. Install: 9oil filter element 9O-ring 1 9oil filter element cover 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 2 CHECKING THE EXHAUST SYSTEM 1. Check: 9exhaust pipe nuts 1 Loose/damage → Tighten/replace. 15 Nm (1.5 m•kg, 11 ft•lb) 9exhaust pipe gasket Exhaust gas leaks → Tighten/replace. 1 3-19 http://mototh.
CLEANING THE AIR FILTER ELEMENT CHK ADJ EAS00086 1 CLEANING THE AIR FILTER ELEMENT 1. Remove: 9center panel (lower) Refer to “REMOVING THE CENTER PANELS”. 2. Remove: 9air filter case cover 1 9air filter element 2 2 3. Clean: 9air filter elements Apply compressed air to the outer surface of the air filter element. 4. Check: 9air filter element Damage → Replace. 5. Install: 9air filter element 9air filter case cover 9breather hose cC Never operate the engine without the air filter element installed.
CLEANING THE AIR FILTER ELEMENT/ ADJUSTING THE CLUTCH RELEASE SYSTEM/ CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD CHK ADJ 6. Install: 9center panel (lower) Refer to “INSTALLING THE CENTERPANELS”. EAS00086 ADJUSTING THE CLUTCH RELEASE SYSTEM 1. Adjust: 9clutch release system ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Loosen the locknut 1 . b. Turn the adjusting screw 2 in completely, then turn the adjusting screw out the specified number of turns. Adjusting screw: 1/8 turns out c. Tighten the locknut. 8 Nm (0.
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/ CHECKING THE FUELAND VACUUM HOSES CHK ADJ 3. Install: 9inner panel 9rear cowlings (left and right) 9front cowling 9center panels (upper and lower) 9side cowlings (left and right) Refer to “COVERS”. EAS00096 CHECKING THE FUELAND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses. 1.
CHECKING THE CRANKCASE BREATHER PIPE/ CHECKINGTHECOOLANTLEVEL CHK ADJ EAS00098 CHECKING THE CRANKCASE BREATHER PIPE 1. Remove: 9side cowlings (left and right) 9center panels (upper and lower) 9front cowling 9rear cowlings (left and right) 9inner panel Refer to “COVERS”. 2. Check: 9crankcase breather pipe 1 Cracks/damage → Replace. Loose connection → Connect properly. cC 1 Make sure the crankcase breather pipe is routed correctly. 3.
CHECKINGTHECOOLANTLEVEL/ CHECKINGTHECOOLINGSYSTEM CHK ADJ cC 99 Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. 99 Use only distilled water. However, if distilled water is not available, soft water may be used. 3. Start the engine, warm it up for several minutes, and then turn it off. 4.
CHANGINGTHECOOLANT CHK ADJ EAS00105 CHANGING THE COOLANT 1. Remove: 9side cowlings (left and right) 9front cowling Refer to “REMOVING THE SIDE COWLINGS” and “REMOVING THE FRONT COWLING”. 2. Remove: 9coolant reservoir tank cover 9coolant reservoir cap 3. Disconnect: 9coolant reservoir hose 1 1 4. Drain: 9coolant (from the coolant reservoir) 5. Remove: 9radiator cap 1 1 w Ahot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot.
CHANGINGTHECOOLANT CHK ADJ 8. Install: 9copper washer 9coolant drain bolt 7 Nm (0.7 m•kg, 5.0 ft•lb) 9. Connect: 9coolant reservoir hose 10. Fill: 9cooling system (with the specified amount of the recommended coolant) Recommended antifreeze YAMAHAGENUINE COOLANT High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Radiator capacity 0.62 L(0.55 Imp qt, 0.66 US qt) Coolant reservoir capacity 0.28 L(0.25 Imp qt, 0.
CHANGINGTHECOOLANT CHK ADJ cC 99 Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. 99 Use only distilled water. However, if distilled water is not available, soft water may be used. 99 If coolant comes into contact with painted surfaces, immediately wash them with water. 99 Do not mix different types of antifreeze. 11.
ADJUSTING THE REAR BRAKE CHK ADJ CHASSIS EAS00113 ADJUSTING THE REAR BRAKE 1. Check: 9brake pedal free play a Out of specification → Adjust. a Brake pedal free play (at the end of the brake pedal) 25–35 mm (0.98–1.38 in) 2. Adjust: 9brake pedal free play ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Turn the adjuster 1 in direction a or b until the specified brake pedal free play is obtained. a b 1 Direction aa Brake pedal free play is Direction bb Brake pedal free play is increased. decreased.
CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE SHOES/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ EAS00120 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: 9front brake pad 1 almost disapWear indicator groove peared → Replace the brake pads as a set. Refer to “REPLACING THE FRONT BRAKE PADS” in chapter 7. 1 1 2 EAS00126 1 CHECKING THE REAR BRAKE SHOES 1. Operate the brake. 2.
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT BRAKE HOSE CHK ADJ 2. Adjust: 9rear brake light operation timing ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time. 1 b a 2 Direction aa Brake light comes on Direction bb Brake light comes on sooner. later. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ EAS00129 CHECKING THE FRONT BRAKE HOSE 1.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM w Bleed the hydraulic brake system whenever: 99 the system is disassembled. 99 a brake hose is loosened, disconnected or replaced. 99 the brake fluid level is very low. 99 brake operation is faulty. NOTE: 9Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow. 9When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake.
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip. h. Tighten the bleed screw and then release the brake lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 m·kg, 4.3 ft·lb) k.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ 1. Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Spin the rear wheel several times and find the tightest position of the drive chain. 3. Check: 9drive chain slack a Out of specification → Adjust. Drive chain slack 25–35 mm (0.93–1.38 in) 4. Adjust: 9drive chain slack ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a.
LUBRICATING THE DRIVE CHAIN/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ EAS00143 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. Use only kerosene to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for non-O-ring chains.
CHECKING THE BRAKE FLUID LEVEL/ CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ cC Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal. EASF0010 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ 4. Adjust: 9steering head ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Loosen the upper ring nut 1 . b. Loosen the lower ring nut 2 and then tighten it to specification with a steering nut wrench 3 . 1 2 NOTE: Set the torque wrench at a right angle to the steering nut wrench. 3 Steering nut wrench 90890-01403 4 Lower ring nut 30 Nm (3.0 m·kg, 22 ft·lb) d. Loosen the lower ring nut counterclockwise 1/4 of a turn. e.
CHECKING THE FRONT FORK CHK ADJ EAS00149 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. 2. Check: 9inner tube Damage/scratches → Replace. 9oil seal Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: 9front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to “FRONTFORK” in chapter 7.
CHECKING THE TIRES CHK ADJ EASF0015 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 9tire pressure Out of specification → Regulate. w 99 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. 99 The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
CHECKING THE TIRES CHK ADJ 2. Check: 9tire surfaces Damage/wear → Replace the tire. Minimum tire tread depth 0.8 mm (0.03 in) 1 Tire tread depth 2 Sidewall 3 Wear indicator w 99 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. 99 When using tube tires, be sure to install the correct tube. 99 Always replace a new tube tire and a new tube as a set.
CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES CHK ADJ w 99 New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. 99 After a tire has been repaired or replaced, be sure to tighten the tire air valve stem locknut 11to specification.
CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVER AND PEDALS/ LUBRICATING THE SIDESTAND/LUBRICATING THE CENTERSTAND CHK ADJ EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. w Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: 9outer cable Damage → Replace. 2. Check: 9cable operation Rough movement → Lubricate.
CHECKING AND CHARGING THE BATTERY CHK ADJ EAS00176 ELECTRICALSYSTEM CHECKING AND CHARGING THE BATTERY w Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 99 Wear protective eye gear when handling or working near batteries. 99 Charge batteries in a well-ventilated area. 99 Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING AND CHARGING THE BATTERY CHK ADJ 3. Disconnect: 9battery leads (from the battery terminals) 2 cC First, disconnect the negative battery lead 1 , and then the positive battery lead 2 . 1 4. Disconnect: 9battery breather hose 5. Remove: 9battery b a 6. Check: 9electrolyte level The electrolyte level should be between the minimum level mark a and the maximum level mark b . Below the minimum level mark → Add distilled water to the proper level. cC Add only distilled water.
CHECKING AND CHARGING THE BATTERY CHK ADJ cC 99 Loosen the battery sealing caps. 99 Make sure the battery breather hose and battery vent are free of obstructions. 99 To ensure maximum performance, always charge a new battery before using it. 99 Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
CHECKING AND CHARGING THE BATTERY CHK ADJ 9warpage or buckling of the battery plates or insulators is evident. 9. Check: 9battery breather hose and battery vent Obstruction → Clean. Damage → Replace. 10. Install: 9battery 11. Connect: 9battery breather hose 1 cC 99 When checking the battery, make sure the battery breather hose is properly installed and routed correctly.
CHECKING THE FUSE CHK ADJ EASF0017 CHECKING THE FUSE cC To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Open the seat and battery cover. 2. Remove: 9fuse holder 1 3. Check: 9fuse ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ 1 a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “ Ω⋅ 1”. Pocket tester 90890-03112 b. If the pocket tester indicates “ the fuse. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ ∞”, replace 4.
REPLACING THE HEADLIGHT BULBS CHK ADJ EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: 9headlight assembly Refer to “REMOVING THE HEADLIGHT ASSEMBLY”. 2. Remove: 9headlight bulb holder 1 2 1 3. Remove: 9headlight bulb w Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: 9headlight bulb Secure the new headlight bulb with the headlight bulb holder.
ADJUSTING THE HEADLIGHT BEAM CHK ADJ EAS00186 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: 9headlight beam (vertically) ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Loosen the bolt 1 . b. Slide the bottom of the headlight unit forward a or backward b . a b 1 Slide forward a Headlight beam is raised. Slide backward b Headlight beam is lowered. c. Tighten the bolt 1 . ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ 3-48 http://mototh.
ENG CHAPTER 4 ENGINE REMOVING THE ENGINE .....................................................................................4-1 COOLING SYSTEM ..........................................................................................4-1 ENGINE OIL......................................................................................................4-1 CARBURETOR .................................................................................................4-1 FOOTREST.....................................
ENG CYLINDER AND PISTON ......................................................................................4-31 REMOVING THE CYLINDER AND PISTON ....................................................4-32 CHECKING THE CYLINDER AND PISTON .....................................................4-33 CHECKING THE PISTON RINGS ....................................................................4-34 CHECKING THE PISTON PIN ..........................................................................
ENG CHECKING THE BEARINGS ...........................................................................4-67 CHECKING THE TIMING CHAIN GUIDE .........................................................4-67 CHECKING THE TIMING CHAIN .....................................................................4-67 INSTALLING THE CRANKSHAFT....................................................................4-68 ASSEMBLING THE CRANKCASE ...................................................................4-68 KICKSTARTER .....
ENG http://mototh.
REMOVING THE ENGINE ENG EASF0018 ENGINE REMOVING THE ENGINE NOTE: It is not necessary to remove the engine in order to remove the following components. 9Cylinder head 9Cylinder 9Piston 9Clutch 9Shift shaft 9Oil pump 9Generator 9Starter clutch 1. Remove: 9side cowlings (left and right) 9front cowling 9center panels (upper and lower) 9rear cowlings (left and right) Refer to “COVERS” in chapter 3. 9drive sprocket Refer to “DRIVE CHAIN AND SPROCKETS” in chapter 7. COOLING SYSTEM 1.
REMOVING THE ENGINE ENG FOOTREST 1. Remove: 9footrest bolts 1 9footrest 1 MUFFLER 1. Remove: 9exhaust pipe nuts 1 9exhaust pipe 2 1 2 2. Remove: 9lower muffler bolt 1 9washer 9upper muffler bolt 2 9washers 9nut 9muffler 3 2 1 3 BRAKE PEDAL 1. Remove: 9rear brake light switch spring 9brake pedal spring 9cotter pin 9brake pedal SHIFT PEDAL 1. Remove: 9shift pedal bolt 1 9shift pedal 2 9sprocket cover 1 2 4-2 http://mototh.
REMOVING THE ENGINE ENG SIDE COWLING BRACKET 1. remove: 9side cowling bracket bolts 1 9side cowling bracket 2 2 1 2 1 WIRE, CABLE AND HOSE 1. Disconnect: 9neutral switch lead coupler 1 9stator coil lead coupler 2 9pick up coil lead coupler 3 9crankcase breather pipe 3 2 1 2. Remove: 9starter motor lead coupler (T135SE) 1 3. Remove: 9spark plug cap 4. Remove: 9fuel cock vacuum hose 1 1 4-3 http://mototh.
REMOVING THE ENGINE ENG 5. Remove: 9crankcase breather pipe 1 1 ENGINE ASSEMBLY 7 A 2 5 A-A A 4 1. Loosen: 9rear lower mounting nut 1 9plate nuts (front and rear) 2 9front mounting nut 3 9rear upper mounting nut 4 9pivot shaft nut 5 8 3 2.
INSTALLING THE ENGINE ENG EASF0019 INSTALLING THE ENGINE ENGINE ASSEMBLY w Securely support the vehicle so there is no danger of it falling over when installing engine. 1.
INSTALLING THE ENGINE ENG WIRE, CABLE AND HOSE 1. Connect: 9starter motor lead coupler (T135SE) 9neutral switch lead coupler 9pickup coil lead coupler 9stator coil lead coupler 2. Install: 9crankcase breather pipe 9fuel cock vacuum hose 9spark plug cap SIDECOWLINGBRACKET 1. Install: 9side cowling bracket 9side cowling bracket bolts b 7 Nm (0.7 m·kg, 5.0 ft•lb) SHIFT PEDAL a 2 1 1. Install: 9sprocket cover 9shift pedal 1 9shift pedal bolt 2 10 Nm (1.0 m•kg, 7.2 ft•lb) 18 Nm (1.
INSTALLING THE ENGINE ENG FOOTREST 1. Install: 9footrest 9footrest bolts 1 23 Nm (2.3 m·kg, 17 ft•lb) 1 CARBURETOR 1. Install: 9carburetor assembly Refer to “CARBURETOR” in chapter 6. 2. Adjust: 9throttle cable free play 9rear brake light operation timing Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” and “ADJUSTING THE REAR BRAKE LIGHTSWITCH” in chapter 3. Throttle cable free play (at the flange of the throttle grip) 3 – 7 mm (0.12 – 0.28 mm) COOLING SYSTEM 1.
CYLINDER HEAD ENG EASF0023 CYLINDER HEAD 1 2 3 4 5 6 7 8 Timing chain tensioner 9 Dowel pin 0 Gasket Water pump Spark plug Cylinder head cover Dowel pin Camshaft sprocket Cylinder head Timing chain guide (exhaust side) 10 Nm (1.0 m•kg, 7.2 ft•lb ) 10 Nm (1.0 m•kg, 7.2 ft•lb ) 3 10 Nm (1.0 m•kg, 7.2 ft•lb ) 8 10 Nm (1.0 m•kg, 7.2 ft•lb ) 13 Nm (1.3 m•kg, 9.5 ft•lb ) E 2 0 9 E 1 6 22 Nm (2.2 m•kg, 16 ft•lb ) LS 5 30 Nm (3.0 m•kg, 22 ft•lb ) 7 10 Nm (1.0 m•kg,7.2 ft•lb ) 4-8 http://mototh.
CYLINDER HEAD ENG EAS00222 REMOVING THE CYLINDER HEAD 1. Remove 9side cowlings (left and right) 9front cowling 9center panels (upper and lower) 9rear cowlings (left and right) Refer to “COVERS” in chapter 3. 9carburetor assembly Refer to “CARBURETOR” in chapter 6. 9muffler Refer to “REMOVING THE ENGINE”. 2. Drain: 9cooling system Refer to “CHANGING THE COOLANT” in chapter 3. 3. Remove: 9water pump assembly bolts 9water pump assembly 9O-rings 4. Remove: 9spark plug cap 1 9spark plug 2 5.
CYLINDER HEAD 6. Align: 9“I” mark a on the generator rotor b on the (with the stationary pointer crankcase) ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a b ENG a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compresc on the sion stroke, align the “I” mark camshaft sprocket with the stationary pointer d on the cylinder head. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ d c 7. Loosen: 9camshaft sprocket bolt 1 NOTE: While holding the generator rotor with a wrench 2 , loosen the camshaft sprocket bolt. 1 2 8.
CYLINDER HEAD 6 10. Remove: 9engine mount nut 9washer 9engine mount bolt 9cylinder head bolts 9cylinder head bolts 9washers 9cylinder head 4 3 2 5 1 NOTE: 9Loosen the nuts in the proper sequence as shown. 9Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. 1 2 ENG 11. Remove: 9dowel pins 1 9gasket 2 9timing chain guide (exhaust side) 3 3 EAS00227 CHECKING THE CYLINDER HEAD 1.
CYLINDER HEAD ENG 3. Measure: 9cylinder head warpage Out of specification → Resurface the cylinder head. Maximum cylinder head warpage 0.03 mm (0.0012 in) ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows. d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern.
CYLINDER HEAD ENG EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: 9timing chain tensioner Cracks/damage → Replace. ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly.
CYLINDER HEAD ENG 3. Tighten: 9cylinder head bolts 1 3 22 Nm (2.2 m·kg, 16 ft•lb) 9cylinder head bolts 4 5 10 Nm (1.0 m•kg, 7.2 ft•lb) 9engine mount nut 72 Nm (7.2 m•kg, 52 ft•lb) 2 6 NOTE: 9Lubricate the cylinder head bolts with engine oil. 9Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages. 1 4. Install: 9camshaft sprocket 1 9timing chain 2 ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ 2 b a. Turn the crankshaft clockwise. b.
CYLINDER HEAD ENG 5. Install: 9timing chain tensioner ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ 1 a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . NOTE: Make sure that the tensioner rod has been fully set clockwise. b. Install the gasket and the timing chain tensioner 2 onto the cylinder. 2 w Always use a new gasket. NOTE: Apply the YAMAHAbond 1215 onto the bolts. Yamaha bond No. 1215 90890-85505 Timing chain tensioner bolt 10 Nm (1.
CYLINDER HEAD b ENG 8. Check: 9“I”mark a Align the “I” mark on the generator rotor b on the with the stationary pointer crankcase. 9“I”mark c Align the “I”mark on the camshaft sprocket with the stationary pointer d on the cylinder head. Out of alignment → Correct. Refer to the installation steps above. a d c 9. Measure: 9valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 10. Install: 9O-rings 9water pump assembly 9water pump assembly bolts 10 Nm (1.
CAMSHAFT ENG EASf0020 CAMSHAFT 1 2 3 4 5 6 Locknut Adjusting screw Camshaft retainer Camshaft Rocker arm shaft Rocker arm 1 2 6 5 E 4 E 5 E LS 1 26 E 3 7 Nm (0.7 m•kg, 5.0 ft•lb ) 7 Nm (0.7 m•kg, 5.0 ft•lb ) 4-17 http://mototh.
CAMSHAFT ENG EASF0022 2 REMOVING THE ROCKER ARMS AND CAMSHAFT NOTE: Prior to remove the rocker arms and camshaft, remove the cylinder head. 1 1. Loosen: 9locknuts 1 9adjusting screws 2 2. Remove: 9camshaft retainer 1 1 3. Remove: 9camshaft 1 NOTE: Screw an 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft. 1 2 4. Remove: 9rocker arm shafts 9rocker arms 4-18 http://mototh.
CAMSHAFT ENG EAS00205 CHECKING THE CAMSHAFT 1. Check: 9camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 9camshaft lobe dimensions a and b → Replace the Out of specification camshaft. Camshaft lobe dimension limit Intake aa 29.613 mm (1.1659 in) bb25.043 mm (0.9859 in) Exhaust aa 29.912 mm (1.1776 in) bb24.989 mm (0.9838 in) 3. Check: 9camshaft oil passage Obstructions → Blow out with compressed air.
CAMSHAFT ENG 2. Check: 9rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrication system. 3. Measure: 9rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 9.985 – 10.000 mm (0.3931 – 0.3937 in) : 9.950 mm (0.3917 in) 4. Measure: 9rocker arm shaft outside diameter Out of specification → Replace. Rocker arm shaft outside diameter 9.966 – 9.976 mm (0.3924 – 0.3928 in) : 9.950 mm (0.3917 in) 5.
CAMSHAFT ENG EAS00207 CHECKING THE CAMSHAFT SPROCKET a 1. Check: 9camshaft sprocket Worn more than 1/4 tooth a → Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain 2 Camshaft sprocket EAS00219 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 9camshaft journals Recommended lubricant Engine oil 2. Lubricate: 9rocker arm inside surface 9camshaft oil passage Recommended lubricant Molybdenum disulfide grease 3.
ENG VALVES AND VALVE SPRINGS EASF0024 VALVES AND VALVE SPRINGS 1 2 3 4 5 6 7 Valve cotter Upper spring seat Valve spring Valve stem seal Lower spring seat Intake valve Exhaust valve 1 2 1 3 2 4 5 3 4 5 7 3 2 1 4 5 7 1 2 3 4 5 6 6 4-22 http://mototh.
VALVES AND VALVE SPRINGS ENG EASF0025 REMOVING THE VALVES NOTE: Prior to remove the valves, remove the cylinder head, camshaft and rocker arms. The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: 9valve sealing → Check the Leakage at the valve seat valve face, valve seat, and valve seat width.
VALVES AND VALVE SPRINGS ENG 2. Remove: 9valve cotters 1 2 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2. 1 Valve spring compressor 90890-04019 Valve spring compressor attachment 90890-04108 3. Remove: 9upper spring seat 1 9valve spring 2 9valve stem seal 3 9lower spring seat 4 9valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
CYLINDER HEAD ENG 5. Install: 9timing chain tensioner ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ 1 a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . NOTE: Make sure that the tensioner rod has been fully set clockwise. b. Install the gasket and the timing chain tensioner 2 onto the cylinder. 2 w Always use a new gasket. NOTE: Apply the YAMAHAbond 1215 onto the bolts. Yamaha bond No. 1215 90890-85505 Timing chain tensioner bolt 10 Nm (1.
CYLINDER HEAD b ENG 8. Check: 9“I”mark a Align the “I” mark on the generator rotor b on the with the stationary pointer crankcase. 9“I”mark c Align the “I”mark on the camshaft sprocket with the stationary pointer d on the cylinder head. Out of alignment → Correct. Refer to the installation steps above. a d c 9. Measure: 9valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 10. Install: 9O-rings 9water pump assembly 9water pump assembly bolts 10 Nm (1.
CAMSHAFT ENG EASf0020 CAMSHAFT 1 2 3 4 5 6 Locknut Adjusting screw Camshaft retainer Camshaft Rocker arm shaft Rocker arm 1 2 6 5 E 4 E 5 E LS 1 26 E 3 7 Nm (0.7 m•kg, 5.0 ft•lb ) 7 Nm (0.7 m•kg, 5.0 ft•lb ) 4-17 http://mototh.
CAMSHAFT ENG EASF0022 2 REMOVING THE ROCKER ARMS AND CAMSHAFT NOTE: Prior to remove the rocker arms and camshaft, remove the cylinder head. 1 1. Loosen: 9locknuts 1 9adjusting screws 2 2. Remove: 9camshaft retainer 1 1 3. Remove: 9camshaft 1 NOTE: Screw an 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft. 1 2 4. Remove: 9rocker arm shafts 9rocker arms 4-18 http://mototh.
CAMSHAFT ENG EAS00205 CHECKING THE CAMSHAFT 1. Check: 9camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 9camshaft lobe dimensions a and b → Replace the Out of specification camshaft. Camshaft lobe dimension limit Intake aa 29.613 mm (1.1659 in) bb25.043 mm (0.9859 in) Exhaust aa 29.912 mm (1.1776 in) bb24.989 mm (0.9838 in) 3. Check: 9camshaft oil passage Obstructions → Blow out with compressed air.
CAMSHAFT ENG 2. Check: 9rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrication system. 3. Measure: 9rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 9.985 – 10.000 mm (0.3931 – 0.3937 in) : 9.950 mm (0.3917 in) 4. Measure: 9rocker arm shaft outside diameter Out of specification → Replace. Rocker arm shaft outside diameter 9.966 – 9.976 mm (0.3924 – 0.3928 in) : 9.950 mm (0.3917 in) 5.
CAMSHAFT ENG EAS00207 CHECKING THE CAMSHAFT SPROCKET a 1. Check: 9camshaft sprocket Worn more than 1/4 tooth a → Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain 2 Camshaft sprocket EAS00219 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 9camshaft journals Recommended lubricant Engine oil 2. Lubricate: 9rocker arm inside surface 9camshaft oil passage Recommended lubricant Molybdenum disulfide grease 3.
ENG VALVES AND VALVE SPRINGS EASF0024 VALVES AND VALVE SPRINGS 1 2 3 4 5 6 7 Valve cotter Upper spring seat Valve spring Valve stem seal Lower spring seat Intake valve Exhaust valve 1 2 1 3 2 4 5 3 4 5 7 3 2 1 4 5 7 1 2 3 4 5 6 6 4-22 http://mototh.
VALVES AND VALVE SPRINGS ENG EASF0025 REMOVING THE VALVES NOTE: Prior to remove the valves, remove the cylinder head, camshaft and rocker arms. The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: 9valve sealing → Check the Leakage at the valve seat valve face, valve seat, and valve seat width.
VALVES AND VALVE SPRINGS ENG 2. Remove: 9valve cotters 1 2 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2. 1 Valve spring compressor 90890-04019 Valve spring compressor attachment 90890-04108 3. Remove: 9upper spring seat 1 9valve spring 2 9valve stem seal 3 9lower spring seat 4 9valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
VALVES AND VALVE SPRINGS ENG 2. Replace: 9valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 ° C in an oven. ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Remove the valve guide with the valve guide remover 1 . b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. c. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valveguide clearance.
VALVES AND VALVE SPRINGS ENG 6. Measure: 9valve stem runout Out of specification → Replace the valve. NOTE: 9When installing a new valve, always replace the valve guide. 9If the valve is removed or replaced, always replace the valve stem seal. Valve stem runout limit 0.01 mm (0.0004 in) EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: 9carbon deposits (from the valve face and valve seat) 2.
VALVES AND VALVE SPRINGS ENG NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ 4. Lap: 9valve face 9valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Apply a coarse lapping compound a to the valve face. cC M Do not let the lapping compound enter the gap between the valve stem and the valve guide. b.
VALVES AND VALVE SPRINGS ENG j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: 9valve spring free length a Out of specification → Replace the valve spring. Valve spring free length Intake and exhaust valve springs 47.33 mm (1.86 in) : 44.96 mm (1.77 in) 2.
VALVES AND VALVE SPRINGS ENG EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 9valve stem end (with an oil stone) 2. Lubricate: 9valve stem 1 9valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybudemium oil M 3. Install: 9valve 1 9lower spring seat 2 9valve stem seal 3 9valve spring 4 9upper spring seat 5 (into the cylinder head) NOTE: Install the valve spring with the larger pitch facing up.
VALVES AND VALVE SPRINGS ENG 4. Install: 9valve cotters 1 2 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 1 Valve spring compressor 90890-04019 Valve spring compressor attachment 90890-04108 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer. cC Hitting the valve tip with excessive force could damage the valve. 4-30 http://mototh.
ENG CYLINDER AND PISTON EASF0027 CYLINDER AND PISTON 1 2 3 4 5 6 7 8 Piston pin 9 Piston Cylinder Cylinder gasket Dowel pin Top ring 2nd ring Oil ring Piston pin clip 1 2 E 3 3 4 5 6 7 8 7 E 9 E 4-31 http://mototh.
CYLINDER AND PISTON ENG EASF0028 REMOVING THE CYLINDER AND PISTON NOTE: Prior to removing the cylinder and piston, remove the cylinder head. 1. Remove: 9cylinder 1 1 2. Remove: 9dowel pins 1 9gasket 2 1 2 3. Remove: 9piston pin clip 1 9piston pin 2 9piston 3 2 1 cC 3 Do not use a hammer to drive the piston pin out. NOTE: 9Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.
CYLINDER AND PISTON ENG EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: 9piston surface 9cylinder wall Vertical scratches → Replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: 9piston-to-cylinder clearance ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. Cylinder bore “C” Limit 54.
CYLINDER AND PISTON ENG Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.0015 – 0.048 mm (0.0006 – 0.0019 in) : 0.15 mm (0.0059) f. If out of specification, replace the cylinder, and replace the piston and piston rings as a set. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ EAS00263 CHECKING THE PISTON RINGS 1. Measure: 9piston ring side clearance Out of specification → Replace the piston and piston rings as a set.
CYLINDER AND PISTON ENG 3. Measure: 9piston ring end gap Out of specification → Replace the piston ring. NOTE: The end gap of the oil ring expander cannot be measured. If the end gaps of the oil ring rails are excessive, replace all three piston rings. Piston ring end gap Top ring 0.10 – 0.25 mm (0.0039 – 0.0098 in) : 0.4 mm (0.0157 in) 2nd ring 0.10 – 0.25 mm (0.0039 – 0.0098 in) : 0.4 mm (0.0157 in) Oil ring rails 0.20 – 0.70 mm (0.01 – 0.03 in) EAS00265 CHECKING THE PISTON PIN 1.
CYLINDER AND PISTON ENG 4. Calculate: 9piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter bb– Piston pin outside diameter aa Piston-pin-to-piston-pin-bore clearance 0.002 – 0.018 mm (0.0001 – 0.0007 in) : 0.068 mm (0.027 in) EAS00267 1 INSTALLING THE PISTON AND CYLINDER 1.
CYLINDER AND PISTON ENG 3. Install: 9gasket 1 9dowel pins 2 4. Lubricate: 9piston 9piston rings 9cylinder (with the recommended lubricant) 2 1 NOTE: Be sure to apply enough engine oil onto them. Recommended lubricant Engine oil 5. Offset: 9piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring å forward 6. Install: 9cylinder 1 NOTE: 9While compressing the piston rings with one hand, install the cylinder with the other hand.
ENG GENERATOR AND STARTER CLUTCH EASF0034 GENERATOR AND STARTER CLUTCH 1 2 3 4 5 6 7 Starter clutch gear Starter clutch roller Starter clutch spring cap Starter clutch spring Starter clutch Woodruff key Generator rotor 8 9 0 q w e r Starter clutch idle gear shaft Starter clutch idle gear Pickup coil Stator coil Gasket Dowel pin Crankcase cover (left) 8 9 T135SE 1 E 5 2 3 6 7 4 14 Nm (1.4 m•kg, 20 ft•lb ) 14 Nm (1.4 m•kg, 20 ft•lb ) 70 Nm (7.0 m•kg, 50 ft•lb ) q e w 10 Nm (1.0 m•kg, 7.
GENERATOR AND STARTER CLUTCH ENG EAS00346 REMOVING THE GENERATOR 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9side cowling (left) Refer to “REMOVING THE SIDE COWLINGS” in chapter 3. 9shift pedal 9drive sprocket cover Refer to “REMOVING THE DRIVE CHAIN AND SPROCKETS” in chapter 6. 3. Disconnect: 9stator coil coupler 1 9pickup coil coupler 2 2 1 4. Remove: 9crankcase cover (left) 1 9gasket 9dowel pins 1 5.
GENERATOR AND STARTER CLUTCH ENG 6. Remove: 9generator rotor 1 (with the flywheel puller 2 ) 9woodruff key 1 Flywheel puller 90890-01362 2 EAS00344 REMOVING THE STARTER CLUTCH (T135SE) 2 1. Remove: 9starter clutch idle gear shaft 1 9starter clutch idle gear 2 9starter clutch gear 3 9washer 1 3 2. Remove: 9starter clutch rollers 1 9starter clutch spring caps 9starter clutch springs 3.
GENERATOR AND STARTER CLUTCH ENG EAS00351 CHECKING THE STARTER CLUTCH (T135SE) 1. Check: 9starter clutch rollers 1 Damage/wear → Replace. 2. Check: 9starter clutch idle gear 1 9starter clutch gear 2 Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: 9starter clutch gear contacting surfaces a Damage/pitting/wear → Replace the starter clutch gear. 1 a 2 4. Check: 9starter clutch operation ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ 1 onto the a.
GENERATOR AND STARTER CLUTCH ENG EAS00355 INSTALLING THE STARTER CLUTCH (T135SE) 1. Install: 9starter clutch 1 14 Nm (1.4 m•kg, 10 ft•lb) NOTE: 9While holding the generator rotor 2 with the sheave holder, tighten the starter clutch bolt. 9Do not allow the sheave holder to touch the projection on the generator rotor. 9Lock the threads on the starter clutch bolts by staking them with a center punch. Sheave holder 90890-01701 EAS00353 INSTALLING THE GENERATOR 1.
GENERATOR AND STARTER CLUTCH ENG 3. Apply: 9sealant (on to the generator lead grommet) Yamaha bond No. 1215 90890-85505 4. Apply: 9sealant NOTE: Be sure to apply the sealant onto the crankcase cover bolt thread as shown one. Yamaha bond No. 1215 90890-85505 5. Install: 9gasket 9crankcase cover 10 Nm (1.0 m•kg, 7.2 ft•lb) 4-43 http://mototh.
OILPUMP ENG EASF0035 OILPUMP 1 2 3 4 5 6 7 8 Gear cover 9 Oil pump assembly 0 Gasket Oil drain bolt O-ring Spring Oil strainer Oil filter cover O-ring Oil filter 10 Nm (1.0 m•kg, 7.2 ft•lb ) 5 6 7 4 0 9 3 2 7 Nm (0.7 m•kg, 5.0 ft•lb ) 8 10 Nm (1.0 m•kg, 7.2 ft•lb ) 32 Nm (3.2 m•kg, 23 ft•lb ) 4-44 http://mototh.
OILPUMP ENG REMOVING THE OILPUMP 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9generator Refer to “GENERATOR AND STARTER CLUTCH”. 3. Remove: 9clutch release shift arm 4. Remove: 9gear cover 5. Remove: 9oil pump assembly 1 9gasket 1 DISASSEMBLING THE OILPUMP 6 1. Remove: 9screw 9pump cover 1 9pin 2 9inner rotor 3 9outer rotor 4 9oil pump housing 5 9oil pump driven cover 6 5 4 1 2 3 4-45 http://mototh.
OILPUMP ENG EAS00364 1 2 CHECKING THE OILPUMP 3 1. Check: 9oil pump driven gear 1 9oil pump housing 2 9outer rotor 9inner rotor Cracks/damage/wear → Replace the defective part(s). 4 2. Measure: 9inner-rotor-to-outer-rotor-tip clearance a 9outer-rotor-to-oil-pump-housing clearance b 9oil-pump-housing-to-inner-rotor-and-outerrotor clearance c → Replace the oil Out of specification pump. 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0.15 mm (0.
OILPUMP ENG EAS00375 ASSEMBLING THE OILPUMP 1. Lubricate: 9inner rotor 9outer rotor 9oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 9oil pump shaft (to the oil pump housing) 9inner rotor 1 9outer rotor 9pin 2 9oil pump housing cover 3 9screw 4 1 Nm (0.1 m•kg, 0.7 ft•lb) 2 1 a NOTE: When installing the inner rotor, align the pin in a in the the oil pump shaft with the groove inner rotor. 4 3 3. Check: 9oil pump operation Refer to “CHECKING THE OILPUMP”.
OILPUMP ENG EAS00376 INSTALLING THE OILPUMP 1. Install: 9gasket 1 9oil pump assembly 1 7 Nm (0.7 m•kg, 5.0 ft•lb) a NOTE: Install the gasket with section a in the position as shown in the illustration. cC After tightening the bolts, make sure the oil pump turns smoothly. 4-48 http://mototh.
CLUTCH ENG EASF0029 CLUTCH 1 2 3 4 5 6 7 8 9 0 q w e r t Clutch pressure plate bolt Clutch spring Clutch pressure plate Friction plate #1 Clutch plate Friction plate #2 Cushion ring Seat plate y u i o p a Clutch push rod #1 Clutch boss nut Clutch boss Clutch housing Clutch push rod #2 Clutch release shift arm Clutch release adjusting screw Clutch shoe housing nut Primary drive gear Clutch shoe housing Cage Clutch shoe housing boss Clutch shoe 12 Nm (1.2 m•kg, 9.
CLUTCH ENG EAS00277 REMOVING THE CLUTCH 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9side cowlings (left and right) Refer to “REMOVING THE SIDE COWLINGS” in chapter 3. 9muffler 9footrest 9brake pedal Refer to “REMOVING THE ENGINE”. 9kickstarter lever Refer to “KICKSTARTER”. 9crankcase cover (left) Refer to “GENERATOR AND STARTER CLUTCH”. 3. Remove: 9clutch release shift arm 1 1 4. Remove: 9crankcase cover (right) 5.
CLUTCH ENG 7. Straighten the lock washer tab. 8. Loosen: 9clutch boss nut 1 3 2 NOTE: While holding the clutch boss 2 with the universal clutch holder 3 , loosen the clutch boss nut. 1 Universal clutch holder 90890-04086 9. Remove: 9clutch boss nut 1 9lock washer 2 9clutch boss 3 9washer 4 9clutch housing 5 9spacer 6 9clutch push rod #2 7 5 6 1 7 2 3 4 10.
CLUTCH 3 1 2 5 6 ENG 11. Remove: 9collar 1 9clutch shoe housing 2 9washer 3 9rollers 4 9cage springs 5 9cage 6 9clutch shoe housing boss 7 9clutch shoe 8 7 4 8 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: 9friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: 9friction plate thickness Out of specification → Replace the friction plates as a set. NOTE: Measure the friction plate at four places.
CLUTCH ENG EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: 9clutch spring Damage → Replace the clutch springs as a set. 2. Measure: 9clutch spring free length a Out of specification → Replace the clutch springs as a set. Clutch spring free length 40.5 mm (1.59 in) : 38.5 mm (1.52 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: 9clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing.
CLUTCH ENG EAS00286 CHECKING THE CLUTCH PRESSURE PLATE 1. Check: 9clutch pressure plate Cracks/damage → Replace. EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check: 9clutch push rod #1 Cracks/damage/wear → Replace the clutch push rod #1. 9clutch push rod #2 Cracks/damage/wear → Replace the clutch push rod #2. 2. Measure: 9clutch push rods bending limit Out of specification → Replace the clutch push rod. Clutch push rods bending limit 0.5 mm (0.0197 in) EAS00292 CHECKING THE PRIMARYDRIVEN GEAR 1.
CLUTCH ENG CHECKING THE CLUTCH SHOE HOUSING 1. Check: 9clutch shoe housing Damage/wear → Replace. a 2. Measure: 9clutch shoe housing inside diameter a Out of specification → Replace. Clutch shoe housing inside diameter 116 mm (4.57 in) : 117 mm (4.61 in) CHECKING THE CLUTCH SHOE 1. Check: 9clutch shoe Scratches → Smooth using coarse sandpaper. Damage/wear → Replace. 2. Measure: 9clutch shoe groove depth a Groove is worn away → Replace. Clutch shoe groove depth 1.0 mm (0.04 in) : 0.
CLUTCH ENG CHECKING THE CLUTCH RELEASE SHIFT ARM 1 1. Check: 9clutch release shift arm 1 Damage/wear → Replace. 9clutch release adjusting screw 2 Damage/wear → Replace. 2 EAS00293 INSTALLING THE CLUTCH 1. Install: 9washer 9cage 1 9cage springs 2 9rollers 3 9clutch shoe housing boss 4 NOTE: After installing the cage 1 , cage springs 2 and rollers 3 , check that the there are right position to turn the lateral direction. And then take care comes off to install them onto the crankshaft. 2.
CLUTCH ENG 4. Tighten: 9clutch boss nut 1 3 2 70 Nm (7.0 m•kg, 50 ft•lb) NOTE: While holding the clutch boss 2 with the universal clutch holder 3 , tighten the clutch boss nut. Universal clutch holder 90890-04086 1 5. Bend the lock washer tab along a flat side of the nut. 6. Lubricate: 9seat plate 9cushion ring 9friction plates #1 9friction plate #2 9clutch plates (with the recommended lubricant) 3 4 Recommended lubricant Engine oil 5 7.
SHIFT SHAFT ENG EASF0032 SHIFT SHAFT 1 2 3 4 5 6 7 8 9 0 q w e r Shift pedal Washer Spring Shift fork guide bar Shift guide Pawl holder Guide t Collar y Plate u Shift drum segment Washer Thrust bearing Dowel pin Shift shaft Shift lever assembly Stopper lever spring Stopper lever assembly 12 Nm (1.2 m•kg, 9.0 ft•lb ) y 10 Nm (1.0 m•kg, 7.2 ft•lb ) u r t w 0 e q E E 8 9 8 E 7 6 1 5 LS E 3 4 2 18 Nm (1.8 m•kg, 13 ft•lb ) 4-58 http://mototh.
SHIFT SHAFT ENG REMOVING THE SHIFT SHAFT 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9clutch Refer to “CLUTCH”. 3. Remove: 9shift pedal 9crankcase cover bolts 9crankcase cover (left) 4. Remove: 9shift fork guide bar 1 9washer 2 9shift guide spring 2 1 5. Remove: 9shift guide 1 9pawl holder 2 9guide 3 9dowel pin 4 4 3 2 1 6. Remove: 9washers 1 9thrust bearing 2 2 1 4-59 http://mototh.
SHIFT SHAFT 7. Remove: 9shift shaft assembly 1 9shift lever assembly 2 1 2 ENG 8. Remove: 9stopper lever assembly 3 9stopper lever spring 4 9collar 3 4 9. Remove: 9stopper lever spring 1 9stopper lever 2 9collar 3 2 3 1 10. Remove: 9plate 9shift drum segment 1 1 4-60 http://mototh.
SHIFT SHAFT ENG EAS00328 CHECKING THE SHIFT SHAFT 1 1. Check: 9shift shaft 1 9shift lever 2 Bends/damage/wear → Replace. 9springs Damage/wear → Replace. 2 EAS00330 CHECKING THE STOPPER LEVER 1 1. Check: 9stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace. 9stopper lever spring Damage/wear → Replace. CHECKING THE SHIFT GUIDE 1. Check: 9shift guide 1 9pawl holder 2 9guide 3 Bends/damage → Replace. 9shift guide spring 4 Damage/wear → Replace. 1234 CHECKING THE OILSEAL 1.
SHIFT SHAFT ENG EAS00331 INSTALLING THE SHIFT SHAFT 1 1. Install: 9shift drum segment 1 9plate 12 Nm (1.2 m•kg, 9.0 ft•lb) NOTE: R Apply locking agent (LOCTITE ) to the threads of shift drum segment screw. 2. Install: 9collar 9stopper lever 1 9stopper lever spring 2 1 2 LT NOTE: 9Apply locking agent (LOCTITE R ) to the stopper lever bolt. 9Hook the ends 3 of the stopper lever spring onto the stopper lever and the crankcase boss. 9Mesh the stopper lever with the shift drum segment assembly. 1 2 3.
CRANKCASE AND CRANKSHAFT ENG EASF0037 CRANKCASE AND CRANKSHAFT 1 2 3 4 5 6 7 Neutral switch Right crankcase Dowel pin Timing chain Timing chain guide (intake side) Crankshaft assembly Left crankcase 2 4 Nm (0.4 m•kg, 3.0 ft•lb ) 3 7 1 3 14 Nm (1.4 m•kg, 20 ft•lb ) 6 5 4 10 Nm (1.0 m•kg, 7.2 ft•lb ) E 4-63 http://mototh.
CRANKCASE AND CRANKSHAFT ENG EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 9engine Refer to “REMOVING THE ENGINE”. 2. Remove: 9starter motor lead (T135SE) 9starter motor (T135SE) Refer to “STARTER MOTOR (T135SE)” in chapter 8. 3. Remove: 9cylinder head Refer to “CYLINDER HEAD”. 9cylinder 9piston Refer to “CYLINDER AND PISTON”. 9clutch Refer to “CLUTCH”. 9shift shaft Refer to “SHIFTSHAFT”. 9generator 9starter clutch Refer to “GENERATOR AND STARTER CLUTCH”. 9oil pump assembly Refer to “OILPUMP”. 4.
CRANKCASE AND CRANKSHAFT ENG 5. Remove: 9crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 6. Remove: 9right crankcase 9dowel pins cC Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly. 7.
CRANKCASE AND CRANKSHAFT ENG 2. Measure: 9big end side clearance Out of specification → Replace the crankshaft. Big end side clearance 0.11 – 0.41 mm (0.0043 – 0.0161 in) 3. Measure: 9crankshaft width Out of specification → Replace the crankshaft. Crankshaft width 45.95 – 46.00 mm (1.809 – 1.811 in) 4. Check: 9crankshaft sprocket 1 Damage/wear → Replace the crankshaft. 9bearing 2 Cracks/damage/wear → Replace the crankshaft. 5. Check: 9crankshaft journal Scratches/wear → Replace the crankshaft.
CRANKCASE AND CRANKSHAFT ENG EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: 9crankcase Cracks/damage → Replace. 9oil delivery passages Obstructions → Blow out with compressed air. EAS00401 CHECKING THE BEARINGS 1. Check: 9bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. CHECKING THE TIMING CHAIN GUIDE 1.
CRANKCASE AND CRANKSHAFT ENG EAS00408 1 INSTALLING THE CRANKSHAFT 2 1. Install: 9crankshaft assembly 1 3 5 NOTE: 2, Use the crankshaft installing tool (spacer 3 4 5 installer pot , installer bolt , adaptor ) to install the crankcase (left). 4 cC To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.
CRANKCASE AND CRANKSHAFT 4. Install: 9neutral switch 9crankcase bolts ENG 4 Nm (0.4 m•kg, 3.0 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 5. Apply: 9engine oil (onto the crankshaft bearings and oil delivery holes) 6. Check: 9crankshaft and transmission operation Rough movement → Repair. 7. Install: 9timing chain 9timing chain guide (intake side) 9timing chain guide (intake side) bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: R Apply locking agent (LOCTITE ) to the threads of timing chain guide (intake side) bolts.
KICKSTARTER ENG EASF0033 KICKSTARTER 1 2 3 4 5 6 7 8 9 0 q w e Oil level plug Kickstarter lever Crankcase cover (right) Gasket Washer Kickstarter gear Guide stopper Collar Kickstarter spring Washer Spring Kickstarter ratchet gear Kickstarter shaft 1 2 3 50 Nm (5.0 m•kg, 36 ft•lb ) 4 6 w e 5 q M 0 8 9 12 Nm (1.2 m•kg, 9.0 ft•lb ) 7 4-70 http://mototh.
KICKSTARTER ENG REMOVING THE KICKSTARTER 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 9coolant (completely from the water jacket) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Remove: 9side cowlings (left and right) 9front cowling 9center panels (upper and lower) 9rear cowlings (left and right) Refer to “COVERS” in chapter 3. 9carburetor assembly Refer to “CARBURETOR” in chapter 6. 9muffler 9footrest 9Brake pedal Refer to “REMOVING THE ENGINE”.
KICKSTARTER ENG 6. Remove: 9clutch Refer to “CLUTCH”. 9shift shaft Refer to “SHIFTSHAFT”. 9oil pump assembly Refer to “SOILPUMP”. 9generator 9starter clutch Refer to “GENERATOR AND STARTER CLUTCH. 7. Remove: 9starter motor (T135SE) Refer to “STARTER MOTOR” in chapter 8. 8. Remove: 9engine Refer to “REMOVING THE ENGINE”. 9. Separate: 9crankcase Refer to “CRANKCASE”. 10. Remove: 9guide stopper 9kickstarter shaft assembly 4-72 http://mototh.
KICKSTARTER 11. Remove: 9washer 1 9kickstarter gear 2 9kickstarter spring 3 9collar 4 9washer 5 9spring 6 9kickstarter ratchet gear 7 9kickstarter shaft 1 2 7 ENG 6 4 5 3 EAS00339 CHECKING THE KICKSTARTER 1. Check: 9kickstarter ratchet gear 1 9kickstarter gear 2 Damage/wear → Replace. 2. Check: 9kickstarter spring Damage/wear → Replace. 4-73 http://mototh.
KICKSTARTER ENG INSTALLING THE KICKSTARTER 1. Install: 9kickstarter ratchet gear 1 (on to the kickstarter shaft) 9kickstarter shaft 2 9kickstarter spring 2 90˚ 1 NOTE: 9Offset the kickstarter ratchet gear as shown, and then align the spline to install the kickstarter ratchet gear. 9Hook the kickstarter spring end onto the pin a in the crankcase, and then turn the kickstarter shaft counter-clockwise to 3/4 turns b . 4 b 3 2. Install: 9guide stopper 3 9guide stopper bolts a 12 Nm (1.2 m•kg, 9.
KICKSTARTER ENG 9. Install: 9piston 9cylinder Refer to “CYLINDER AND PISTON”. 9cylinder head Refer to “CYLINDER HEAD”. 9radiator assembly Refer to “RADIATOR” in chapter 5. 9cylinder head Refer to “CYLINDER HEAD”. 10. Install: 9muffler 9footrest 9brake pedal Refer to “REMOVING THE ENGINE”. 9inner panel 9center panels (left and right) 9front cowling 9side cowlings (left and right) Refer to “COVERS” in chapter 3. 11.
TRANSMISSION ENG EASF0041 TRANSMISSION 1 2 3 4 5 6 7 8 9 0 q w e r t y Shift fork guide bar Shift fork “R” Shift fork “L” Shift drum 2nd pinion gear 3rd pinion gear 4th pinion gear Main axle/1st pinion gear 1st wheel gear 4th wheel gear 3rd wheel gear 2nd wheel gear Side plate spring Side plate Washer Drive axle 9 0 E q y t r M e M w 8 E 4 M 7 1 6 M 6 2 E E 3 4-76 http://mototh.
TRANSMISSION ENG EASF0042 REMOVING THE TRANSMISSION 1 NOTE: Prior to removing the transmission, separate the crankcase. 4 2 1. Remove: 9shift fork guide bar 1 9shift fork guide bar springs 9shift fork “R” 2 9shift fork “L” 3 9shift drum 4 3 NOTE: Note the position of each part. Pay particular attention to location and direction of shift forks. 1 2. Remove: 9main axle assembly 1 9drive axle assembly 2 2 DISASSEMBLING THE TRANSMISSION 1.
TRANSMISSION 1 2 3 2. Remove: 9circlips 1 9washers 2 91st wheel gear 3 94th wheel gear 4 93rd wheel gear 5 9side plate 6 9side plate spring 7 92nd wheel gear 8 9drive axle 9 4 1 2 5 9 1 6 ENG 7 8 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to both of the shift forks. 1. Check: 9shift fork cam follower 1 9shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Check: 9shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends → Replace.
TRANSMISSION ENG EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: 9shift drum grooves 1 Damage/scratches/wear → Replace the shift drum assembly. 9shift drum bearing Damage/pitting → Replace the shift drum assembly. 1 EAS00424 CHECKING THE TRANSMISSION 1. Measure: 9main axle runout (with a centring device and dial gauge 1 ) Out of specification → Replace the main axle. Main axle runout limit 0.03 mm (0.0012 in) 2.
TRANSMISSION ENG 4. Check: 9transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 2 1 NOTE: When reassembling the drive axle, press the 2nd wheel gear 1 onto the drive axle 2 as shown. 21.1~21.3 mm 5. Check: 9transmission gear movement Rough movement → Replace the defective part(s). 6. Check: 9circlips Bends/damage/looseness → Replace. EAS00426 INSTALLING THE TRANSMISSION 1 1.
TRANSMISSION ENG 2. Check: 9transmission 9shift drum 9shift forks Rough movement → Repair. NOTE: 9Oil each gear, shaft, and bearing thoroughly. 9Before assembling the crankcase, be sure that the transmission is in neutral and that the gears turn freely. 4-81 http://mototh.
ENG http://mototh.
COOL CHAPTER 5 COOLINGSYSTEM RADIATOR ............................................................................................................5-1 WATER PUMP.......................................................................................................5-2 REMOVING THE RADIATOR ...........................................................................5-3 CHECKING THE RADIATOR ............................................................................5-4 CHECKING THE THERMOSTAT...................
COOL http://mototh.
COOLING SYSTEM COOL EAS00454 COOLING SYSTEM RADIATOR 1 2 3 4 5 6 7 8 9 Radiator assembly 0 Fan motor assembly Radiator cap Bracket Water pump inlet hose Radiator outlet hose Radiator inlet hose Bracket Thermostat housing cover Thermostat 1 0 10 Nm (1.0 m•kg, 7.2 ft•lb ) 9 3 4 6 5 2 7 8 10 Nm (1.0 m•kg, 7.2 ft•lb ) 5-1 http://mototh.com 10 Nm (1.0 m•kg, 7.
COOLING SYSTEM COOL EAS00468 WATER PUMP 1 2 3 4 5 6 7 8 9 Bearing 0 Water pump seal q Water pump housing O-ring O-ring Water pump cover Gasket Plate Impeller Plate Housing cover gasket 10 Nm (1.0 m•kg, 7.2 ft•lb ) 5 7 8 LS q 0 1 6 9 LS 2 LS 4 3 10 Nm (1.0 m•kg, 7.2 ft•lb ) 5-2 http://mototh.
COOLING SYSTEM COOL REMOVING THE RADIATOR w Ahot radiator is under pressure. Therefore,do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape.
COOLINGSYSTEM COOL 5. Remove: 9bracket 9thermostat cover 1 9thermostat 2 1 2 6. Remove: 9fan motor EAS00455 CHECKING THE RADIATOR 1. Check: 9radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: 9radiator hoses 9radiator pipes Cracks/damage → Replace. 5-4 http://mototh.
COOLING SYSTEM COOL 3. Measure: 9radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap opening pressure 93.2 – 122.6 kPa (0.93 – 1.23 kg/cm 2, 13.5 – 17.8 psi) ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 . Radiator cap tester 11 90890-01325 Radiator cap tester adapter 22 90890-01352 b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
COOLINGSYSTEM COOL EAS00462 CHECKING THE THERMOSTAT 1. Check: 9thermostat 1 Does not open at 80.5 – 83.5° C (176.9 – 182.3° F) → Replace. ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
COOLING SYSTEM COOL 2. Remove: 9plate NOTE: Slide the plate as shown, and then remove the plate from the water pump housing. 3. Remove: 9impeller 1 9bearing 2 2 4 NOTE: Remove the bearing from the outside of the water pump housing. 1 3 3 Water pump housing 4. Remove: 9water pump seal 4 NOTE: Remove the water pump seal from the inside of the water pump housing. EAS00473 CHECKING THE WATER PUMP 1.
COOLINGSYSTEM COOL EAS00475 ASSEMBLING THE WATER PUMP 1. Install: 9water pump seal 1 NOTE: Install the water pump seal with the special tools. Mechanical seal installer 90890-04145 22 Middle driven shaft bearing driver 90890-04058 33 å Push down. 2. Lubricate: 9water pump seal 1 Recommended lubricant Lithium soap base grease 3. Install: 9impeller 9plate 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: 9Align the slit in the impeller shaft with the slot of the plate.
COOLING SYSTEM COOL EAS00478 INSTALLING THE WATER PUMP LS 1. Install: 9O-rings 9water pump housing 1 1 10 Nm (1.0 m•kg, 7.2 ft•lb) w Always use a new O-ring. a b NOTE: 9Align the projection a on the impeller shaft with the slit b on the camshaft. 9Lubricate the O-ring with a thin coat of lithiumsoap-based grease. LS 2 2. Install: 9water pump housing cover 2 10 Nm (1.0 m•kg, 7.2 ft•lb) 9water pump inlet hose 9water pump outlet hose EAS00456 INSTALLING THE RADIATOR 1.
COOLINGSYSTEM COOL 4. Check: 9cooling system Leaks → Repair or replace any faulty part. ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Attach the radiator cap tester 1 to the radiator. Radiator cap tester 90890-01325 Radiator cap tester adapter 90890-01352 b. Apply 100 kPa (1.0 kg/cm 2 , 14.22 psi) of pressure. c. Measure the indicated pressure with the gauge. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ 5. Measure: 9radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR”. 6.
CARB CHAPTER 6 CARBURETOR CARBURETOR......................................................................................................6-1 REMOVING THE CARBURETOR.....................................................................6-2 DISASSEMBLING THE CARBURETOR...........................................................6-5 CHECKING THE CARBURETOR......................................................................6-6 ASSEMBLING THE CARBURETOR.............................................................
CARB http://mototh.
CARBURETOR EASF0043 CARBURETOR CARBURETOR 1 2 3 4 5 6 7 8 9 0 q Coasting enricher assembly Carburetor top cover Throttle valve spring Needle set Throttle valve Throttle stop screw set Pilot air screw set Needle jet Main jet Needle valve assembly Float w e r t y u Float chamber rubber gasket Float pivot pin Float chamber Fuel drain screw Carburetor overflow hose Throttle position sensor u 2 4 3 5 1 6 0 8 9 q 7 e w r y t 6-1 http://mototh.
CARBURETOR CARB REMOVING THE CARBURETOR w Gasoline is highly flammable. Avoid spilling fuel on the hot engine. 1. Remove: 9battery 9seat assembly with battery box 2. Remove: 9starter relay 1 (T135SE) 1 3. Remove: 9positive lead 1 (from the battery box) 1 4. Remove: 9negative lead (from the frame) 5. Loosen: 9rear cowling (left) Refer to “REMOVING THE REAR COWLINGS” in chapter 3. 6-2 http://mototh.
CARBURETOR CARB 6. Loosen: 9fuel drain screw 1 7. Drain: 9fuel (from float chamber) 1 8. Loosen: 9clamp screw 9air filter assembly bolt 2 1 9. Remove: 9carburetor top cover 1 9o-ring 9choke cable 2 9accelerator pump cable 3 3 10. Remove: 9throttle valve assembly 1 9throttle valve spring 2 2 1 1 11. Remove: 9throttle valve 1 9jet needle set 2 9holder 3 2 cC Do not make a burr when remove the holder 33from throttle valve 11. 3 6-3 http://mototh.
CARBURETOR CARB 12. Remove: 9carburetor assembly NOTE: Use the ball point hexagon wrench to loosen the bolts. 13. Disconnect: 9fuel hose 1 9carburetor overflow hose 2 9vacuum sensing hose 3 9air vent hose 4 9vacuum sensing hose 5 4 1 3 2 5 14. Remove: 9carburetor assembly 15. Remove: 9intake manifold bolt 9intake manifold 1 9joint 2 1 16. Move: 9air filter assembly 2 6-4 http://mototh.
CARBURETOR CARB DISASSEMBLING THE CARBURETOR NOTE: The following parts can be cleaned and inspected without disassembly. 9Coasting enricher 9Throttle stop screw 9Pilot air screw 1. Remove: 9coasting enricher assembly 9o-ring 2. Remove: 9pilot air screw set 1 1 3. Remove: 9throttle stop screw set 1 1 4. Remove: 9float chamber 1 9float chamber rubber gasket 1 6-5 http://mototh.
CARBURETOR CARB 5. Remove: 9main jet 1 9needle jet 2 9pilot jet 3 1 3 2 6. Remove: 9float pivot pin 1 9float 2 9needle valve 3 3 2 1 EAS00485 CHECKING THE CARBURETOR 1. Check: 9carburetor body 9float chamber Cracks/damage → Replace. 2. Check: 9fuel passages Obstructions → Clean. ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ 3.
CARBURETOR CARB 5. Check: 9float Damage → Replace. 6. Check: 9needle valve Damage/wear → Replace. 7. Check: 9coasting enricher assembly 1 Cracks/damage → Replace. 1 1 8. Check: 9jet needle 1 9needle jet 2 9main jet 3 9pilot jet 4 9pilot air screw 5 9throttle stop screw 6 Bends/damage/wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 2 3 4 5 6 9. Check: 9throttle valve Damage/scratches/wear → Replace. 6-7 http://mototh.
CARBURETOR CARB 10. Check: 9accelerator pump stuck or unsmooth operation the float chamber. → Replace 11. Check: 9air vent hose 9fuel hoses Cracks/damage/wear → Replace. Obstructions → Clean. Blow out the hoses with compressed air. 6-8 http://mototh.
CARBURETOR CARB EAS00487 ASSEMBLING THE CARBURETOR cC 99 Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. 99 Always use a new gasket and new O-rings. 1. Measure: 9float height a Out of specification → Adjust. Float height 9.2 mm (0.36 in) a ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Hold the carburetor upside down. b. Measure the distance from the mating surface of the float chamber (with the gasket removed) to the top of the float.
CARBURETOR CARB EAS00492 INSTALLING THE CARBURETOR 1. Install: 9needle set 2 2. Install: 9joint 1 9intake manifold 2 1 10 Nm (1.0 m·kg, 7.2 ft·lb) 3. Connect: 9fuel hose 1 9carburetor overflow hose 2 9vacuum sensing hose 3 9air vent hose 4 9vacuum sensing hose 5 4 1 3 2 5 4. Install: 9carburetor assembly 9intake manifold bolts 9clamp screw 10 Nm (1.0 m·kg, 7.2 ft·lb) 5. Install: 9throttle valve assembly NOTE: 9Align the slit a of the throttle valve with the tab b of the carburetor body.
CARBURETOR CARB 7. Adjust: 9engine idling speed Engine idling speed 1,300–1,500 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 8. Adjust: 9throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3–7 mm (0.12–0.18 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: 9Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted.
CARBURETOR CARB c. Connect the pocket tester (DC20V) to the terminals of the throttle position sensor. Positive (+) pocket tester probe →→ yellow terminal 33 Negative (-) pocket tester probe →→ B/LLY 2 3 black/blue terminal 22 Throttle position sensor input voltage 5V at 20 ° C (yellow-black/blue) ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ 2. Adjust: 9throttle position sensor angle ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ 1 a. Connect the digital circuit tester to the throttle position sensor 1 .
CARBURETOR CARB EAS00506 CHECKING THE FUELCOCK OPERATION 1. Remove: 9rear cowling (left) Refer to “REMOVING THE REAR COWLINGS” in chapter 3. 2. Place a container under the end of the fuel hose 1 . 1 3. Check: 9fuel cock operation ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Suck on the end of the vacuum hose 1 . 1 Fuel flows. Fuel cock is OK. Replace the fuel cock. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ Fuel does not flow. 4. Install: 9rear cowling (left) Refer to “INSTALLING THE REAR COWLINGS” in chapter 3.
AIR INDUCTION SYSTEM CARB AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700 ° C.
AIR INDUCTION SYSTEM CARB AIR INDUCTION SYSTEM DIAGRAMS 1 2 3 4 Bend hose (air filter case to air cut-off valve) Air cut-off valve AIS resonator Vacuum sensing hose 4 2 3 1 6-15 http://mototh.
AIR INDUCTION SYSTEM CARB REMOVING THE AIR INDUCTION SYSTEM 1. Disconnect: 9vacuum sensing hose 9bend hose 2. Remove: 9air cut cut-off valve assembly 1 9reed valve assembly 2 1 2 CHECKING THE AIR INDUCTION SYSTEM 1. Check: 9hoses Loose connections → Connect properly. Cracks/damage → Replace. 9pipes Cracks/damage → Replace. 2. Check: 9reed valve 9reed valve stopper 9reed valve seat Cracks/damage → Replace the reed valve. 3. Check: 9air cut-off valve Cracks/damage → Replace.
CHAS CHAPTER 7 CHASSIS FRONT WHEELAND BRAKE DISC.....................................................................7-1 REMOVING THE FRONTWHEEL....................................................................7-2 CHECKING THE FRONTWHEEL.....................................................................7-3 CHECKING THE BRAKE DISC.........................................................................7-5 CHECKING THE SPEEDOMETER GEAR UNIT...............................................
CHAS REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM................................7-49 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM..............................................................................................7-50 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES...........................7-52 CHECKING THE SWINGARM...........................................................................7-53 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM.........................................
FRONT WHEELAND BRAKE DISC CHAS EASF0044 CHASSIS FRONT WHEELAND BRAKE DISC 1 2 3 4 5 6 7 Front wheel axle Brake disc Spacer Oil seal Bearing Spacer Speedometer gear unit 23 Nm (2.3 m•kg, 17 ft•lb ) 2 1 3 4 5 LS LS 7 6 5 40 Nm (4.0 m•kg, 29 ft•lb ) 7-1 http://mototh.
FRONT WHEELAND BRAKE DISC CHAS EAS00519 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9speedometer cable 1 9axle nut 2 9washer 3 3 2 1 3. Elevate: 9front wheel NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 4. Remove: 9front wheel axle 1 9spacer 2 9speedometer gear unit 3 9front wheel 3 1 2 5. Remove: 9brake disc 1 7-2 http://mototh.
FRONT WHEELAND BRAKE DISC CHAS EAS00526 CHECKING THE FRONT WHEEL 1. Check: 9wheel axle Roll the wheel axle on a flat surface. Bends → Replace. w Do not attempt to straighten a bent wheel axle. 2. Check: 9tire Damage/wear → Replace. Refer to “CHECKING THE TIRES” in chapter 3. 3. Check: 9spokes Bends/damage → Replace. Loose → Tighten. Tap the spokes with a screwdriver. Refer to “CHECKING AND TIGHTENING THE SPOKES” in chapter 3. 4.
FRONT WHEELAND BRAKE DISC CHAS 5. Check: 9spacers Damage/wear → Replace. w 99 After mounting a new tire, ride conservatively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim. Failure to do so could lead to an accident with possible injury to the rider or damage to the vehicle. 99 After a tire has been repaired or replaced, be sure to tighten the tire air valve stem locknut 11properly. 6.
FRONT WHEELAND BRAKE DISC CHAS d. Install the new wheel bearings and oil seals in the reverse order of disassembly. cC Do not contact the wheel bearing inner race 44 or balls 55. Contact should be made only with the outer race 66. NOTE: Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ EAS00527 CHECKING THE BRAKE DISC 1. Check: 9brake disc Damage/galling → Replace. 2.
FRONT WHEELAND BRAKE DISC CHAS 3. Measure: 9brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Brake disc thickness limit (minimum) 3.0 mm (0.12 in) 4. Adjust: 9brake disc deflection ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 23 Nm (2.3 m·kg, 17 ft·lb) LOCTITE® d.
FRONT WHEELAND BRAKE DISC CHAS EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: 9wheel axle 9wheel bearings 9oil seal lips 9speedometer gear unit Recommended lubricant Lithium-soap-based grease 2. Install: 9brake disc 9front wheel Refer to “CHECKING THE BRAKE DISC”. NOTE: Make sure the projection a on the speedometer gear unit fits between the projections on the outer tube. 3. Tighten: 9wheel axle nut 40 Nm (4.0 m·kg, 29 ft·lb) 4.
REAR WHEELAND BRAKE CHAS EASF0049 REAR WHEELAND BRAKE 1 2 3 4 5 6 7 8 9 0 q w e r t y Collar Brake camshaft lever Pin Drive chain puller (right) Brake shoe wear indicator Brake shoe plate Brake camshaft Brake shoe Rear wheel Cotter pin Brake torque rod Rear wheel drive hub damper Rear wheel drive hub Drive chain puller (left) Rear wheel axle Brake rod 7 Nm (0.7 m•kg, 5.0 ft•lb ) 3 2 5 4 t LS 6 0 7 8 1 19 Nm (1.9 m•kg, 14 ft•lb ) q 0 16 Nm (1.6 m•kg, 12 ft•lb ) y LS 9 7 Nm (0.7 m•kg, 5.
REAR WHEELAND BRAKE CHAS EAS00563 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: 9brake rod adjusting nut 1 9brake rod 2 9compression spring 3 9washer 9pin 4 1 4 3 NOTE: Press down on the brake pedal to remove the pin from the brake rod. 2 3.
REAR WHEELAND BRAKE CHAS 5. Remove: 9rear wheel axle nut 1 9washer 9rear wheel axle 2 9washer 9collar 2 1 6. Remove: 9rear wheel assembly 1 1 NOTE: Push the rear wheel forward and remove the drive chain from the driven sprocket. 7. Remove: 9brake shoe plate assembly 1 1 8. Remove: 9collar 1 9rear wheel drive hub assembly 2 1 2 9. Remove: 9spacer 1 1 7-10 http://mototh.
REAR WHEELAND BRAKE CHAS 10. Remove: 9O-ring 9rear wheel drive hub dampers 1 1 1 DISASSEMBLING THE BRAKE SHOE PLATE 1 1. Remove: 9brake shoes 1 9brake shoe springs 2 (48 mm, 1.89 in) 9brake shoe springs 3 (52 mm, 2.01 in) 2 3 2.
REAR WHEELAND BRAKE CHAS 2. Check: 9tire Damage/wear → Replace. Refer to “CHECKING THE TIRES” in chapter 3. 3. Measure: 9radial wheel runout 9lateral wheel runout Refer to “FRONTWHEELAND BRAKE DISC”. EAS00567 CHECKING THE REAR WHEELDRIVE HUB 1. Check: 9rear wheel drive hub Cracks/damage → Replace. 9rear wheel drive hub dampers Damage/wear → Replace. 7-12 http://mototh.
REAR WHEELAND BRAKE CHAS EAS00539 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: 9brake shoe lining Glazed areas → Repair. Sand the glazed areas with course sandpaper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. 2. Measure: 9brake shoe lining thickness a Out of specification → Replace. Brake shoe lining thickness limit (minimum) 2.0 mm (0.08 in) w Do not allow oil or grease to contact the brake shoes.
REAR WHEELAND BRAKE CHAS EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 9brake camshaft 1 9brake shoe wear indicator 2 9brake camshaft lever 7 Nm (0.7 m·kg, 5.0 ft·lb) ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Install the brake camshaft so its punch mark a is positioned as shown. b. Align the projection b on the brake shoe wear indicator with the notch in the brake camshaft. c. Align the punch mark in the brake camshaft with the mark on the brake camshaft lever. d.
REAR WHEELAND BRAKE CHAS 4. Adjust: 9drive chain slack Drive chain slack 25–35 mm (0.98–1.38 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 5. Tighten: 9wheel axle nut 60 Nm (6.0 m·kg, 43 ft·lb) cC Do not loosen the wheel axle nut after tightening it to the specified torque. 7-15 http://mototh.
CHAS FRONT BRAKE FRONT BRAKE EASF0052 FRONT BRAKE CALIPER 1 2 3 4 5 Brake pad retaining pin Air bleed screw Brake caliper Brake caliper bracket Lower brake caliper retaining bolt 6 Brake caliper piston 7 Brake caliper dust seal 8 Brake caliper piston seal 9 Brake pad 0 Brake pad spring LS 6 Nm (0.6 m•kg, 4.6 ft•lb ) 2 5 4 LS 35 Nm (3.5 m•kg, 25 ft•lb ) 3 1 6 7 8 9 0 7-16 http://mototh.
FRONT BRAKE CHAS EAS00579 cC Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: 99 Never disassemble brake components unless absolutely necessary. 99 If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. 99 Never use solvents on internal brake components. 99 Use only clean or new brake fluid for cleaning brake components.
FRONT BRAKE CHAS 2. Remove: 9clips 9brake pad retaining pin 9brake pads 1 9brake pad spring 1 3. Measure: 9brake pad wear limit a Out of specification → Replace the brake pads as a set. a Brake pad wear limit 0.8 mm (0.03 in) 4. Install: 9brake pad spring 9brake pads 1 NOTE: Always install new brake pads and a new brake pad spring as a set. 2 ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b.
FRONT BRAKE CHAS 5. Lubricate: 9brake pad retaining pin Recommended lubricant Lithium-soap-based grease cC 9Do not allow grease to contact the brake pads. 9Remove any excess grease. 6. Install: 9brake caliper bolts 35 Nm (3.5 m·kg, 25 ft·lb) 7. Check: 9brake fluid level a → Add Below the minimum level mark the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 8. Check: 9brake lever operation Soft or spongy feeling → Bleed the brake system.
FRONT BRAKE CHAS 1. Remove: 9union bolt 1 9copper washers 2 9brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 1 2 2. Remove: 9brake caliper 1 9pin 9brake pad retaining pin 9brake pads 9brake pad spring 1 3. Remove: 9brake caliper bracket 1 1 4. Remove: 9brake caliper piston 1 9brake caliper piston seal 2 9brake caliper dust seal 3 ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ 2 3 a.
FRONT BRAKE CHAS EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every two years Brake hose Every four years Brake fluid Every two years and whenever the brake is disassembled 1. Check: 9brake caliper piston 1 Rust/scratches/wear → Replace the brake caliper pistons. 9brake caliper cylinder 2 Scratches/wear → Replace the brake caliper assembly. 9brake caliper body 3 Cracks/damage → Replace the brake caliper assembly.
FRONT BRAKE CHAS EAS00634 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER w 99 Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. 99 Never use solvents on internal brake components as they will cause the piston seals to swell and distort. 99 Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 3 or 4 1.
FRONT BRAKE CHAS 5. Fill: 9brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 3 or 4 w 99 Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. 99 Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT BRAKE CHAS EASF0050 FRONT BRAKE MASTER CYLINDER 1 Brake master cylinder kit 2 Brake master cylinder reservoir cap 3 Brake master cylinder reservoir diaphragm 4 Brake master cylinder 5 Brake master cylinder holder 6 Brake hose 7 Brake lever 8 Front brake light switch 2 1 5 3 4 7 8 6 26 Nm (2.6 m•kg, 19 ft•lb ) 7-24 http://mototh.
FRONT BRAKE CHAS EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: 9side cowlings (left and right) 9front cowling Refer to “REMOVING THE SIDE COWLINGS” and “REMOVING THE FRONT COWLING” in chapter 3. 9headlight assembly Refer to “REMOVING THE HEADLIGHT ASSEMBLY” in chapter 3. 2.
FRONT BRAKE CHAS 5. Remove: 9brake master cylinder kit 1 1 6. Remove: 9brake master cylinder reservoir cap 1 9brake master cylinder reservoir diaphragm holder 2 9brake master cylinder reservoir diaphragm3 3 2 1 7. Remove: 9brake hose 1 9brake hose clamp 2 9brake hose holder 3 3 1 2 EAS00590 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 1. Check: 9brake master cylinder 1 Damage/scratches/wear → Replace.
FRONT BRAKE CHAS 3. Check: 9brake master cylinder reservoir 1 Cracks/damage → Replace. 9brake master cylinder reservoir diaphragm2 Damage/wear → Replace. 1 2 4. Check: 9brake hose 1 Cracks/damage/wear → Replace. 1 EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER w 99 Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. 99 Never use solvents on internal brake components. 1 Recommended brake fluid DOT 3 or 4 1.
FRONT BRAKE CHAS 2. Install: 9copper washers 1 9brake hose 2 9union bolt 26 Nm (2.6 m·kg, 19 ft·lb) 2 w Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING”. 1 NOTE: Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. 3.
FRONT BRAKE CHAS 4. Bleed: 9brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: 9brake fluid level a → Add Below the minimum level mark the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Check: 9brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. a 7-29 http://mototh.
FRONT FORK CHAS EASF0054 FRONT FORK 1 2 3 4 5 6 7 8 9 Front fork cap bolt Dust seal Oil seal clip Oil seal Fork spring Damper rod Inner tube Outer tube Damper rod bolt 43 Nm (4.3 m•kg, 31 ft•lb ) 1 7 5 2 3 4 8 6 9 23 Nm (2.3 m•kg, 17 ft•lb ) 7-30 http://mototh.
FRONT FORK CHAS EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: 9side cowlings (left and right) 9front cowling 9center panels 9inner panel Refer to “COVERS” in chapter 3. 3.
FRONT FORK CHAS 5. Remove: 9front fork cap bolt 1 (with a 10-mm hexagonal wrench) 6. Loosen: 9lower bracket pinch bolt 2 1 w 2 Before loosening the lower bracket pinch bolt, support the front fork leg. 7. Remove: 9front fork leg EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: 9fork spring 2. Drain: 9fork oil 1 NOTE: Stroke the inner tube draining the fork oil. 1 several times while 3.
FRONT FORK CHAS 4. Remove: 9damper rod assembly bolt 9copper washer NOTE: While holding the damper rod assembly with a 10 mm hexagon nut/socket wrench 1 and the Thandle 2 , loosen the damper rod assembly bolt 3. T-handle 90890-01326 5. Remove: 9inner tube 9rebound spring 9damper rod NOTE: Pull out the inner tube and damper rod together. 6. Remove: 9oil seal 1 2 Rag 7-33 http://mototh.
FRONT FORK CHAS EAS00657 1 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 9inner tube 1 9outer tube 2 Bends/damage/scratches → Replace. 2 w Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2.Measure: 9spring free length a Out of specifications → Replace. Spring free length 295.3 mm (11.63 in) : 289.4 mm (11.39 in) 3. Check: 9damper rod 1 Damage/wear → Replace.
FRONT FORK CHAS EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. w 99 Make sure the oil levels in both front fork legs are equal. 99 Uneven oil levels can result in poor handling and a loss of stability. NOTE: 9When assembling the front fork leg, be sure to replace the oil seal. 9Before assembling the front fork leg, make sure all of the components are clean. 1.
FRONT FORK CHAS NOTE: Tighten the damper rod assembly bolt 1 while holding the damper rod with the T-handle 2 and a 10 mm hexagon nut/socket wrench 3 . T-handle 90890-01326 4. Install: 9oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachment 3 ) Fork seal driver weight 90890-01184 Fork seal driver attachment 90890-01186 cC Make sure the numbered side of the oil seal faces up. NOTE: 9Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
FRONT FORK CHAS 6. Fill: 9front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.064 L(2.26 Imp.oz, 2.16 US oz) Recommended oil Fork oil 10W or equivalent Front fork leg oil level aa (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) 104.5 mm (4.11 in) NOTE: 9While filling the front fork leg, keep it upright. 9After filling, slowly pump the front fork leg up and down to distribute the fork oil. 7.
FRONT FORK CHAS 3. Install: 9front fender 10 Nm (1.0 m·kg, 7.2 ft·lb) 4. Install: 9front wheel Refer to “FRONTWHEELAND BRAKE DISC”. 9brake hose clamp 9brake caliper assembly Refer to “FRONTBRAKE”. 7-38 http://mototh.
HANDLEBAR CHAS EASF0055 HANDLEBAR 9 Throttle cable 0 Handlebar bracket 1 Rear view mirror (left and right) 2 Throttle grip 3 Throttle housing 4 Master cylinder 5 Handlebar 6 Left handlebar switch 7 Handlebar grip 8 Starter cable 1 3 2 6 5 4 9 0 7 8 23 Nm (2.3 m•kg, 17 ft•lb ) 8 53 Nm (5.3 m•kg, 39 ft•lb ) 9 7-39 http://mototh.
HANDLEBAR CHAS EAS00666 REMOVING THE HANDLEBAR 1.Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9side cowlings (left and right) 9front cowling 9center panels Refer to “REMOVING THE FRONTCOWLINGS” in chapter 3. 9headlight assembly Refer to “REPLACING THE HEADLIGHT BULBS” in chapter 3. 3.
HANDLEBAR CHAS 7. Remove: 9lever holder 1 1 8. Remove: 9throttle cable 1 9throttle grip 2 2 1 9. Remove: 9grip end 1 1 10. Remove: 9handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. 7-41 http://mototh.
HANDLEBAR CHAS 11. Remove: 9relay 9wire harness strap 1 1 2 12. Remove: 9handlebar 1 9washers 9bushings 9handlebar bracket 2 1 2 EAS00668 CHECKING THE HANDLEBAR 1. Check: 9handlebar 1 Bends/cracks/damage → Replace. 1 w Do not attempt to straighten a bent handlebar as this may dangerously weaken it. EAS00670 INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. 2. Install: 9handlebar bracket 1 53 Nm (5.
HANDLEBAR CHAS 3. Install: 9bushings 9washers 9handlebar 23 Nm (2.3 m·kg, 17 ft·lb) 9wire harness strap Refer to “CABLE ROUTING” in chapter 2. 4. Install: 9handlebar grip ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag. w Do not touch the handlebar grip until the rubber adhesive has fully dried. ✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬ 1 5.
HANDLEBAR CHAS 7. Install: 9brake master cylinder 11 Nm (1.1 m·kg, 8.0 ft·lb) Refer to “FRONTBRAKE”. 8. Install: 9plastic locking ties Refer to “CABLE ROUTING” in chapter 2. 9. Adjust: 9throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. Throttle cable free play (at the flange of the throttle grip) 3–7 mm (0.12–0.28 in) 7-44 http://mototh.
STEERING HEAD EASF0057 STEERING HEAD 1 2 3 4 5 6 7 8 Upper ring nut Lower ring nut Ball race cover Bearing inner race Upper bearing Bearing outer race Lower bearing Lower bracket 1 1st: 30 Nm (3.0 m•kg, 22 ft•lb ) 2nd: 75 Nm (7.5 m•kg, 54 ft•lb ) 2 3 LS 4 5 6 LS 6 7 4 8 43 Nm (4.3 m•kg, 31 ft•lb ) 7-45 http://mototh.
STEERING HEAD CHAS EAS00679 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9side cowlings (left and right) 9center panels 9inner panel Refer to “REMOVING THE FRONTCOWLINGS” in chapter 3. 9front fork Refer to “FRONTFORK”. 9handlebar Refer to “HANDLEBAR”. 3.
STEERING HEAD 2 CHAS 2. Check: 9bearings 1 9bearing races 2 Damage/pitting → Replace. 1 3. Replace: 9bearings 9bearing races ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new rubber seal and new bearing races. cC If the bearing race is not installed properly, the steering head pipe could be damaged.
STEERING HEAD CHAS EAS00683 INSTALLING THE STEERING HEAD 1. Lubricate: 9upper bearing 9lower bearing 9bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 9lower ring nut 9upper ring nut Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3. 3. Install: 9front fork legs Refer to “FRONTFORK”. 7-48 http://mototh.
REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM CHAS REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM 1 2 3 4 5 6 Rear shock absorber Brake torque rod Swingarm Bushing Swingarm pivot shaft Drive chain case 46 Nm (4.6 m•kg, 33 ft•lb ) 6 2 1 46 Nm (4.6 m•kg, 33 ft•lb ) 4 3 66 Nm (6.6 m•kg, 48 ft•lb ) 4 LS 5 7-49 http://mototh.
REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM CHAS EAS00691/EAS00702 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1. Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: 9center panel 9rear cowlings (left and right) Refer to “REMOVING THE REAR COWLINGS” in chapter 3. 9muffler Refer to “REMOVING THE ENGINE” in chapter 4.
REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM CHAS 5. Remove: 9rear shock absorber bolt (upper and lower) 1 9washer 9rear shock absorber nut (upper and lower) 2 9washers 9rear shock absorber assembly 3 2 3 1 6. Measure: 9swingarm side play 9swingarm vertical movement ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ ∫ a. Measure the tightening torque of the swingarm pivot shaft nut. Pivot shaft nut 66 Nm (6.6 m·kg, 43 ft·lb) å b. Measure the swingarm side play å by moving the swingarm from side to side. c.
REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM 7. Remove: 9swingarm pivot shaft nut 1 9washer 2 9swingarm pivot shaft 3 9swingarm 4 3 2 CHAS 1 4 EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both rear shock absorber assemblies. 1. Check: 9rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. 9rear shock absorber → Replace the rear shock Oil leaks absorber assembly. 9spring Damage/wear → Replace the rear shock absorber assembly.
REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM CHAS EAS00707 CHECKING THE SWINGARM 1. Check: 9swingarm Bends/cracks/damage → Replace. 2. Check: 9swingarm pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. w Do not attempt to straighten a bent pivot shaft. 3. Wash: 9swingarm pivot shaft 9washer 9bushings Recommended cleaning solvent Kerosene 4. Check: 9washer Damage/wear → Replace. 9bushings Damage/wear → Replace.
REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM CHAS 2. Install: 9swingarm 9swingarm pivot shaft 9collar 9swingarm pivot shaft nut 66 Nm (6.6 m·kg, 48 ft·lb) 3. Install: 9rear shock absorber assemblies 9rear shock absorber nuts 9rear shock absorber bolts 46 Nm (4.6 m·kg, 33 ft·lb) 4. Install: 9brake torque rod (to swingarm) 16 Nm (1.6 m·kg, 12 ft·lb) 5. Install: 9drive chain case 10 Nm (1.0 m·kg, 7.2 ft·lb) 6. Install: 9rear wheel Refer to “REAR WHEELAND BRAKE”.
DRIVE CHAIN AND SPROCKETS CHAS DRIVE CHAIN AND SPROCKETS 1 2 3 4 5 6 7 8 9 0 Circlip q Drive sprocket cover Rear wheel drive hub Driven sprocket Lock washer Collar Oil seal Bearing Master link Drive chain Drive sprocket 1 30 Nm (3.0 m•kg, 20 ft•lb ) 2 3 7 8 9 LS 4 0 6 5 q 7 Nm (0.7 m•kg, 5.0 ft•lb ) 7-55 http://mototh.
DRIVE CHAIN AND SPROCKETS CHAS EAS00706 REMOVING THE DRIVE CHAIN AND SPROCKETS 1.Stand the vehicle on a level surface. w Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: 9rear wheel 9rear wheel drive hub assembly Refer to “REAR WHEELAND BRAKE”. 3. Remove: 9shift pedal bolt 9shift pedal 1 9drive sprocket cover bolts 9drive sprocket cover 2 1 2 4.
DRIVE CHAIN AND SPROCKETS CHAS 7. Straighten the lock washer tabs. 8. Remove: 9driven sprocket nuts 9driven sprocket bolts 9lock washers 1 9driven sprocket 2 1 2 1 EAS00710 CHECKING THE DRIVE CHAIN 1 23 4 5 67 8 90 qwe rt y qwe rt y 1. Measure: 9Measure the length of 15 links on the inner side a and outer side b of the pin and calculate the length between pin centers.
DRIVE CHAIN AND SPROCKETS CHAS 4. Check: 9drive chain rollers 1 Damage/wear → Replace the drive chain. 9drive chain side plates 2 Cracks/damage/wear → Replace the drive chain. 5. Lubricate: 9drive chain Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 6. Check: 9drive sprocket 9driven sprocket Worn more than 1/4 tooth a → Replace the drive chain and sprockets as a set. Bent teeth → Replace the drive chain and sprockets as a set.
DRIVE CHAIN AND SPROCKETS CHAS 3. Install: 9drive sprocket 1 9sprocket holder 2 9Sprocket holder bolt 1 2 4. Lubricate: 9drive chain 9master link Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 5. Install: 9master link body 9master link plate 6. Install: 9master link clip 1 cC 99 The closed end of the master link clip must face in the direction of drive chain rotation.
CHAS http://mototh.
ELEC CHAPTER 8 ELECTRICALSYSTEM ELECTRICALCOMPONENTS ..............................................................................8-1 CHECKING SWITCH CONTINUITY......................................................................8-3 CHECKING THE SWITCHES ................................................................................8-5 CHECKING THE BULBS AND BULB SOCKETS .................................................8-7 TYPES OF BULBS ...................................................................
ELEC http://mototh.
ELECTRICALCOMPONENTS ELEC EAS00729 ELECTRICALSYSTEM ELECTRICALCOMPONENTS 1 2 3 4 5 6 7 Positive battery lead (T135S) 8 Fuse 9 Wire harness Ignition coil Main switch Rear brake light switch Negative battery lead Battery Positive battery lead (T135SE) 2 1 3 9 7 8 4 6 5 8-1 http://mototh.
ELECTRICALCOMPONENTS 1 2 3 4 5 6 7 ELEC 8 Thermo sensor 9 C.D.I. unit Horn Turn signal relay Starter relay (T135SE) Fuel gauge Rectifier/regulator Fan motor relay Neutral switch 3 4 2 1 5 6 9 7 8 8-2 http://mototh.
CHECKING SWITCH CONTINUITY ELEC EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. cC Never insert the tester probes into the cou11. Always insert the pler terminal slots probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
CHECKING SWITCH CONTINUITY 8-4 http://mototh.
CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch.
CHECKING THE SWITCHES 1 2 3 4 5 6 7 8 9 Horn switch Dimmer switch Turn signal switch Neutral switch Rear brake light switch Fuse Start switch Front brake light switch Main switch 8-6 http://mototh.
CHECKING THE BULBS AND BULB SOCKETS ELEC EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. No continuity → Repair or replace the bulb, bulb socket or both. TYPES OF BULBS A C The bulbs used on this vehicle are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 9bulb w Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. cC 99 Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: 9bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭✭ a. Install a good bulb into the bulb socket. b.
8-10 http://mototh.com 1 3 4 9 0 q w Br L Ch Dg G B L Br Dg Ch B G G G z Br Br R B x (BLACK) G B (BLACK) (BLACK) Main switch Fuse G B Battery (BLACK) A. C. magneto C. D. I. unit Ignition coil Spark plug Sb Y/W W G/W P L/W Y/W Sb G/W W L/W P ; 1 ON OFF Y Ch Dg R B W W Sb Sb m, 5 R/W R/W R Br R/W L/W R/W R/W L/W R Br R Br v b n L 4R R 3 R R Br R/W L/W R/W L/W P P c .
IGNITION SYSTEM EAS00736 ELEC EAS00739 TROUBLESHOOTING 2. Battery 9Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The ignition system fails to operate (no spark or intermittent spark). Check: 1. fuse 2. battery 3. spark plug 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. pickup coil resistance 8. main switch 9. wiring connections (of the entire ignition system) Minimum open-circuit voltage 12.
IGNITION SYSTEM EAS00742 ELEC EAS00744 4. Ignition spark gap 5. Spark plug cap resistance 9Disconnect the spark plug cap from the spark plug. 9Connect the ignition checker 1 as shown. 9Remove the spark plug cap from the spark plug lead. 9Connect the pocket tester (“ Ω⋅ 1k” range) to the spark plug cap as shown. 9Measure the spark plug cap resistance. 2 Spark plug cap 9Set the main switch to “ON”.
ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Pickup coil resistance 9Disconnect the ignition coil connector from the ignition coil terminal. 9Connect the pocket tester ( Ω⋅ 1) to the ignition coil as shown. Positive tester probe →→ terminal 11 →→ Negative tester probe 9Disconnect the pickup coil coupler from the wire harness. 9Connect the pocket tester ( Ω⋅ 100) to the pickup coil terminal as shown.
IGNITION SYSTEM EAS00754 9. Wiring 9Check the entire ignition system wiring. Refer to “CIRCUITDIAGRAM”. 9Is the ignition system wiring properly connected and without defects? YES Replace the C.D.I. unit. NO Properly connect or repair the ignition system wiring. 8-14 http://mototh.
8-15 http://mototh.com 1 3 4 5 6 7 8 (BLACK) Br L Ch Dg G B (BLACK) L Br Dg Ch B G G G z Br Br R Main switch x Fuse G G B B Battery(BLACK) (BLACK) Starter motor B Starter relay Right handlebar switch Start switch Sb Y/W W G/W P L/W Y/W Sb G/W W L/W P ; 1 ON OFF Y Ch Dg R B 5 R/W R/W W W Sb Sb m, R Br R/W L/W R/W R/W L/W R Br R Br v b n L 4R R 3 R R Br R/W L/W R/W L/W P P c .
ELECTRIC STARTING SYSTEM (T135SE) EAS00757 ELEC EAS00739 TROUBLESHOOTING 2. Battery 9Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The starter motor fails to turn. Check: 1. fuse 2. battery 3. starter motor 4. starter relay 5. main switch 6. start switch 7. wiring connections (of the entire starting system) Minimum open-circuit voltage 12.8 V or more at 20 ° C 9Is the battery OK? YES NO 9Clean the battery terminals. 9Recharge or replace the battery.
ELECTRIC STARTING SYSTEM (T135SE) EAS00761 ELEC EAS00764 4. Starter relay 6. Start switch 9Remove the starter relay from the starter relay coupler on the wire harness. 9Connect the pocket tester ( Ω⋅ 1) and battery (DC 12 V) to the starter relay coupler as shown. Positive battery terminal →→ brown 11 →→ Negative battery terminal blue/white 22 9Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. 9Is the start switch OK? YES NO Replace the right handlebar switch.
STARTER MOTOR (T135SE) EASF0061 STARTER MOTOR (T135SE) 1 2 3 4 5 Starter motor yoke Armature Brush set Starter motor lead Starter motor front cover 1 2 5 3 4 8-18 http://mototh.
STARTER MOTOR (T135SE) ELEC REMOVING THE STARTER MOTOR 1. Remove: 9breather pipe 1 1 1 2. Remove: 9starter motor 1 1 3. Remove: 9starter motor lead 1 DISASSEMBLING THE STARTER MOTOR 2 1. Remove: 9starter motor front cover bolts (with washers) 9starter motor front cover 1 9O-ring 2 9armature 3 3 1 EAS00769 CHECKING THE STARTER MOTOR 1. Check: 9commutator Dirt → Clean with 600-grit sandpaper. 8-19 http://mototh.
STARTER MOTOR (T135SE) ELEC 2. Measure: 9commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 16.6 mm (0.65 in) 3. Measure: 9mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 1.35 mm (0.05 in) NOTE: The mica of the commutator must be undercut to ensure proper operation of the commutator. 4.
STARTER MOTOR (T135SE) ELEC 5. Measure: 9brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) a 6. Measure: 9brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 3.92–5.88 N (400–600 gf) 7. Check: 9gear teeth Damage/wear → Replace the armature. EAS00772 ASSEMBLING THE STARTER MOTOR 1.
8-22 http://mototh.com 2 3 4 9 Br L Ch Dg G B L Br Dg Ch B G (BLACK) (BLACK) x G G z Br Br R Rectifier/ regulator B Fuse Battery A. C. magneto G B (BLACK) (BLACK) G B Sb Y/W W G/W P L/W Y/W Sb G/W W L/W P ; 1 ON OFF Y Ch Dg R B 5 R/W R/W W W Sb Sb m, R Br R/W L/W R/W R/W L/W R Br R Br v b n L 4R R 3 R R Br R/W R/W L/W P P c .
CHARGING SYSTEM EAS00774 ELEC EAS00739 TROUBLESHOOTING 2. Battery 9Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The battery cannot be charged. Check: 1. fuse 2. battery 3. charging voltage 4. charging coil resistance 5. wiring connections (of the entire charging system) Minimum open-circuit voltage 12.8 V or more at 20 ° C 9Is the battery OK? YES NOTE: 9Before troubleshooting, remove the following part(s): 1. side cowlings (left and right) 2.
ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Charging coil resistance 9Connect the engine tachometer to the spark plug lead. 9Connect the pocket tester (DC 20 V) to the battery as shown. Positive tester probe →→ 9Disconnect the stator coil coupler from the wire harness. 9Connect the pocket tester ( Ω⋅ 1) to the charging coil terminals as shown.
8-25 http://mototh.com Br L Ch Dg G B L Br Dg Ch B G G G z Br Br R B x (BLACK) (BLACK) G B (BLACK) (BLACK) G B Sb Y/W W G/W P L/W Y/W Sb G/W W L/W P ; 1 ON OFF Y Ch Dg R B W W Sb Sb m, 5 R/W R/W R Br R/W L/W R/W R/W L/W R Br R Br v b n L 4R R 3 R R Br R/W L/W R/W L/W P P c .
ELEC LIGHTING SYSTEM EAS00781 EAS00776 TROUBLESHOOTING 1. Lighting coil resistance 9Disconnect the stator coil coupler from the wire harness. 9Connect the pocket tester ( Ω⋅ 1) to the lighting coil terminals as shown. Positive tester probe →→ yellow 11 →→ Negative tester probe black 22 Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light, or meter light. Check: 1. lighting coil resistance 2.
LIGHTING SYSTEM ELEC EAS00788 3. Voltage CHECKING THE LIGHTING SYSTEM 9Connect the pocket tester (AC 20 V) to the headlight and high beam indicator light connectors as shown. 1. The headlight and the high beam indicator light fail to come on. EAS00784 å When the dimmer switch is set to “ % ”. ∫ When the dimmer switch is set to “ & ”. 1. Dimmer switch 9Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. 9Is the dimmer switch OK? YES NO The dimmer switch is faulty.
LIGHTING SYSTEM EAS00789 ELEC EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light bulb and socket 1. Tail/brake light bulb and socket 9Check the meter light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. 9Are the meter light bulb and socket OK? 9Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
LIGHTING SYSTEM 4. The auxiliary light fails to come on. 1. Meter light bulb and socket 9Check the meter light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. 9Are the meter light bulb and socket OK? YES NO Replace the auxiliary light bulb, socket or both. 2. Voltage 9Connect the pocket tester (AC 20 V) to the auxiliary light coupler (wire harness side) as shown.
8-30 http://mototh.com Br L Ch Dg G B L Br Dg Ch B G G G z Br Br R B x (BLACK) (BLACK) G B (BLACK) (BLACK) G B Sb Y/W W G/W P L/W Y/W Sb G/W W L/W P ; 1 ON OFF Y Ch Dg R B W W Sb Sb m, 5 R/W R/W R Br R/W L/W R/W R/W L/W R Br R Br v b n L 4R R 3 R R Br R/W R/W L/W P P c .
SIGNALING SYSTEM 1 3 4 u i o p s f g h j z x c n m , . / ! Main switch Fuse Battery Front brake light switch Rear brake light switch Turn signal relay Horn Horn switch Turn signal switch Tail/brake light Rear turn signal light Front turn signal light Fuel gauge Fuel sender Neutral switch Turn signal indicator light Neutral indicator light 1st gear position indicator light 2nd gear position indicator light 3rd gear position indicator light 4th gear position indicator light 8-31 http://mototh.
SIGNALING SYSTEM EAS00794 ELEC EAS00739 TROUBLESHOOTING 2. Battery 99 Any of the following fail to light: turn signal light, brake light or an indicator light. 99 The horn fails to sound. 9Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20 ° C (68 ° F) Check: 1. fuse 2. battery 3. main switch 4. wiring connections (of the entire signaling system) 9Is the battery OK? YES NO 9Clean the battery terminals.
SIGNALING SYSTEM ELEC EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 9Disconnect the pink connector at the horn terminal. 9Connect a jumper lead 1 to the horn terminal and ground the jumper lead. 9Set the main switch to “ON”. 9Does the horn sound? 1. The horn fails to sound. 1. Horn switch 9Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. 9Is the horn switch OK? YES Br NO Replace the left handlebar switch. 1 2.
SIGNALING SYSTEM ELEC EAS00797 3. Voltage 2. The tail/brake light fails to come on. 9Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe →→ green/yellow 11 Negative tester probe →→ black 22 1. Tail/brake light bulb and socket 9Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
SIGNALING SYSTEM ELEC EAS00799 3. Voltage 3. The turn signal light, turn signal indicator light or both fail to blink. 9Connect the pocket tester (DC 20 V) to the turn signal relay coupler as shown. Positive tester probe →→ brown 11 →→ Negative tester probe ground 1. Turn signal indicator light bulb and socket 9Check the turn signal light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
SIGNALING SYSTEM ELEC 4. Voltage 5. Voltage 9Connect the pocket tester (DC 20 V) to the turn signal relay coupler as shown. Positive tester probe →→ brown/white 11 →→ Negative tester probe ground 9Connect the pocket tester (DC 20 V) to the turn signal light coupler (wire harness side) as shown.
SIGNALING SYSTEM EAS00801 9Set the main switch to “ON”. 9Set the turn signal switch to “ 4 ” or “6 ”. 9Measure the voltage (DC 12 V) of the chocolate 1 or dark green lead terminal 2 at the turn signal light coupler (wire harness side) and chocolate 3 or dark green 4 at the turn signal indicator light coupler (wire harness side). 9Is the voltage within specification? YES 4. The gear position indicator lights fail to come on. 1.
ELEC SIGNALING SYSTEM EAS00804 3. Voltage 5. The fuel level gauge fails to operate. 9Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. 1. Fuel sender 9Remove the fuel sender from the fuel tank. 9Connect the pocket tester to the fuel sender coupler (fuel sender side) as shown.
SIGNALING SYSTEM ELEC 2. Voltage 3. Fuel level gauge 9Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe →→ brown 11 Negative tester probe →→ ground 9Set the main switch to “ON”. 9Move the float up 1 or down 2 . 9Check that the fuel level gauge needle moves to “F” or “E”. NOTE: Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes.
8-40 http://mototh.com 1 3 4 0 r t (BLACK) Br L Ch Dg G B (BLACK) L Br Dg Ch B G G G z Br Br R Main switch x G G Fuse B B Battery(BLACK) (BLACK) B C.D.I. unit Fan motor relay Thermo sensor Sb Y/W W G/W P L/W Y/W Sb G/W W L/W P ; 1 ON OFF Y R Br R/W L/W Ch Dg R R/W R/W L/W R Br R Br B v b n L 4R R 3 R R Br W Sb .
COOLING SYSTEM EAS00739 TROUBLESHOOTING 2. Battery 9The radiator fan motor fails to turn. 9Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. fuse 2. battery 3. main switch 4. fan motor 5. fan motor relay 6. thermo sensor 7. wiring harness (of the entire cooling system) Minimum open-circuit voltage 12.8 V or more at 20 ° C (68 ° F) 9Is the battery OK? YES NO 9Clean the battery terminals. 9Recharge or replace the battery.
ELEC COOLING SYSTEM 4. Radiator fan motor 5. Radiator fan motor relay 9Disconnect the radiator fan motor coupler from the wireharness. 9Connect the battery (12 V) as shown. Battery positive lead →→ blue 11 →→ Battery negative lead black 22 9Disconnect the radiator fan motor relay coupler. 9Connect the pocket tester to the radiator fan motor relay coupler (relay side) as shown.
COOLING SYSTEM ELEC 6. Thermo sensor 9Remove the thermo sensor from the cylinder. 9Connect the digital circuit tester ( Ω⋅ 100) to the thermo switch 1 as shown. 9Immerse the thermo sensor in a container filled with coolant 2 . 3 NOTE: Make sure that the thermo sensor terminals do not get wet. 1 2 9Place a thermometer 3 in the coolant. 9Slowly heat the coolant, then let it cool to the specified temperature as indicated in the table.
SELF-DIAGNOSIS ELEC SELF-DIAGNOSIS The T135SE/S features a self-diagnosing system for following circuit (-s). 1. Throttle position sensor (TPS) 2. Thermo sensor 1. ENGINE TROUBLE INDICATOR LIGHT When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the coolant temperature warning indicator light (irrespective of whether the engine is running or not).
SELF-DIAGNOSIS ELEC Display order on the coolant temperature warning indicator light When one item being monitored Fault code Condition å [1] ∫ 1 2 3 2 3 4 5 2 3 2 1 4 5 2 Repetition 3 4 5 2 3 45 2 3 4 å [2] ∫ 1 1 Repetition å [3] ∫ 1 3 1 4 3 2 1 2 3 4 5 3 seconds 1 second 1.5 seconds 0.5 seconds 0.
ELEC SELF-DIAGNOSIS TROUBLESHOOTING 1. Wire harness The coolant temperature warning indicator light starts to display the self-diagnosis sequence. 9Check the wire harness for continuity. Refer to “CIRCUITDIAGRAM”. 9Is the wire harness OK? Check: 1. throttle position sensor 2. thermo sensor YES Repair or replace the wire harness. NOTE: 9Before troubleshooting, remove the following part(s): 1. side cowlings (left and right) 2. front cowling 3.
SELF-DIAGNOSIS 2. Thermo sensor CIRCUITDIAGRAM 2. Thermo sensor 9Check the thermo sensor. Refer to “COOLING SYSTEM”. 9Is the thermo sensor OK? Br B/L P G/R W B O G/W L W/Y Y (BLACK) 9 W ELEC (BLACK) W YES O NO O B Replace the C.D.I. unit. B R B/L LY L Y e L Y 0 Br Br r W/Y L Br Br (BLACK) G/R B/L t G/R W/Y L W/Y L G/R B/L y G/W B/L L B P B/L Br B L B B Br 0 C.D.I. unit t Thermo sensor 1. Wireharness 9Check the wireharness for continuity. Refer to “CIRCUITDIAGRAM”.
ELEC http://mototh.
TRBL SHTG CHAPTER 9 TROUBLESHOOTING TROUBLESHOOTING ...........................................................................................9-1 ELECTRICALSYSTEM ....................................................................................9-1 COMPRESSION SYSTEM ...............................................................................9-2 INTAKE AND EXHAUSTSYSTEM ...................................................................9-3 http://mototh.
TRBL SHTG http://mototh.
TROUBLESHOOTING TRBL SHTG EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICALSYSTEM *CHECK ALLWIRES CONNECTIONS MAIN SWITCH (see page 8-5) IGNITION COIL(see page 8-13) 8 Main switch is shorted 8 Primary or secondary windings are broken or faulty 8 Spark plug wire is faulty 8 Spark plug cap is faulty C.D.I. unit 8 C.D.I.
TROUBLESHOOTING TRBL SHTG COMPRESSION SYSTEM WEAR/SCRATCHES INSUFFICIENT TIGHTENING TORQUE INSUFFICIENT TIGHTENING TORQUE DAMAGE DAMAGE WEAR/SCRATCH/DAMAGE WEAR/STUCK/BROKEN DAMAGE WEAR/CARBON DEPOSITS INSUFFICIENT TIGHTENING TORQUE 9-2 http://mototh.
TROUBLESHOOTING TRBL SHTG INTAKE AND EXHAUST SYSTEM FUELCOCK 8 Clogged FUELTANK CAP FUELHOSE 8 Clogged DRYTYPE AIR FILTER ELEMENT 8 Dirty or clogged 8 Clogged, damaged or kinked SILENCER EXHAUST PIPE 8 Clogged 8 Cracked or broken 8 Carbon deposits NEEDLE SET 8 Improperly adjusted (medium speed) PILOT JET 8 Clogged (low speed) THROTTLE STOPSCREW MAIN JET 8 Improperly adjusted (idling and starting) 8 Incorrect size 8 Clogged (high speed) FLOAT PILOT AIR SCREW 8 Incorrect fuel level adjustmen
TRBL SHTG http://mototh.
http://mototh.
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN http://mototh.
T135SE/ T135S WIRING DIAGRAM 1 Main switch 2 Rectifier/regurator OFF R Br ON Br B/L P G/R W R Br B O (BLACK) 1 W Br R 2 R R R W W Y/R Y/R 3 Fuse G/W L W/Y Y (BLACK) W 9 W W O O q B WB R R Br å T135SE R/W L/W W Y/R B Y/R R W Y B w B R Br R/W L/W 3 Br L/W Br L/W Br Br R R B R B/L LY e 6 R 4 R/W R R 7 Br L/W R/W Br Br r W/Y L Br Br (BLACK) G/R t W/Y L W/Y L G/R B/L L/W y G/W B/L 5 0 L Y G/R B/L R/W R/W L/W L/W R/W L Y L/W B OFF START L B
