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Запчасти Yamaha YBR 125
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Запчасти Yamaha YBR 125
Расходники
Пластик, оптика
Тормозные колодки
Управление
Электрика, электроника
Двигатель, железо, подвеска
Тюнинг и аксессуары
Остальное
Уцененные товары
Запчасти Honda CB400
Запчасти Stels Flame 200
Запчасти IRBIS
IRBIS TTR250
IRBIS TTR250R
Запчасти ИЖ
Запчасти Минск
Запчасти Восход, Сова
Тормозные колодки
Масла и химия
Резина
Мотоцепи
Цепи 415
Цепи 420
Цепи 428
Цепи 520
Цепи 525
Цепи 530
Замки для цепей
Звезды
Комплекты цепь + звезды
Сальники и пыльники вилки
Аксессуары
Руководство по эксплуатации YBR 125 — 1.4 Mb
Руководство по эксплуатации YBR 125 обновленное — 3.2 Mb
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Сборник руководств по эксплуатации и техническому обслуживанию мотоциклов Yamaha YBR125.
- Издательство: Yamaha Motor Co., Ltd.
- Год издания: -/2007
- Страниц: 80/83
- Формат: PDF
- Размер: 22,3 Mb
Сборник руководств на английском языке по эксплуатации и техническому обслуживанию мотоциклов Yamaha моделей YBR125, YBR125ED, YBR125K и YBR250 Custom.
- Издательство: Yamaha Motor Co., Ltd.
- Год издания: 2003-2008
- Страниц: —
- Формат: PDF
- Размер: 18,9 Mb
Руководство на английском языке по эксплуатации и техническому обслуживанию мотоциклов Yamaha Gladiator (YBR125).
- Издательство: Yamaha Motor India
- Год издания: —
- Страниц: 77
- Формат: PDF
- Размер: 2,4 Mb
Руководство на английском языке по ремонту мотоциклов Yamaha YBR125ED 2005 года выпуска.
- Издательство: Yamaha Motor Co., Ltd.
- Год издания: 2005
- Страниц: 330
- Формат: PDF
- Размер: 10,0 Mb
Сборник руководств на английском, французском, немецком, испанском и итальянском языках по ремонту мотоциклов Yamaha модели YBR15ED и др.
- Издательство: Yamaha
- Год издания: —
- Страниц: —
- Формат: ISO
- Размер: 1,7 Gb
YBR125(JYM125/125-2)
Chongqing Jianshe·YAMAHA Motor Co.,LtdFirst edition Jan.2003
All rights reserved.Copy in any manner,in whole or part,or use without writtenauthorization of company,prohibited.
Notice
This service manual compiled by ChongqingYAMAHA Motor co.,Ltd, is specially used for dealer and maintenance
station of Chongqing JiansheYAMAHA Motor co.,Ltd. It is not possible to include all the knowledge of a mechanic in one
manual,it is only used for repairing and maintaining JiansheYAMAHA motorcycle and understand the principle of vehicle,
procedure of maintenance as well as technology of maintenance.If without the knowledge on this field,the improper ass-
embly and dangerous condition occuredafter assembly would be happened when repairing the motorcycle.
Chongqing JiansheYAMAHA Motor co.,Ltd is continually striving to improve all its models.Modifications and si-
gnificant changes in specifications of procedures will be forwarded to all authorized dealers and will appear in future
editions of this manual where applicable.
·
·
·
·
Note:Design and specification are subject to changes without notice.
Important Information
Warning
Particularly important information is distinguished in this manual by the following notations:
The safety Alert Symbol means ATTENTION!BECOME ALERT!YOUR SAFETY IS INVOLED!
Failure to follow WARNING instructions could result in severe injury of death to the vehicle operator,
a bystander or a person inspecting or repairing the vehicle.
CAOTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine.
NOTE: A NOTE Provides key information to make procedures easier or clearer.
How to use this manual
Manual Organization
Exploded Diagram
This manual includes many chapters which explain the main contents of each title individually.First title:An abbreviation and symbol in the upper right corner of each page indecates the current chapteSecond title:This title is shown in the left of section symbol of upper right corner of each page.Third title:It is a title of the smallest unit,which is compiled step by step and matched with relevent picture
In order to understand the parts and treatment procedure,the exploded diagram is provided at the beginn
of each exploded chapter:.A clear exploded diagramis used for disassembly and reassembly of the motorcycle..In the exploded diagram,the numbers as symbolsis used for explaining the removing procedure.If therearound the numbers,it is the explanation of disassembly procedure.Symbolin the exploded diagram is the explanation of work and key points.For the meaning of each symbopage.
.There is work indication tableunder each exploded diagram,which provides such informations as work procename of parts key pionts of work etc.
.For other informations concerning work,there is detailed explanation on progressive stepsbesides explodeand work indication table.
12
3.
4
5
2 1
3
8
4
5
6
7
Index
§ 1 General information
§ 2 Specification
§ 3 Periodic inspectionand adjustment
§ 5 Carburetor
§ 6 Chassis
§ 7 Electrical system
§ 4 Engine
8§ 8 Troubleshooting
7
6
5
4
3
2
1GENINFO
ADJ
Chapter 1 General information
Chapter 2 Specification
Chapter 3 Periodic inspection and adjustment
Motorcycle identification
Motorcycle identifcation code
Points for attention in maintenance
Special tool
Main specification
Inspection specification
Engine
Chassis
Electrical system
Main tighten torque specification
Position to be applied lubricating-oil and kinds of lubricating-oil
Engine
Chassis
Engine lubrication diagram
Layout of cable pipeline
Brief introduction/Contents of periodic inspection
Removal and installation of cushion,fuel tank and cover alike
Inspection and adjustment of air valve clearance
Adjustment of idle speed
Drainage/Check and adjustment of free play of throttle cable
Check of spark plug
Check of compression pressure
Check of lubricating -oil quantity of engine
Replacement of engine lubricating-oil/Check of lubricating-oil pressure
Check and adjustment of clutch
Check and clear of air filter
Adjustment of front brake (drum rype)
Check of front brake pad
Check of front brake(disk type)
Check the brake liquid quantity/Exhausting air
Replacing brake fluid
Check and adjust rear brake
Check and adjust brake light switch
Check and adjust driving chain
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1-1
1-1
1-2
1-5
2-1
2-4
2-4
2-6
2-8
2-9
2-12
2-12
2-13
2-14
2-16
3-1
3-3
3-5
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-16
3-16
3-17
3-18
3-19
3-20
3-21
3-21
Check of front fork
Adjustment of rear shock absorber
Check of tire
Check of steering device
Check of battery
………………………………………………………………………………
Electrical system
Chapter 4 Disassembly of engine
Dissassembly of engine
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Disassembly of exhaust pipe and lead wire
Disassembly of carburetor,clutch cable,speedometer cable and driving chain
Disassembly of engine
Disconnection of engine
Disasembly of cylinder head,cylinder and piston
Disassembly of starting motor,clutch and oil pump
Disassembly of starting axle and idle gear
Disassembly of shift axle
Disassembly of rotator
Disconnection of crankcase
Disassembly of balance device,transmission and shift rod
Disassembly of crank,balance block
Disassembly of rocker arm,camshaft
Disassembly of air valve
Cylinder head
Air valve seat
Air valve and guide pipe of air valve
Air valve spring
Camshaft
Rocker arm and rocker arm shaft
Timing chain,sprocket,guide plate of chain,chain tensioner
Cylinder and piston
Piston pin
Piston ring
Crank
Balance device
Clutch
Transmission,shift rod
Check and repair
…
4-1
4-1
4-2
4-3
4-4
4-7
4-10
4-11
4-11
4-12
4-13
4-14
4-15
4-16
4-18
4-19
4-21
4-22
4-23
4-24
4-25
4-26
4-27
4-28
4-29
4-31
4-31
4-33
3-22
3-23
3-24
3-25
3-26
Kick starter
Engine oil pump,filter
Crankcase
Bearing,oil seal
Elastic circlip,washer
Assembly and adjustment of engine
Air valve
Rocker arm,cam shaft
Crank,balance device
Transmission
Shift cam,shifting fork
Crankcase
Shift axle,starting axle,idle gear
Clutch,engine il pump
Timing ,pneumatic system
Rotator,starting mechanism,chain guide plate,idle pulley
Piston and piston ring
Cylinder and piston
Cylinder head
Cam axle and locating key
General drawing of carburetor
Removal of carburetor
Adjustment of fuel level
Inspection of front and rear wheels
Front wheel
Inspection of front wheel
Speedometer gear assy
Front brake
Installation of front wheel
Rear wheel
Rear brake hub
Drive chain,sprocket
Drive chain
Inspection of drive chain
………………………………………………………………………………………
Assembly and adjustment of engine
Chapter 5 Disassembling of carburetor
Chapte 6 Motorcycle body
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o
4-36
4-36
4-37
4-38
4-38
4-39
4-40
4-41
4-43
4-45
4-46
4-49
4-51
4-54
4-59
4-60
4-62
4-63
4-64
4-65
5-1
5-2
5-5
6-1
6-1
6-4
6-5
6-6
6-9
6-10
6-13
6-15
6-15
6-17
Inspection of clutch hub
Installation of drive chain
Removal of front fork
Inspection of front fork
Front fork assembling
Steering shaft and handle
Removal of handle
Inspection of handle
Inspection of front steering shaft
Installation of steering shaft
Installation of handle bar
Rear shock absorber and rear arm
Removal
Inspection
General drawing of circuit
Electric components
Inspection of socket connector
Inspection of switch
Ignition system
Starting system
Starting motor
Charge system
Lighting system
Signal system
Electric appliance system
Compression system
Intake and exhaust system
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Front fork
Chapter 7 Circuit
Chapter 8 Troubleshooting
Troubleshooting of engine
6-17
6-18
6-19
6-22
6-23
6-27
6-28
6-29
6-30
6-30
6-31
6-32
6-33
6-33
7-1
7-3
7-5
7-6
7-8
7-12
7-17
7-22
7-26
7-31
8-1
8-2
8-3
Chapter 1 General information
Motorcycle identification…………………………
Motorcycle identification code
Points for attention in maintenance
Special tool
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GENINFO 1Motorcycle identification
General informationMotorcycle identification
Motorcycle identification code
Motorcycle identification codeis stampedon the right side of steering bar.It consists ofthree portions.First portion (the first 3 digits)is the identification code of world manufact-urer identification(WMI); Second portion(6digits)is vehicle definition section(VDS);Third portion (8 digits)is vehicle indicationsection(VIS)
Engine series No.Engine series Nos is stamped on the crankcase.
Engine stamping codeJYM154FMI 00000001
Note:Design and specification are subject to changes wit-hout notice.
1-1
1GENINFO
1GENINFO
Note:Do not use compressed air to spin the bearings dry.This will damage the bearing surfaces.
1GENINFO
1GENINFO
1GENINFO
Main specification
Inspection specification
Engine
…………………………………………………2-1
……………………………………………2-4
…………………………………………………………2-4
Chassis
Electrical system
Main tighten torque specification
Position to be applied lubricating-oil and kinds of lubricating-oil
…………………………………………………………2-6
………………………………………………2-8
…………………………………2-9
……2-12
Engine
Chassis
Engine lubrication diagram
Layout of cable pipeline
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2
2
2
YAMALUBE,four-strokeSAE20W40SF’’or “SAE10W30SF” machine oilMachine oil type:
Engine oil
2
VM22SHMIKUNI
CR6HSA
0.6mm0.7mmWet,multi-piece
Spur gear
Chain drive
Constant mesh 5-speed shiftLeft foot operation
68/20(3.400)
45/14(3.211)
37/14(2.643)32/18(1.778)25/19(1.316)23/22(1.045)21/24(0.875)
Diamond26.4
With tube2.75-18(42P)90/90-18(51P)
175kPa(1.75kgf/cm)196kPa(2.0kgf/cm)
2
2
Drum or single-disc brakeRight hand operationDrum brakeRight foot operation
2
Wheelbase
PositionNeutral lightHighbeam indicatorSteering indicatorSteering light
Bulb(voltage/watt×quantity):HeadlightBrake light/tail lightMeter light
Headlinght typeHeadlight bulb type
Electrical systemIgnition systemGenerator systemBattery typeBattery capacity
Shock absorber:FrontRear
Suspension:FrontRear
Retractable sleeve typeRocker arm type
12V 35W/35×112V 21W/5W×112V 1.7W×414V 1.2W× 112V 4W× 114V 3W× 114V 3W× 114V 3W× 212V 10W×4
Bulb typeIncandescent bulb
CDIA · C · magneto
12V5Ah
1290mm
Coil spring/oil damperCoil spring/oil damper
Immediately use
JYM125(JYM125-2)
2 — 3
<4.950><4.935>
2
0.08~0.12mm0.10~0.14mm
5.000 5.012mm5.000 5.012mm0.010 0.037mm0.025 0.052mm
2
2
2
Rear wheelTypeRim dimensionRim materialRim runout (radial)
(lateral)
DID1480H1182030mm
Clutch leverClutch lever free play
Brake lever and brake pedal:Free play of front brakeFree play
Rear brakeType
Model of brake drumInside diameter of brake drumThickness of brake blockFree length of brake shoe spring
Front brake:Type
Disc outside dia×thicknessUse limit of disc thicknessThickness of brake pad (Inside)
(Outside)Master cylinder inside dia.
Long pincers cylinder inside dia.Appointed brake fluid
TypeInside diameter of brake drumThickness of brake shoeFree length of brake shoe spring
Driving chain:Type/manufacturerNo.of linksTwist quantity
Spoke/casting wheel1.85×18(W)
5.510.5mm/1015mm()2030mm
disc/drum
Drum type130mm4mm36.5mm
35DOT3 or DOT4
130mm4mm36.5mm
mmφ
Drum type
Disc brake245×4
1015mm
0.5mm0.5mm
3.5mm0.8mm0.8mm
131mm
2.0mm
131mm2.0mm
2 — 7
2
7
N
2Tighten torque
Tighten torqueEngine
Tighten parts Part Dimension Qty′Tighten torque
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
19
21
22
23
24
25
26
27
18
20
90105-08742
9131N-06090
90153-06803
94700-00372
9502L-06020
5VL-E1186-00
9570N-12500
9580N-06020
90170-05302
90101-08590
9131N-06012
9502L-06016
90155-06800
90340-12097
9131N-06020
9581N-08020
9502L-06030
9502L-06045
9502L-06055
9502L-06035
9502L-06050
9890L-06016
9502L-06035
9502L-06045
90179-12813
9851L-06012
9502L-06025
9131N-08016
90179-12813
5VL-E6337-00
90170-12060
No. NameKgf.m N.m
Cylinder head
Cylinder head(Side of timing chain)
Bolt of oil drainage port
Spark plug
Side cover 3 of cylinder head
Side cover of cylinder head(Air valve)
Rotator plate 2 of chain
Guide plate 2 of chain
Locking nut of air valve
Timing sproket
Hold-down of cylinder head
Tensioner assy
Oil pump assy
Oil drainage bolt
Silencer assy(Side of cylinder head)
Silencer assy(finished vehicle)
Kick starter assy
Hold-down of idler
Start generator assy
Start clutch assy
Main driving gear
Hold-down
Clutch hub body
2
Left&right crankcase
Crankcase cover 1
Chain cover
Crankcase cover 2
Hexagonal flange faced bolt
Internal hexagonal cylinder head bolt
Cross recess hexagonal head holt
Hexagonal flange faced bolt
Hexagonal flange faced nut
Hexagonal flange faced bolt
Hexagonal nut
Hexagonal bolt
Internal hexagonal cylinder head bolt
Hexagonal flange faced bolt
Cross recess bolt
Bolt
Internal hexagonal cylinder head bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt(small head)
Hexagonal flange faced bolt(small head)
Hexagonal flange faced bolt(small head)
Hexagonal flange faced bolt(small head)
Hexagonal flange faced bolt(small head)
Cross recess pan head bolt
Hexagonal flange faced bolt(small head)
Hexagonal flange faced bolt(small head)
Nut
Cross recess pan head bolt
Hexagonal flange faced bolt(small head)
Intenal hexagonal cylinder head bolt
Nut
Elastic screw
Hexagonal nut
M8×1.25
M6×1.0
M6×1.0
M10×1.0
M6×1.0
M45×1.5
M12×1.25
M6×1.0
M5×0.5
M8×1.25
M6×1.0
M6×1.0
M12×1.5
M6×1.0
M8×1.25
M6×1.0
M6×1.0
M6×1.0
M12×1.0
M6×1.0
M8×1.25
M12×1.0
M5×0.8
M12×1.0
M6×1.0
M6×1.0
M6×1.0
M6×1.0
M6×1.0
M6×1.0
M6×1.0
4
2
1
1
2
2
1
1
2
1
1
2
2
1
2
1
2
7
1
1
6
2
6
6
1
2
2
3
1
4
1
2.2±0.2
1.0±0.2
0.7±0.2
1.25±0.25
1.0±0.2
7.0±1.0
1.0±0.2
0.75±0.15
2±0.2
1.0±0.2
1.0±0.2
0.7±0.2
2±0.5
1.0±0.2
2.2±0.2
1.0±0.2
1.0±0.2
1.0±0.2
1.0±0.2
1.0±0.2
0.7±0.2
1.0±0.2
1.0±0.2
5.0±1.0
0.7±0.2
1.0±0.2
3.0±0.3
7.0±1.0
0.6±0.2
6.0±1.0
22±2
10±2
7±2
12.5±2.5
10±2
17.5±2.5
70±40
10±2
7.5±1.5
20±2
10±2
10±2
7±2
20±5
10±2
22±2
10±2
10±2
10±2
10±2
10±2
7±2
10±2
10±2
50±10
7±2
10±2
30±3
70±10
6±2
60±10
2 — 9
Tighten torque 2
kgf.m N.m
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
9502L-08040
90176-22800
5VL-F3346-00
90179-25615
9502L-08035
90105-10852
90150-088A6
9531L-10080
90105-08007
90105-08802
90150-08803
9560N-12200
90176-10810
90176-10810
90109-08848
90149-06801
90105-05832
5VL-F5181-10
5VL-F5181-00
5VL-F5381-00
90109-08864
90109-08847
90101-06848
90111-08805
M8×1.25
N22×1.0
M10×1.25
M25×1.0
M8×1.25
M10×1.25
M6×1.0
M8×1.25
M10×1.25
M8×1.25
M8×1.25
M8×1.25
M12×1.25
M10×1.25
M10×1.25
M8×1.25
M6×1.0
M6×1.0
M14×1.25
M10×1.25
M14×1.5
M8×1.25
M8×1.25
M56×1.0
M8×1.25
2
1
2
2
4
1
2
2
2
1
1
2
1
2
2
1
4
2
1
1
1
4
1
1
6
1.8-2.8
10-12
2.3-3.5
3.0-3.5
1.8-2.8
2.3-2.7
0.75-1.2
3.5-4.0
4.6-6.0
3.5-4.0
3.5-4.0
3.5-4.0
4.5-7.2
2.4-3.9
3.1-4.9
1.5-2.3
0.5-0.8
0.3-0.5
7.1-11.2
3.5-5.6
7.1-11.1
3.5-4.5
1.5-2.3
0.75-1.2
1.8-2.8
18-28
100-120
23-35
30-35
18-28
23-27
7.5-12
35-40
49-60
35-40
35-40
35-40
45-72
24-39
31-49
15-23
5-8
3-5
71-112
35-56
71-111
35-45
15-23
7.5-12
18-28
Tiighten parts Part Dimension Qty′Tighten torque
No. Name
Handle bar seat and inner tube
Handle bar seat and steering shaft
Lower bracket and inner tube
Steering shaft and circular nut
Handle bar and its seat
Caliper and front fork(pan)
Front main cylinder and handle bar(pan)
Front portion of engine and support 2 of engine
Support 2 of engine and frame
Rear portion of engine and frame
Upper portion of engine and support3/4 of engine
Support3/4 of engine and frame
Rotation shaft and nut
Rear shock absorber and rear arm
Rear shock absorber and frame
Pulling rod and reararm
Fuel tank and fuel cock
Fuel signal sensor
Front wheel shaft and nut(pan)
Front wheel shaft and nut(drum)
Rear wheel shaft and nut
Sproket and clutch hub
Pulling rod and brake shoe cover
Cam shaft arm and cam shaft
Brake pan and front wheel(pan)
Hexagonal flange faced bolt(small head)
Cap-shape nut
Hexagonal flange faced bolt
Nut
Hexagonal flange faced bolt(small head)
Hexagonal flange faced bolt
Hexagonal flange faced bolt(small head)
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Nut
Nut
Hexagonal flange faced bolt
Hexagonal flange faced bolt(small head)
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt
Hexagonal flange faced bolt(small head)
2 — 10
Tighten torque 2For noraml tighten torque,tighten screw and nutcan decide tighten torque according to diameter of thread(width of two faces)and space of threadexcept appointed tighten torque.(see the table inthe right side).
Dia of screw(width of two faces)Space of thread× Tighten torque
M5(8mm)×0.8M6(10mm)×1.0M8(12mm)×1.25M10(14mm)×1.25M12(17mm)×1.5
34Nm(0.30.4kg.m)58Nm(0.50.8kg.m)1219Nm(1.21.9kg.m)2439Nm(2.43.9kg.m)4572Nm(4.57.2kg.m)
Width of two faces
Dia. of thread
Pitch of thread
Tighten sequence of steering system
2.
3.
4. .
5.
1. Tight the nut ofto3035N.m
Then turn the steering bar 2-3 times by leftward and
rightward.In turing,binding and loosening of bearingrace is not allowed.
Loosen nut of by1/4turn and then tighten it with
tighten toque of 2024N.m
Turn the nut of to close to flat washer of .
Put the special washer and stop pawl ofinto groove
of nut of and.If it is not aligned with groove,
turn the nut ofto ensure the alignment.
2 — 11
2Position to be applied lubricant
Position to be applied lubricant Symbol
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
YAMAHA bond No.125
Lip of oil seal(all)
Bearing lock piece(all)
Bolt(cylinder cover)
Crank pin
Piston pin
Timing chain/cam sprocket
Piston/piston ring
Valve stem
End of valve stem(intake&exhaust)
Rocker arm shaft
Cam and bearing(cam shaft)
Inside of rocker arm
Left and right closed face of crankcase
O-ring(all)
Inside of foot pedal gear
Inside of idle gear of foot pedal
Crank sleeve of foot pedal
Axial surface of starting idle gear
Start clutch(outside/rotating portion)
Gear inside of starting wheel
Pushing rod
Inside of main driving gera
Shaft of pushing rod
Spindle/inside of driving gear
Shift fork/guide fork/shift shaft/shift cam
2Position to be applied lubricant
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Position to be applied lubricant SymbolSurroundings of rotation shaft of rear arm
Upper&lower steel ball race of steering vertical tube
Inside of guide tube and handle bar cover
Contact face of clutch lever and cable
Rotation face of clutch lever and holder
Contact face of brake cable and holder lever
Rotation face of brake lever and holder
Inside of brake pedal
Main support and its rotation shaft
Rotation face of side support and its holder
Rotation face of rear footrest
Meter gear
Cam and shaft of cam shaft
Rotation portion of brake pad pin
Lip portion of oil seal of hub assy,clutch assy and brake cover assy
YAMAHA -stoke engine oil4 Light-weight lithium-soapbase grease
Molybdenum disuflide grease
2 — 13
2
Rocker arm(intake)
arm(exhaust)Cam shaft
Rocker arm shaftRocker
Lubrication diagram
Centrifugal filter
Oil pump
Pushing rod
Filtering web
2 — 14
2
2Layout of cable pipline
E Wire of starting generator shall pass through the interior ofbattery
F Flowing guide tube of battery shall pass through theinterior of battery
G Fix the wire of magneto and brake switch at the wireclip
H Pass the brake cable and flexible shaft of meter thoughguide frame.
—
Drum type without fairing
2Layout of cable pipline
Drum type without fairing
Drum type without fairing
2Layout of cable pipline
A Pass the wire of the cable,brake cable,brake switch and handle bar switch throughguide frame.
B Pass the wire of clutch cable,handle bar switch and clutch switch through guideframe.
C Fix the wire of left handle bar switch and clutch switch with bands.D Fix the wire of right handle bar switch and brake switch with bands.
Drum type withoutfairing
2Layout of cable pipline
Disc type with fairing
2Layout of cable pipline
Disc type without fairing
2Layout of cable pipline
Wire of front brake switch
Brake cable
Wire of right turning light
Throttle cable
Wire of right handle bar switch
Wire of left turning light
Wire of clutch switch
Wire of left handle bar switch
Clutch cable
Fig. A
1
2
3
45
6
7
8
9
2 — 21
Brief introduction/Contents of periodic inspection
Removal and installation of cushion,fuel tank and cover alike
Check and adjustment of air valve clearance
Adjustment of idle speed
Drainage/Check and adjustment of free play of throttle cable
Check of spark plug
Check of compression pressure
Check of lubricant quantity of engine
Replacement of engine lubricant/Check of lubricant pressure
Check and adjustment of clutch
Check and clear of air filter
Adjustment of front brake(drum type)
Check of front brake shoe
Check of front brake(disc type)
Check the brake liquid quantity/Exhausting air
Replaceing brake liquid
Checking,adjusting rear brake
Checking,adjusting rear brake light switch
Checing,adjusting driving chain
Check of front fork
Adjustment of rear shock absorber
Check of tire
Check of steering device
Check of battery
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…………………………………………………………………………Electrical system
3-1
3-3
3-5
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-16
3-16
3-17
3-18
3-19
3-20
3-21
3-21
3-22
3-23
3-24
3-25
3-26
3INSPADJ
RoutineRun-in period
or 1 month1,000 (600)
Initial
or 3 months
3000(2,000)
Every
or 3 months
3, 000(2,000)Items
Air valves*
Spark plug
Air filter
Carburetor*
Fuel line*
Engine oil
Oil filter
Front brake*
Rear brake
Clutch
Rocker arm fulcrum*
Wheel*
Wheel bearing*
Steering bearing*
Front fork*
Rear shock absorber*
Rear suspending armfuleram*
Check valve clearance,adjust if necessary.
Check condition,clean or replace if necessary.
Clean,replace if necessary.
Check idle speed/starter operation,adjust if necessary.
Check fuel hose for cracks or damage,replace if necessary.
Repace(warm engine before draining)l
Clean or replace
Check operation/brake fluid leakage/refer to theremarks.Adjust if necessary.
Check operation.Adjust if necessary.
Check operation,adjust if necessary.
Check swing arm assy,for looseness,tightenif necessary. Repair if damaged.***Check operation.Disassemble to repair ifnecessary.***Check the bearing for looseness,repair ifnecessary.Disassemble to repair every 12,000(8,000) or 12months if appropriate.
Check bearingassembly for looseness/damage.Replace if damaged.
Check the balance/damage/runout/tighten spoke,repair if necessary.
Check operation/oil leakage.Repair if necessary.
Check operation/oil leakage.Repair if necessary.
3INSPADJ
RoutineRun-in period
or 1 month1,000 (600)
Initial
or 3 months
3000(2,000)
Every
or 3 months
3000(2,000)
Drive chain
Fittings/fasteners*
Main and side stand*
Battery*
Check tension/alignment.Adjust if necessary.Chean and lubricate.
Check all chassis fittings and fasteners.Correct if necessary.
Check operation.Repair if necessary.
Check specific gravity of electrolyte.Check breatherfor proper operation. Correct if necessary.
Check prior to driving
Items
It is recommended that these items be serviced by YAMAHA authorized service station or dealer.Heavy-duty or medium truck wheel bearing grease.
Lithium-soap base grease
Remark:
Replace brake fluid
1.
2.
3.
If disassembling brake master cylinder or long pincers cylinder,the brake fluid must be replaced.Check the
The oil seal of brake master cylinder or long pincers cylinder must be replaced every two years.
The brake hose must be replaced every 4 years or immediately if any crack or damage is found.
under normal conditionand refill if necessary.
3 — 2
3INSPADJ
Removal and installation of cushion, fueltank and cove alike1.Side cover(left)
Openwith the key, then pull out set pin of side cover, finally take out side cover along the direction pio-nted by arrow .
2.Side cover(right)Take out bolt at positionwith screwdriver,then pullout set pin of side cover,finally take out side coveralong the direction pointed by arrow .
3.Side cover of guide flowing(right)Take out the bolt of ,seperate the connecting blockwhich connects side cover,then pull out the set pin ofside cover , finally take out the side cover along thedirection pointed by arrow .
4.Side cover of guide flowing(left)Take out the bolt of , separate the connecting blockwhich connects side cover, then pull out the set pin ofside cover , finally take out the side cover along thedirection pointed by arrow .
5.CushionTake out bolt as per fig.indicated position(one each atleft and right side),then take off the cushion forward.
3 — 3
3INSPADJ
6.Fuel cock
Switch the fuel cock off
Note:First close the fuel cock on the fuel tank at the position
“ ”,then take off the fuel pipe.
7.Fuel tank
Bolt
Shim
Rubber pad
Fuel tank
8.InstallationConduct as per reverse procedure of removal operationpay attention to the following
1.InstallationFuel tankTorque
Bolt torque(see upper fig)
2Kgf.m (20N.m)
2.Installation
Cushion
Note:First insert the convex tip position at the rear portionof cushion into insert hole on the frame, then installthe bolt of cushion into every hole seperately, finallytighten the nut.
Bolt torque(see fig.)1Kgf.m (10N.m)
3 — 4
3INSPADJInspection and adjustment of air valve clearance
Engine
Inspection and adjustment of air valve clearance
Note:The valve clearance must be adjusted when theengine is cool.Adjust the air valve clearance when the piston is atthe Top Dead Center(T.D.C) on compression stroke.
1.Remove the following parts.Side cover(left,right)CushionFuel tank
(Refer to removal and installation of cushion,fuel tankand cover alike)
2.Remove the following parts.
Side cover of cylinder head ,bolt
Spark plug
Rocker arm cover (Intake)
Rocker arm cover (Exhaust)
3.Remove the following parts
Cock with O-ring
Cock with O-ring
3 — 5
3INSPADJ
Inspection and adjustment of air valve clearance
4.Turn the rotator counter-clockwise,align the T.D.Cmark a of rotator with the T.D.C mark b on the cran-kcase cover.
5. Conduct the following inspection.Air valve clearance
Standard air valve clearance:IN:0.080.12 mmEx:0.100.14 mm
Conduct adjustment for the valve under standard value****************************** ************
Adjusting sequence:
Loosen fix nut
Insert feeler gauge
Install the air valve adjusting toolon the adjustera
Turn the adjuster util the standard value is obtained.Ton
avoid the adjuster turn together,fix the adjusting tool
before locking the set screw.
Confirm the air valve.If it is out of standard value,readjust it.
Locking torque of set screw:7.5Nm (0.75kg.m)
3 — 6
3INSPADJIdle speed inspection/adjustment
Idle speed adjustment
1.
2.
Start and warm the engine for several minutes.
Install the following parts
Rpm meter of engine
Install Rpm meter of engine on the wire of high
pressure(spark plug wire).
Rpm meter of engine:90890-03113
3. Confirm the following itemsStandard idle speed rpm
Standard idle speed rpm1300-1500rpm
Adjust if out of standard value
4. Conduct the following adjustment
Standard idle speed rmp
Adjusting sequence:Turn the P.S adjusting screwto the end slightlg.
Note:Do not lock it tightly.
Ratate to standard rpm turns.
Standard rpm turns of P.S adjusting screw:2.0
Start the engineRotate idle speed adjusting screw leftward and right-ward until the standard idle speed rpm turns are obtained.
Screw in→Increase the engine
Screw off→Decrease the engine speed
3 — 7
3INSPADJDrainage and adjustment of freeplay of throttle cable
5.Remove the following partsRpm meter of engine
Adjustmet of co content at idle speedn1.
2.
Install the following measuring meter:measuring meterwith detector for normal temperature and rpm meter ofengine.Warm the engine until the oil temperature reachs tospecified value.
Specified oil temperature:556
3.rConfirm idle speed value: 1400 pm4.5.
Install the measuring meterfor CO contentCheck the CO density.
Standard co density:1.54.5%
Out of standard value→adjust P.S adjusting screw(match
with adjusting idle screw)
Inspection/adjust the free clearance ofthrottle cable
1.Conduct the following inspection Free clearance a of surrounding of throttle cable
mmFree clearance of surrounding of throttle cable:
Out of specified value→adjst
1.Conduct the following adjustment
Free clearance of surrounding of throttle cable
Adjust sequenceFirst step(Throttle steel cable)
Loosen the locking screwAdjust the adjuster
Screw in→increase the clearance
Screw off→decrease the clearance
Tighten the locking screw
3 — 8
3INSPADJ
Adjustment of frdd play of throttle cable and check of spark plug
Note:When the adjustment could not done by the steelcable at throttle handle bar,it could be done by theadjuster at the carburetor.
Second step(carburetor)
Loosen the locking screw
Adjust the adjuster
Screw in→Increase the dearance
Screw off→Decrease the dearance
Tighten the locking screws
WarningAfter adjustment,start the engine, turn the steeringhandle bar leftward and rightward,confirm that the idlespeed of engine will not increase.
Check of spark plug
1.
2.
Conduct the following checkCheck electrode,pollution of insulation, damage underburning, damage under burning for deposits→replacethe pollutant and deposit→clean with spark plug det-ergent or steel wire brush.Conduct the following checkCheck the clearance a between center electrode andside one
Out of specified value→adjust side eclectrode
Clearance between electrode:0.60.7mm
Standard spark plug
NGK
CR6HSA
3 — 9
3INSPADJ
Check of compression pressure
Note:Insufficient compression pressure wil result in theperformance loss.
1.
2.3.4.5.
Check:Air valve clearance→adjustRefter to «adjustment of air valve»Start and warm the engine for several minutes.Stop the engineRemove:spark plugInstall:Pressure manometerJoint
Pressure manometer:90890-03081
Joint:90890-04082
6.CheckCompression pressure
Measurement steps:Crank over the engine with the electric starter or kick
starter with the throttle wide-open until the compression
reading on the manoeter reach to the max.value,then
read the max. one.
Check readings with specified levels.
When compression pressurePoor air valve contact will cause compressionleakage.Adjustment of air valve clearance is poorPiston,cylinder and piston ring will be worn out
When compression pressure is too highA The burning room of cylinder head will have
carbon depositB Piston head will have carbon deposit
A
B C
Standard compression pressure:1200KPa( 12kg/cm) 2
7.Install:Spark plug,spark plug cap
3 — 10
3INSPADJ
Check of lubricant quantity of engine/Recommended lubricantoil/Replace engine lubricant oil
Check of lubricant quantity of engine
Note:When inspecting,the motorcycle should be rested atflat position and in vertical condition.
1.Conduct the following checkLubricant quantity of engine
Run the engine with idle speed for 23 minutes, then
stop the engine for 23 minutes.keep the machine invertical position and take out cock
. Check the oil level on the cock if it is betweenand.
Lubricant quantity of engine *Recommendedlubricant oil
When normally replacing:
1.0L1000mL )When repairing the engine
1.2(1200mL)
Refer to the indication in the fig,select the proper enginelubricating-oil which suits for viscosity code of localtemperature.Recommended engine oil: YAMAHA four-strokelubricating-oil.
3 — 11
3INSPADJReplacement of engine lubricating-oil/check of lubricating-oil pressure
Replacement of engine oil
Note:Do not add any chemical additives.Engine oil alsolubricates the clutch and additives could cause clutchslippage.Do not allow foreign material to enter thecrankcase.
1.2.
3.
4.5.6.
Rest the machine on a level place.Warm up the engine for several minutes,and stop it.Place an oil container under the oil drain plug.Remove:Filling-in cock of engine oil.Drain cockGasket(installed on drain cock)Drain oilAdd the engine oil from filling-in cock.InstallFilling-oil cock of engine oilGasket(installed on drain cock)Drain plug
Torque of drain cock:
20N.m(2kgkm)
Check of oil pressure
1.2.
3.
Remove:oil pressure inspection boltStart and run the engine for several minutes inidle speed.Check:Machine oil condition of overflowing holeOverflow of machine oil→oil pressure is normalMachine oil can’t overflow→oil pressure is insufficient
Note:If the oil still does not over-flow after one minute,stopthe engine immediately to prevent it from being da-maging.
3 — 12
3INSPADJ
Adjustment ofclutch/adjustment of front brake
Adjustment of clutch
1.Check:Freeplay of clutch cable a out of specified range→adjust
Free play:1015mmMeasure at end portion of clutch lever
2.Adjust:Free play of clutch cabl
1.
2.3.
e
Confirm that adjusting deviceand locking nuthavebeen fully tightened.Loosen the lock nutScrew in or screw out adjusting nutuntil the specifiedfree play has been obtained.
Adjusting steps:
Screw in→free play increased
Screw out→free play decreased
4.Tighten locknut
Note:If the free play is improper,use adjusting device(a partof clutch lever)to adjust the free play of clutch cable.
5.6.
Loosen locking nut Screw in or screw out the adjusting deviceuntil theproper free play has been obtained.
Screw in→free play increased
Screw out →free play decreased
7.Tighten locking nut
3 — 13
Clear of air filter
Clear of air filter
1.RemoveSide cover(right)CushionCase of air filter
2.RemoveCore of air filter
3 — 14
Install filtercore 2 on filtercore.
1
2
Note:There is check hoseat the bottom of the air filter.Ifdust or water collects in this hose,clean the air filtercore and case.
Note:The engine should never be run without the air filter;otherwise, unfiltered air will get into the engine, thusexcessive wron out or damaging the engine will beresulted.In addition,the operation of carburetor will beinfluenced and engine may be overheated if runningwithout core of air filter.
3INSPADJ
3.Check:
Clean of air filter 3INSPADJ
Filter core of air filter
Damage Replacement
Dusty Blowing off dust on net with compressed air
→
→
Blown dry with air
e the filter cores1and 2 , and clean them by Remov
blowing with high-pressure air.
If the filter core 2 is too dirty, it may be washed with
neutral solution.It must be blown dry after washing.
The filter core may not be painted engine oil.
Coution:
Coution:
It should be confirmed that the filter core has beenfixed correctly in filter case.
Coution:It is strictly forbidden to run engine without fitting filtercore of air filter. It will cause over wear of piston/cy-linder.
3-15
Adjust of front brake(drum type)
1.
2
Check:
Free travel a of brake cover
Exceeding specified range adjustment
Adjustment:
Free travel of brake lever
→.
Adjusting procedure(lever side)
Loosen the lock nut
Screw in or screw out the adjusting nut until reac-
hing specified free travel.
Toghten up the lock nut
Adjustment(brake drum side):
Screw in or screw out the adjusting nut until reac-hing specified free travel.
Check of front brake pad
Screw in Free travel increment→
Screw in Free travel reduction→
Screw out Free travel increment→
1.
Check:
Needle(wear indicating plate)Needle reaching the wear limit line of indicating plate
Replacing brake pad.→
3-16
Note:Should confirm no blocking of brake after adjusting.
Adjust of front brake 3INSPADJ
Screw out Free travel reduction→
Check of front brake 3INSPADJ
Check of front brake(disk-type)
WrningIf feeling loose and soft braking,the bad brake effectmay be caused by oil leakage or mixing with air.Youshould check brake liquid capacity,and lock brakesteel cable,or eliminate air.
1.
2.
Conducting following check:
If there is vibration when turning leftward or rightwardor driving, you should check if the brake nose contact
other part.Contacting correcting.Check the free play of the front end part of brake handle.
→
Free play of front end part of brake handle:
a 5.5~10.5mm
Note:This play is ensured by manufacturing .No adjustmentis needed.
Checking brake pad
1.
Conduct following checkingCheck the wear condition of brake padIf the wear indicator hardly contactin brake rounddisk replacing whole set of brake pad. →
3-17
Check the brake liquid quantity/Exhausting air 3INSPADJ
Check the brake liquid quantity
1.
Conductfollowing checkingBrake liquid levelCheck the liquid level when the brake liquid level cover
is in horizonal state.The liquid level should be abovein figure.
If the liquid level is below the lower position,sup-ply the brake liquid until above the lower limit position.Appionted brake liquid:genuine YAMAHA brake liquid DOT4
Note:Do not mix and use brake liquid of different brandDOT3 oil can be used if there is no No DOT4 oil.Thebrake liquid will corrupt the painting surface and pla-stic part.wipe off it inmedinately when splashing.
Exhausting air
WarningWhen disassembling related parts of braked liquid,you must confirm that other parts are locked andsealed. Then the air can be released.
Procedures:1.2..3.
4.
of releasing airRemove the cover of brake liquid vat.Remove the diaphragm of brake liquid vatMount plastic rubber pipe on front end of oil drainingScrew and place a oil container at the front end ofplastic rubber pipe.After braking several times ,loosen the oil drainingscrew about 1/2 turn when gripping brake handle,then ghten it up again quickly.ti
Note:Do not release the brake handle before tightening upthe oil draining screw again.
5.Repeat above procedures until the bubble is eliminatedcompletely.
Note:Supply the brake liquid at the same time.Do not let itbelow the lower limit.
3-18
3INSPADJ
Exhausting air/Replacing brake liquid
WarningGrip the brake hadlebar to check brake liquid leakage,Wipe off the brake liquid sprayed on brake disk, tireand rim.
Warning
6.Refit the diaphragm of brake liquid vat.
7.Refit the cover of brake liquid vat.
Replacing brake liquid:
1.Make the main liquid vat in horizontal state,and disass-emble the cover of liquid vat.
2.Fit the plastic rubber hose on front end of oil drain-ing screw ,and prepare oil continter at the front end ofplastic rubber hose. Loosen the oil draining screw, andrepeat that several times until no brake liquid is drainedby oil draining screw.
Wipe off the brake liquid sprayed on brake disk, tireand rim.
3.Lock the oil draining screw
Oil draining screw:6 Nm (0.6 kg.m)
5.4.Remove the diaphragm of brake liquid vat.
Fill the brake liquid until above lower limit.
Appointed brake liquid:genuine YAMAHA brake liquid DOT4
Note:Do not mix and use brake liquid of different brandDOT3 oil can be used if there is no DOT4 oil.
6.Pull the brake handlebar to make the brake liquid pipefilled with brake liquid.
Note:Supply the brake liquid at the same time.Do not let itbelow the lower limit.
3-19
Checking,adjusting rear brake/Check of rear brake shoe
7.
8.
Operate the brake handlebar until no bubble sends outfrom the small hole of brake liquid vat and the brakehandlebar is felt powerful.
Release air.Assemble according to reverse procedures after adjus-ting .
9.
3INSPADJ
Check and adjust rear brake
a
1.
2.
Conduct following checking
Check brake and free play of front end part of pedal
Free travel of frontend part of brake pedal:2030 mm
Unconformable to specified value Adjustment→
3.Conduct following adjustment.
Free play of brake pedalAdjusting order:
Adjust the free play to specified value with adjuster
Screw in Reduction→
Screw out Increment→
Check of rear brake shoe
1.
CheckNeedle (wear indicating plate)The needle has reached wear limit line Replacingbrake shoe
→
Note:The tension spring must be replaced when replacingbrake shoe.
3-20
3INSPADJ
Checking rear brake light switch/Checking,adjusting driving chain
Checking rear brake switch
1.
2030mm.
Conduct following checkingBrake lightCheck if the brake light comes on when treading downthe brake pedal Brake light does not come on adjustment(Rotate the adjusting nut for adjustment)Rear brake light switchAdjusting nut
→
Checking,adjusting driving chain
1.Conduct following check.
Support the motorcycle with main stand.
Check the slackness a of driving chain.
Exceeding specified value range adjustment→
1
a
Slackness of driving chain:2030 mm
2.
Adjust driving chain
Loosen the lock nut of axle
Loosen the lock nut of adjuster
Screw in or out the adjusting device until reachingthe specified slackness.
Adjusting procedures:
Screw in Slackness reduction→Screw out Slackness increment→
3-21
3INSPADJ
Checking,adjusting driving chain/Check of fronk fork
Checking,adjust driving chain
Note:There is graduation mark on chain adjuster.Whenadjusting,should ensure the identical graduation valueon driving chain adjusters of two sides of rear arm.After the left and right adjuster is adjusted properly,tighten up the lock nut of adjuster and lock nut of axle.
Lock nut of axle:91 N.m (9.1kgfm)
Lubrication of driving chain
The driving chain includes many cooperating parts.Theywill be worn rapidly without proper maintenance.So per-iodical checking and repair should be conducted,which isespecially important when driving under dusty condition.
Spraying-type lubrication oil may be used. Get rid of alldirts and mud on chain with brush or cloth. Spray thelubricating oil onto the position between two side platesof chain and middle roller.When washing chain,remove the chain from the moto-rcycle, and immerse it into solvent to clean it as far aspossible. Take out the chain from solvent and dry it.Lubricate it quickly to avoid rust.
1.
2.
Note:Never use lubricating grease when lubricating chain.
Check of front fork
1.
2
→
Place the motorcycle on flat place.
Check:Inner tubeScar or damage ReplacementOil seal
Serious oil leakege Replacement
.
→
3-22
3INSPADJ
Check of front fork/adjustment of rear shock absorber
3.
4.
Keep the motorcycle in vertical parking state,and acti-vate front brake.
Check:Activating state
Make the front fork sliding up and down certain times.Blocking in activating Repair
Refer to section of Front fork in Chapter 6
→
“ ”
Adjustment of rear shock absorber
WarningAlways adjust the preload value of each shock ab-sorber identical to set constant value. Uneven adj-ustment will worsen the operation and reducereliability.Support the motorcycle firmly to avoid turning over.
1.Adjust:Spring preload
Turn the adjusting device in direction a or b
Turn in direct a Spring preload value increases→
Turn in direct b Spring preload vlaue reduces→
Adjusting device position:Standard: 3Min: 1Max: 5
ab
Note:The adjusting device should not be trned exceedingMax. or Min. position.
u
3-23
3INSPADJ
Check of tire
Warning
1.Measure
Tire pressure
Exceeding specified valueadjustment→
Front wheel Rear wheelPressure ofcold tire
175kPa(1.75kgfcm )2
196(2.0
kPaKgf/cm )2
196kPa(2.0Kgf/cm )2
245(2.5
kPaKgf/cm )2
Load below0~90 kg
*
Max,load100kg
*
* Load means total weight of cargo,driver and accessaries
Specification of front wheel
Specification of rear wheel
2.75-18(42P)
90/90-18(51P)
2.Check
Tire surfaceWear/damage Replacement→
Min depth of tire thread(front &rear wheel):
1.0 mm
Repth of threadSide wallWear indication layer
Driving the motorcycle with worn tire is dangerous.Replace the tire immediately when the tire is wornto line.You would better not to mend the brokentire tube with rubber. Mend the tire tube especiallycarefully if you have to do so. And replace it withhigh quality substitute as soon as possible.When using tiretube type tire,be sure to mountcorrect tire tube.
—
3-24
3INSPADJ
Check of steering device
Check of steering device
1.
2.
2-11
Conduct following device
Support the front wheel,and sway the lower part of frontfork to check if the steering axle is loose.Check if the
steering bar can be turned to left and right smoothly.
Loose steering axle,unsmoothed turning adjusting nut
of steering axle
Conduct following adjustment
Steering nut
Disassemble steering handlebar(Refer to Chapter 6 “Steering handlebar”)
Disassembling steering handlebar seat
Lock the nut with steering nut wrench
(The locking procedures and method refersto
→
)
Adjusting procedures:
Mount steering bar seatMount steering handlebar
3-25
3INSPADJ
Check of battery
Check of battery
1.
2.
Disassemble:Side cover(left)Reter to section “Disassembly of side cover”Check:Electrolyte levelThe electrolyte level must be between upper mark line
If the electrolyte level is too low, supply the electrolyteproperly.
and lower mark line .
Note:Only distilled water can be supplied.The tap watercontains mineral which is harmful to battery.
3.Check:Terminal of batteryDirty terminal cleaning with steel wire brush Bad connecting correction
→→
Note:Paint a layer of little lubricating grease after cleaningterminal.
4.Check:Airflow hoseJamming EliminatingDamage Replacement
→→
Note:Be sure to arrange the way of airflow hose correctlywhen checking battery.Be careful not to let electrolyteof bubble contacting frame or other part to avoid cor-rosion.
3-26
Warning
5.
6.
Connet:Airflow hoseMust confirm firm connection and correct way of air flow hose.Check:Specific gravitySmaller than1.08 Recharge→
Charging current:0. 5 A / 10 hSpecific gravity:1.28 at 20 68o F
Replace the battery when finding following condition.
During charging,the votage can not reach the specified
value or no bubble rises.
One or several battery unit elements are suphidized.
Recharging becomes slow after a period of time. The
specific gravity reading of one battery element is lower
than others.
Obvious buckle or bending of electrode plate of insulator
(The electrod plate becomes white or substance
gathers on bottom of battery unit element)
The battery electrolyte is damgerous.It containssulpharic acid which is poisonous and corrosive.Must obey following preventing measures:Avoid to contact electrolyte because it will causeserious burn and permanent damage of eye.Protect your eyes when operating or working nearbattery.
1
3INSPADJ
Check of battery
Note:To new battery,the primary charging must be cond-ucted before using to assure its best performanceand service life.
3-27
WarningMethod for detoxication(external)
Skin——Wash with water.Eyes——Wash with water for 15 minutes,and
see a doctor immediately.Method for detoxication(internal)
Drink plenty of water of milk.Then take oxidized milk with egg or rapseed oil,and see a doctor immediately.
The battery will produces explosive gas. Following protecting measures must be taken:
Conduct chatging at ventilated place(far awayfrom welding equipment,lighting cigaret etc).
Do not smoke when charging or work at battery.The battery or electrolyte should be placed far
away from children.
3-28
3INSPADJ
Check of battery
Chapter 4 Disassembly of engine
Disassembly of exhaust pipe and lead wire
Disassembly of carburetor, clutch cable, speedometer cable and driving chain
Disassembly of engine
Disconnectin of engine
Disassembly of cylinder head, cylinder and piston
Bassembly of starting motor , clutch and oil pump
Disassembly of starting axle and idle gear
Disassembly of shift axle
Disassembly of rotator
Disconnection of crankcase
Disassembly of balance device, transmission and shift rod
Disassembly of crank , balance block
Disassembly of swaying arm, cam axle
Disassemblyof air valve
Cylinder head
Air valve seat
Air valve and guide pipe of air valve
Air valve spring
Cam axle
Swaying arm and swaying arm axle
Timing chain, chair wheel, guide plate of chain,chain tensioner
Cylinder and piston
Piston pin
Piston ring
Crank
Balance device
Clutch
Tranmission , shift rod
Kick starter
Engine oil pump, filter
Crankcase
Bearing, oil seal
Elastic circlip, washer
Disassembly of engine
Cheek and repair
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Assembly and adjustment of engine
Assembly and adjustment of engine ……………………………………
Air valve ………………………………………………………………
Swaying arm, cam axle………………………………………………
Crank, balance device …………………………………………………
Transmission…………………………………………………………
Shift cam, shifting yoke………………………………………………
Crankcase………………………………………………………………
Shift axle , starting axle , idle gear
Clutch , engine oil pump
……………………………………
………………………………………………
Timing , pneumatic system ……………………………………………
Rotator , starting, chain guide plate,idle pulley …………………………
Piston and piston ring ……………………………………………………
Cylinder and piston ……………………………………………………
Cylinder head …………………………………………………………
Cam axle and locating key ……………………………………………
ENGDisassembly of engine
Thorough repair of engine
Disassembly of engine
1.Disassemble:
Side cover
Cushion
Fuel tank
Refer to section of “Disassembly of cushion, fuel tank
and side cover”.
Engine oil
1.Oil draining:
Engine oil
Refer to section of “Replacement of engine oil” in
Chapter3.
Exhaust pipe
1.Disassemble:
Exhaust pipe
Fixing bolt
Carbauretor
1.Disassemble
Carburetor
Cable and guide wire
1.Disconnect
Guidewire of neutral switch
Guidewire of stator coil
Guidewire of charging coil
Guidewire of pulser coil
4 — 1
ENGDisassembly of engine
3.
4.i
Disconnect
Guid wire of positive and negative electrode of batt
Guid wire of starting motor
Dsconnect
Cable of clutch
Shift pedal and driving chainLoosen
Nut of rear wheel shaft
1.
2.
3.
:
:
Disassemble
Shift pedal
Disassemble
Small chain gear
Driving chain
Kick starterDisassemble
Nut
Kick starter
1. :
Disassembly of enginePlace a proper support under frame and engine
(or support the main stand and make it stable )
Disassemble
Mounting bolt(support of lower part of front
side and engine )
Mounting bolt, (support of lower part of
front side and frame)
1.
2. :
Note:Loosen the nut of chain adjusting device and increasethe slackness of chain.
3.
4.
5.
Disassemble:
Mounting bolt(rear part of engine and frame)
Disassemble:
Mounting bolt , nut ( lower side )
Disassemble:
Mounting bolt ( upper part of engine and support )
mounting bolt ( upper support and frame )
Disassembly of engine ENG
Disassembly of engineCylinder cover, cylinder and piston
Disassemble:
Spark plug
Disassemble:
Intake divided manifold (connecting pipe of
cylinder and
Disassemble:
Timing rotating plug
1.
2.
3.
carburetor)
,
4 — 3
ENGDisassembly of engine
4.
5.
6.
Disassemble:
Air valve cover(intake)
:
Air valve cover ( exhaust)
Disassemble
Side cover of cylinder cover
Timing adjustment
Make the mark“ ”on rotator aiming at the fixing needle
on crankcase cover.
3
******************************* ***********Timing adjusting procedure
Rotate the crank counterclockwise with wrench.
******************************** **********
4 — 4
Make mark“ ” on rotator aiming at fixing needle b
on crankcase cover. When mark“ ”aiming at fixing
a
needle , the piston is on upper dead center (T , D , C ).
At the same time the calibration mark c of cam chain
gear should aim at calibration mark d on cylinder cover.
The swaying arms on both sides must form valve gap.
If there is no gap, rotate the crank counterclockwise to
meet above requirement.
ENGDisassembly of engine
7.
8.
Loosen
Cover bolt(chain tensioner device )
Disassemble
Chain tensioner device
9.
Disassemble:
Bolt
Cam chain gear
Note:Fix the timing chain with protective steel wire to prevent the chain dropping into crankcase.
10.
Disassemble:
Bolt
Cylinder head
Firstly loosen each bolt 1 / 4 turn. After loosening allbolts, remove them.Loosen them successively fromMin.number . The reverse order of the number st-amped on cylinder means the order of tightening thebolts.
Note:
4 — 5
ENGDisassembly of engine
11.Disassemble
Guide board of chain
Locating pin
Cylinder pad
Cylinder
12.Disassemble:
Locating pin
Papper pad
13.
Piston pin
Disassemble:
Elasric circlip of piston pin
Piston
Note :Before disassembling the cirlip of piston pin,cover apiece of clean cloth on crankcase to prevent theelastic circlip dropping into crankcase.Before disassembling the piston, clean the grooveand pin hole of circlip. If it is difficult yet to disas-semble the piston after doing that, use disassembingtool of piston pin.
4 — 6
ENGDisassembly of engine
Disassembling tool of piston pin:90890-01304
Left crankcase cover,starting motorDisconncct
Neutral light switch
Disassemble:
Left crankcase cover
Locating pin
Seal papper pad
Disassemble
Starting motor
1.:
2.
3.
Clutch, oil pump
1.Disassemble:
Kick starter device
2.
Disassemble:
Crankcase cover (right)
Seal papper pad
Locating pin
Note:Firstly loosen each bolt 1 /4 turn according to crosscurve order, then remove all bolts.
4 — 7
ENGDisassembly of engine
3.
:Disassemble
Bolt
Clutch spring
Pressing pan
Friction wafer
Clutch wafer
Pushing rod1
Steel ball
Note:Firstly loosen each bolt 1 /4 turn according to order ofopposite angle, then remove all bolts.
4.Flatten:
Smoothen the tongue of lock washer
5.
Loosen:
Nut
Note:When loosening nut ( convex seat of clutch ), fix theclutch hub with clutch jig.
Universal clutch jig:90890-04086
4 — 8
ENGDisassembly of engine
5.Disassemble:
Nut
Lock wacher
Clutch hub
Spline washer
Main driven gear
Washer
Elastic washer
6.
u
Disassemble:
Primary driving gear nt
Do not place cloth strip, aluminium plate and copperbar etc . between main driven gear and primary drivinggear ( see a ).Fix with sleeve at position of rotator fixing nut , thendisassemble primary driving gear nut .
Note:
4 — 9
ENGDisassembly of engine
7.
Disassemble:
Primary driving gear
Key
Engine oil filter
Engine oil pump
1.Disassemble
Bolt
Engine oil pump
Gasket
Driving gear of engine oil pump
Starting axle and idle gear
1.Disassemble:
Elastic circlip
Flat washer
Idle gear
Flat washer
Elastic circlip
2.Disassemble:
Resetting spring
Starting axle assy
4 — 10
ENGDisassembly of engine
Shift axle
1.Disassemble
Shift rod
Resetting spring
Bolt
Stop device
Rotator
1. :
Disassemble
Nut
Note:Fix the rotator with rotator jig, then loose nut.
90890-01701Rotator jig:
2.Disassemble:
Rotator
Half-round key
Note:Push the fly wheel backward with disassembling toolof fly wheel, then may disassemble the fly wheel .
Disassembling tool of fly wheel:
90890-01362
4 — 11
ENGDisassembly of engine
3.Disassemble:
Starting idle gear 1
4. :
Washer
Disassemble
Pressing plate of gear
Starthing idle gear2
5.
Disassemble:
Chain guide board
Timing chain
Crankcase ( right )
1.Disassemble:
Screw ( crankcase )
Note:Loosen the screw at position as shown in Fig (po-sition in circle ).Firstly loosen each screw 1 /4 turn , then removeall screw.If there is several bolts and nuts , generally loosenthem according to opposite angle order. Looseningorder : from outside to inside .
4 — 12
ENGDisassembly of engine
2.Disassemble:
Star-shape gear
Locating pin
Note:Disassemble the crankcase from right side.Disassemble the shift cam (star-shape gear ) .Be careful not to damage the matching surface ofcrankcase .
Balance device , transmission and shift rod
1.Disassemble:
Guide rod of shifting yoke ( short )
Guide rod of shifting yoke ( long )
Shifting yoke C
Shifting yoke R
Shifting yoke L
Shift cam
4 — 13
ENGDisassembly of engine
1.
Disassemble
Main axle
Inner pushing rod of clutch
2
Driving axle
Washer
Pushing rod of clutch
3. :Disassemble
Idle switch
Disassembly of crank and balance
1.Disassem :leb
Balance block
Crank
Disassemble with disassembling toolof crank .
90890-01135
Disassembling tool of crank:
Tighten up the supporting bolt of disassembling tool, but ensure the tool body vertical to crank. When cessary, screw a screw back ward a little to ca-librate the tool body state.Never beat the crank directly with hammer etc .
Note:
ne
4 — 14
ENGDisassembly of engine
Rocker arm and camshaft
1.
Disassemble:
Lock pressure plate
2.Disassemble :
Camshaft( with bearing
Note :Disassemble the camshaft with 8 mm bolt.
3.Disassemble:
Rocker shaft
Rocker arm
Note :Disassemble the rocker arm with sliding hammerbolt and weight block .
Sliding hammer bolt:
Weight block:90890-01083
90890-01084
4 — 15
ENGDisassembly of engine
Valve
Before disassembling the inner parts of cylinderhead (such as valve , valve spring and valve seat ) ,check the seal of valve firstly .
Note :
1. Check:
Seal part of valve
Leakage of valve seat→Checing working face of valv
Valve seat and width of valve
Refer to section of “Check and repair of valve seat”.
Checking procedures:
Inject the clean solventinto intake orifice
and exhaust orifice.
Check the seal of air valve.
.There should be no leakage at valve seat*********************************************
2.
Disassemble:
Lock piece of valve
Note:When disassembling valve lock piece, compressthe valve spring with tool.
Compressing tool of valve spring
90890-04019
4 — 16
ENGDisassembly of engine
3.Disassemble
Upper seat of air valve spring
Air valve spring
Air valve
Oil seal of air valve
Spring
Note:Mark postions of each part in order to refiting themto oringinal position.
4 — 17
ENGCheck and repair
Cylinder head
1.Clean
Carbon deposit
(Clean from burning chamber)
Use round-head scraper
Note:Do not use sharp tool for avoiding the damagementof the spark plug thread and air valve seat.
2. Check:
Cylinder head
Scratched marks damage→Replacement
3. Measure:
The tilt of cylinder
Check if there is skew at 6 directions of combinating
faces with cylinder.
Gradient
Less than 0.03mm
4.Repair the surface
Cylinder head
******************************** *********
Repairing procedure:
Place a wet sand paper about 400-600 on flatform, and
grind the surface according “8”toshape.
Note:Move the cylinder head several times to avoid toomuch wearing on one side.
******************************* ***********
ENGCheck and repair
Air valve seat
1.Clean:
Carbon deposit
(Clean from working face of air valve and air valve seat)
Check:
Air valve seat
Corrosive pitting or wear→Repair the air valve surface
2.
Measure:
Width of air valve seat a
3.
Exceeding specification both are usable value range
→Repairing air valve seat
Width of air valve seat:
Intake:
0.91.1 mm
Exhaust:
0.91.1 mm
******************************** *********
Meauring procedures:
1.
2.
3.
4.
5.
Paint blue dykem on working face b of air valve
Fit the air valve into cylinder cover.
Push and press the air valve to air valve seat through
guide pipe of air valve,thus to get clear trace.
Measure the width of this mark which is width of air
valve seat.No matter wherever the air valve seat contacts
working face of air valve,blue colour will never disappear.
If the air valve seat is too wide, too narrow or not in the
middle,it must be repaired.
******************************** *********
4 — 19
ENGCheck and repair
4. Grind:
Working face of air valve
Air valve seat
Note:After replacing air valve and guide pipe of air valve,grind the air valve seat and working face of air valve.
*****************************************
Grinding procedure
Paint rough abrasive sand on working face of air valve.
Note:Do not let the abrasive sand enter into slit betweenair valve rod and guide pipe of air valve.
Paint disulfide containing moly on surface of air valve
rod.
Fit the air valve into cylinder cover.
Rotate the air valve until the working face of air valve
and air valve seat polish evenly.Then wipe off all san-
ding agent.
Note:In order to get better grinding effect,when rotating theair valve forward and backward with hands,you maybeat the air valve lightly.
Paint fine sand agent on working face of air valve.
Then repeat above procedures.
Note:After each grinding,wipe off the sanding agent onworking face of air valve and air valve seat.
Measure the air valve seat width again.
If the air valve width exceeds specified value,
repair and grind air valve seat.
4 — 20
ENGCheck and repair
Air valve and guide pipe of air valve
1.Measure:
Clearance between air valve rod and guide pipe
Clearance between air valve and guide pipe=Inner diameter of air valve guide pipe air valve rod diameter
—
Exceeding specified value range→Replacing guide pipe of air valve
Clearance between air valve rod and guide pipe:Intake:
0.010.037 mm Limit valve:0.08 mmExhaust:
0.0250.052 mm Limit valve:0.10 mm
5.000~5.012mm5.000~5.012mm
5.042mm5.042mm
Standard innerdiameter Using limit
Note:After replacing guide pipe of air valve,repair the sur-face of air valve seat.
2. Clean:
Carbon deposit
(clean from working surface of air valve)
4 — 21
ENGCheck and repair
3.Check:
Working face of air valve
Corrosive pitting or wear→polishing the surface
Air valve rod end
Mushroom shape or diameter more than other part of air
valve rod→replacing
4. Measure:
Run-out tolerance (air valve rod)
Exceeding specified value range→Replacement
Run-out tolerance
Less than0.01 mm
Air valve spring
1.Measure:
Free length a (air valve spring)
Exceeding specified value range→Replacement
Free length of air vlave spring:
Standard: 32.28 mm
Limitation: 31.90 mm
4 — 22
ENGCheck and repair
2. Check:
Vertical angel degree of air valve spring
Side angle limitation a :
1.2 mm
3. Check:
Contacting face of air valve spring
Above2 / 3 of outer circle are not in horizontal conta-
cting state→Replacement
Camshaft
1. Convex part of cam
Corrosive pitting,scratch, blueing
→Replacement
Measure:
Convex part A and B of cam
Exceeding specified value range→Replacement
2.
A B
Length of convex part of convex part of cam
IntakeA Standard: 25.88125.981 mm
Limitation: 25.851 mmB Standard: 21.19521.295 mm
Limitation: 21.165mm
4 — 23
ENGCheck and repair
Length of convex part of cam:Exhaust:A Standard: 25.84125.941 mm
Limitation: 25.811 mmB Standard: 21.05021.150 mm
Limitation: 21.02 mm
3. Check:
Bearing
Jamming,swaying→Replacing
Rocker arm and rocker shaft
1. Check:
Contacting face of rocker arm and convex part of
cam
Adjusting device surface
Wearing, corrosive pitting, scratch, blueing
Replacement
Then check lubrication system
→
2. Measure:
Inner diameter of rocker arm a
Standard value of inner diameter of rocker arm:
10.00010.015 mmUsing limitation:
10.030 mm
Exceeding specification→Replacement
4 — 24
ENGCheck and repair
3. Measure:
Outer diameter b of rocker shaft
Outer diameter of rocker shaft:
Standard value:9.9819.991 mm
Limitation:9.95 mm
Timing chain,sprocket,guide plate of chainand chain tensioner1. Check:
Timing chain
Hardening or crack→Replace the whole set of timing
chain and chain wheel
2.Check:
Sprocket
Hardening or crack→Replacing the whole set of timing
1 / 4
chain and sprocket
tooth
Correct assembly
Roller
Sprocket
3.Check:
Guide plateof chain(exhaust side)
Guide plateof chain(intake side)
Wearing or damage→Replacement
4 — 25
ENGCheck and repair
4.Check:
Free movement of timing chain tensiener
.
Press the tensioning device lightly with finger,and screw
the tensioning device rod to dead with small screwdriver
When pressing screwdriver lightly with finger to loosen
the screwdriver, confirm that the tensioning device
come out smoothly.
Otherwise, replace the tensioning device assy.
Checking procedure:
Cylinder and piston1.
2.
3.
4.
Clean:
Carbon deposit(from top of piston and ring groove)Check:
Side wall of pistonWearing,scratch,damage→ReplacementCheck:
Cylinder wallWaring or scratch→Reboring cylinder or replacing
Measure:Clearance between piston and cylinder
gauge at D3D4position (40 mm to cylinder top)
Measure cylinder diameter and “C ”with cylinder Measuring procedure:
Note:Measure cylinder diameter «C» from parallel and ver-tical direction to crank.Then caculate the average value.
Standard valve of cylinder inner diameter:
54.024 54.056 mm
Exceeding standard range→Replacement
4 — 26
ENGChe ck and repair
Piston measurement
1. Measure:Measure diameter of skirt section of piston with micr-ometer at the point 5mm to bottom edge of piston.
Outer diameter standard of piston:
53.997 54.029 mm
Clearance between piston and cylinder
Inner dia-meter ofcylinder
Outer dia-meter ofpiston = Clearance
Exceeding specified value→Replacement
Piston pin
1.Check:
Piston pin
Blueing or becoming groove→Replacing, then checking
lubrication system.
2.Measure:
Outer diameter a of piston pin
Exceeding specified value range→Replacing
Outer diameter of piston pin:
14.991 15.000 mm
Limitation:14.969 mm
4 — 27
ENGCheck and repair
3.Measure:
Inner diameter of piston pin hole b
Exceeding limitation→Replacement
2.Measure:
Push the piston ring a into cylinder(at point 5mm to top
Inner diameter of piston pin hole:
15.002 15.013 mm
Using limitation:
15.043 mm
Piston ring
1. Measure:
Side clearance
Exceeding specified value range→Replacing the whole
set of piston and piston ring.
Note:Before measuring side clearance,get rid of carbondeposit in piston ring groove and each ring.
Side clearance:
1 ring:0.030.07 mm
Using limitation:0.12 mm
2 ring:0.02 0.06 mm
Using limitation:0.12 mm
Note:Eject and push piston ring with piston to make thering vertical to cylinder surrounding.
4 — 28
ENGCheck and repair
3.Measure:
End clearance
Note:When measuring the oil ring end clearance,do notmeasure at parting slip of cup ring of oil ring.Only canmeasure the end clearance of upper and lower guardrails. If the clearance is too large, replace all the
rings.three
End clearance:
1st ring:0.15 0.30 mm
Using limitation:0.4 mm
2nd ring:0.30 0.45 mm
Using limitation:0.55 mm
Oil ring:0.2~0.7mm
3.Me asure:En d clearance
Cra nkshaft1.Che ck:Ru nout toler ance of cr ank
2.Ch eck: Sid e clearanc e of big en d
E xceeding limitation Replac ementЎъ
End c learance :1stri ng:0.15 Ў« 0.30 mmUsing limitatio n:0.4 mm2ndr ing:0.30 Ў«0.45 m mUsing limitatio n:0.55 m mOilrin g:0.2~0. 7mm
R unout tole rance lim itation of crank:0.03 m m
4 29-
E xceeding l imitation Replacem entЎъ
Not e:Whe n measur ing the oi l ring end clearance ,do notmea sure at par ting slip of cup ring o f oil ring.O nly canmea sure the e nd clearan ce of uppe r and lowe r guardrails . If the cl earance i s too larg e, replace all the rings.thre e
Not e:Rota te the cra nkshaft gr adually to measure
Stan dard side clearan ce: 0.15 Ў«0 .45 mmUsin g limitati on: 0.8 mm
Ch eck an d repai rEN G
Crankshaft1.Check:
Runout tolerance of crank
Runout tolerance limitation of crank:0.03 mm
Exceeding limitation→Replacement
Note:Rotate the crankshaft gradually to measure
2.Check:
Side clearance of big end
Standard side clearance:
0.15 0.45 mm
Using limitation:
0.8 mm
Exceeding limitation→Replacement
4 — 29
ENGCheck and repair
3.Measure:
Crankshaft width(measure with square calliper)
Standard width:
46.95 47.00 mm
Exceeding standard→Replacement
4.Check:
Sprocket of crankshaft
Damage,wearing →Replacing crankshaft
5.Check:
Oil way of crankshaft
Jamming→Clean by compressing a
Bearing
Abnormal noise,unstable rotation,loosening→
Replacing
ir
4 — 30
ENGCheck and repair
Balance device
1.Check:
Driving gear of crankshaft
Driven gear of balancer
Wearing,damage →Replacement
2. Check:
Balancer
Wearing,damage→Replacement
Clutch
1.Check:
Driving gear of spindle
Driven gear of spindle
Wear or damage→Replacing two gears
Loud noise while running→Replacing two gears
2.Check:
Friction wafer
Damage or wear→Replacing the whole set of friction
wafer
4 — 31
ENGCheck and repair
3. Measure:Thickness of friction waferExceeding specified value range→Replacing the wholeset of friction wafer.Measuring at four points of upside,lowside,leftside,and rightside.
Thickness of friction wafer:
3.0 mm
Using limitation: 2.8 mm
4.Check:
Clutch wafer
Damage→Replacing the whole set of clutch w
5.
afer
Measure:
Buckling of clutch wafer
Exceeding specified value range→Replacing the whole
set of clutch wafer
Should use flat plate and thickness gauge
3 . Measure: Thickness of frictio n wafer Exceeding specified value rang eRepla cing the w set of fric tion wafer. Measuring at four po ints of up lowside,le ftside,and rightside. Ўъ
4 .Ўъ5 .
Check: Clutch wa fer Damage Replacin g the who le set of cl utch waferMeasure: Buckling of clutch w afer Exceeding specified value ran geRepla cing the w of clut ch wafer Should us e flat plat e and thick ness gaug eЎъset ўЩ
6 . Check:The lengt h of clutch spring a Damage Replacin g the who le set of sp ringЎъ Fric tion limit ation va lueЈє Less th an 0.05 mm
4 32-
Thickne ss of fric tion waf er:3.0 m mUsing limitatio n: 2.8 mm
Sp ring leng th of clu tch 33.0 m mLim itation: 31.0 mm
Check and re pair ENG
Friction limitation value
Less than 0.05 mm
6.Check:
The length of clutch spring a
Damage→Replacing the whole set of spring
Spring length of clutch33.0 mm
Limitation: 31.0 mm
4 — 32
ENGCheck and repair
7.Check:
Retainer of main&driven gear
Scratch,wear,damage→Deburring of replacing
Clutch hub
Scratch,wear,damage→Replacing clutch hub
8.
1
Check:
Steel ball
Pushing rod
Pressing plate
Wear,damage→Replacement
Transmission and shift rod
1.Check:
Driven part of shifting yoke cam
Shifting yoke jaw
Scratch,bending,damage→Replacement
4 — 33
ENGCheck and repair
Warning
2.Check:
Shift cam groove
Wear or damage→Replacement
3.Check:
Guide rod of shifting yoke(short on left, long on right
Shift cam
Deformation, scratch, wear, damage→Replacement
)
4.Check:
Action of shifting yoke
Uneasy action→Replacing shifing yoke or guide rod
Do not try to align the bending guide rod.
4 — 34
ENGCheck and repair
5.Measure:
Run-out tolerance (driving axle and main axle)
Exceeding specified value range→Replacement
Warning
Do not try to align bending axle
6.Check:
Gear teeth of gear
Blueing,corrosive pitting, wear→Replacing
matching gear
Rounding of edge, fracture, dislocation→Replacement
7.Check:
Shift axle
Damage, bending, wear→Replacement
Torsion spring(retainer lever)
Reset spring(reset axle)
Damage→Replacement
4 — 35
ENGCheck and repair
Kick starter
1.
T
Check:
Teeth of kick starter gear
eeth of kick starter over-gear
Damage or wear→Replacing two gear by pa
2.
ir
Measure:
Tension of work carrier of kick starter
Exceeding specified value range→replace to
Use spring balance
Tension of work carrier of kick starter
0.81.2 kgK ick sta rter1 . T Ўъ
2 .
Check: Teeth of k ick starte r geareethofk ick starter over-gea rDamageo r wearR eplacing two gear b y pair
Measure: Tension o f work ca rrier of kic k starterExceedin g specified value ran gerepla ce to Use sprin g balance
ўЩ ўЪ
ЎъўЩ
E ngine o il pump and oil filter1 . a ,
Measure Gear tip c learanceA (Between inner rota tornd o uter rotat or)Side clear ance B (Between outer rota torand p ump case )Exceeding specified value rang eRepla cing oil pu Clearance C of oute r & inner rotator and pump ca(Thickness differenc e of inner & outer ro tator pump cas e)
ўЩ ўЪўЪ ўЫЎъ ўЩўЪўЫ
Tension of work c arrier of kick starte0.8Ў«1 .2 kg
4 36-
G ear tip c learanceA : 0.15 m mS ide B: 0. 06 Ў«0.10 mmThicknes s differen ce C:0.06 Ў«0.10 m
Check and re pair ENG
Engine oil pump and oil filter
1.Measure
Gear tip clearanceA
(Between inner rotatorand outer rotator)
Side clearance B
(Between outer rotatorand pump case)
Exceeding specified value range→Replacing oil pump
Clearance C of outer & inner rotator and pump case
(Thickness difference of inner & outer rotator , and
pump case)
Gear tip clearanceA: 0.15 mm
Side B: 0.06 0.10 mm
Thickness difference C:0.06 0.10 mm
4 — 36
ENGCheck and repair
2.Check:
Centrifugal eigine oil filter
→
→
Crazine, damage Replacement
Dirty Washing
3.Check
Engine oil filter net
Crazine, damage ReplacementDirty Washing
→→
Crankcase
1.
2.
3.
Rinse the combinating face of the crankcase thoroughly
with a little warm solvent.
Wash all matching surface of gasket and crankcase th-
oroughly.
Check:
Crankcase
Crack or damage Replacement
Oil hole
Jamming Blowing with compressed air
→
→
4-37
Check and repair ENG
Bearing and oil seal
1.
→
Check:
Bearing
Wash and lubricate it, then rotate the inner ring with fi-
nger.
Uneven Replacement
Note:Do not dry it by making the bearing rotating by itselfthrough blowing in compressed air.Otherwise willcause damage of bearing surface.
2. Check:
Oil seal
Damage or wear Replacement→
Elastic circlip and washer
1.Check:
Elastic circlip
Washer
Damage, loosening, bending Replacement→
4-38
Assembling and adjustment of engine ENG
Assembly and adjustrment of engine
Air valve rod(intake) 13 O-ring Air valve,swaying arm and cam axle
Lock piece of air valve
Upper seat of air valve spring
Oil seal of air valve rod
Air valve spring
Air valve spring seat
Air valve spring rod(exhaust)
Lock nut 14 Guide pi
4-39
Adujstin
S
g bolt
waying arm
Swaying arm pin(intake11 )
Swaying arm pin(exhaust)12
15 Cam a
16 Pressing p
pe of air valve
xle
late
NEW
NEW
Assembling and adjustment of engine ENG
Assembly of engine and adjustment ofair valve1.Deburr
End of air valve rod
Polish the end of air valve rod with oil stone
2.Paint:
Molybdenum disulfide lubrication oil
(Painting on air valve rod and oil seal of air valve)
4-stroke engine oil
(Painting on air valve rod top)
3. Assembly:
Spring seat of air valve
Oil seal of air valve
Air valve
Air valve spring
Upper seat of air valve
Note:Make the side of large pitch a upward,and mountthe air valve spring b small pitch.
4-40
Assembling and adjustment of engine ENG
4.Mount:
Lock piece of air valve
Note:When mounting the air valve lock piece,compress thespring with compressing tool of air valve spring.
Compressing tool of air valve spring:
90890-04019
5.Beat lock piece of air valve lightly with soft hammer to fix it on air valve rod.
Note:Do not boat it forcedly to advoid damaging the air valve.
Rocker arm and camshaft
1
2.
.Lubricate:Molybdenum disulfide lubricating oil(Painting on the confacting face of rocker arm hole andcamshaft )4-Stroke engine oil(Painting to rocker shaft and O-ring)Mount:Rocker armRocker shaft Aim at screw hole of cylinder head to mount,until the rocker arm can not be seen.
Note:Be sure to make the mouth part of screw outward tomount.
4-41
Assembling and adjustment of engine ENG
3.Mount:
Camshaft
4.Mount:
Pressing plate
Bolt
4-42
Assembling and adjustment of engine ENG
Crank and balance device
Crank bearing Crank pin
Semi-round keyCrank(left)
Connecting rod Balancer
Balancer bearing
Roller bearing of end side
4-43
Mount of crank and balance axle
1.Mount:
Crank
Shielding hood of crank assembly:90890-04081
Sleeve of crank assembly90890-01274
Bolt of crank assembly90890-01275
Template pipe joint90890-01378
Assembling and adjustment of engine ENG
Note:Keep the connecting rod on dead piont. When mounting, never contact crankcase.Never use hammer to beat crank.
2.Mount:
Balance axle
aim the engraving mark a of driving gear of crank at
engraving mark b balance axle gear, then mount them.
4-44
Assembling and adjustment of engine ENG
Transmission assembly
161718
Main axleCirclipBearing
Driving chain wheel
Oil seal
Bearing
Driving gear- 5gear
Driving axle
Driving gear-
Driving gear-
Driving gear-
Driving gear-
Bearing
2
3
4
1
11
12 13
14 15
Bearing
Drive gear-5gearDrive gear-2gear
Drive gear-3gearDrive gear-4gear
4-45
Assembling and adjustment of engine ENG
Shiftcam,shifting yoke
Guide rod of shifoing yoke(long)1
Shifting yoke 3
Shifting yoke 1
Cam
Star-shape gear
Guide,rod 2 of shifing yoke(short)
4-46
Assembling and adjustment of engine ENG
Installation of thransmission,change cam andchange fork
1.
Installation:
Clutch push rod 2
2.Installation:Main shaft
Note:Before installing the main shaft, first installing the
push rod in the clutch into the inner hole of main sh-aft,then installing it.
4. Installation:
O-ring
Garket
O-ring.
Drive shaft
Install the O-ring into the installing groove of firm
bracket of sprocket of drive shaft,(avoid damage of oil
sealing lip)after installing the drive shaft,take out the
4-47
3. Inspection:
Installing width of main shaft gear a
Standard installing width of main width82.25~83.45 mm
Assembling and adjustment of engine ENG
5.
Installation
Change cam
(The convex point on the change cam should alig
Change fork“R”
(The surface signed with “R” is toward clu
2
1
n the
contact point in the neutral switch of crankcase)
L
(The surface signed “L” is toward clutch)
“ ”Change cam
tch)
Change fork“C”
(The surface signed with “C ” is toward clutch)
Change fork guide rod
Change fork guide rod
6.Inspection:
Operation of change cam
The operation of change cam
→The operation is unsmooth reinstall
Turn the change cam cam with hand to make surethat the driving and fork is smooth in operation.
Note:
4-48
Fastening order
1.
2.
3.
4.
5.
Left crankcase
Dowel pin
Airflow pipe
Right crankcase
Clutch fastening clip
Assembling and adjustment of engine ENG
Yamaha bonder No.1215
4-49
Crankcase(Right)
1. Application
Seal gum(Apply to the linking surface of left and right crankcase)
2.
3.
Installation:
Dowel pinInstallation
Install the right crankcase to the left crankcase
6.
7.
→
Application
Engine oil of 4 stroke engine(Apply to the crankshaft pin,bearing and crankshaft holeInspection:Action of crankshaft and transmission.The action is not smooth repair
5.Fastening:
Screw(crank case)
Seal gum(Yamaha bonder No.1215)90890-85505
Note:Never allow any seal gum to enter into the lubricati-on oil hole
Note:Before installing and fastening the fastening screws of cranrcase, be sure to turn the shift cam with hand to check if the transmission functions normally.
Note:From the screw marked with the Minnumber, tightenup the screws orderly.
·
Assembling and adjustment of engine ENG
4-50
Assembling and adjustment of engine ENG
Shift shafl,pedal spindle and pedal idle speed gear
Shift shaft
RetainerReset spring
Tortion springStar wheel
Start shaft assy
11
Circlip
WasherIdler pulley
WasherCirclip
4-51
Assembling and adjustment of engine ENG
Shiftcam
1.Installation:
Dowel pin
2. Installation
Star wheel
Note:When installing the star wheel ,pay attention to installthe pin hole on the star wheel and the pin hole a on the cam correctly.
3.Installation:
Retainer
Spring
Bolt (Retainer)1.0kgf.m (10Nm)
Note:The retainer and the shift start wheel should be eng-aged each other.
4. :Installation
Shift shaft
Note:When installing the shift shaft,be sure to jam thetortion spring on the dowel pin .
4-52
Assembling and adjustment of engine ENG
Pedal shaft and pedal idle speed gear
1.Installation :
Drive shaft
H oop
Sprin g
N:oteThe projecting part should be installed on the a po-sition of crankcase,and the fastening of spring should be down only after it turns 1turn.
2. Installation:
Circlip
Washer
Idler pulley
Washer
Circlip
4-53
19Paper pad of oil
1Push platePush rod Friction linerClutch plate
SpringPress plate
Clutch hubRetaining washerMain driven gearSteel ballPush rodPush rod assy
1112
131415 161718
Drive gearOil filterDowel pinDrive gear of oil pumpDrive gear of oil pumpOil pump case
Clutch,oil pump
Assembling and adjustment of engine ENG
4 54-
Assembling and adjustment of engine ENG
Oil pump
1.supplement of oil
4-stroke engine oil
(supply to the oil hole in the crankcase and oil hole in
the oil pump)
2.Installation:
Oil pump
Oil filter
1. Installation:
Drive gear of oil pump
Centrifugal filter
Note:Install the dowel pin a of centrifugal filter into theretainning groove of crankshaft b .
Main drive gear
1.Installation
Main drive gear
Dowel pin
Washer
Nut
Note:When locking the nut, in order to avoid the rotation ofcrankcase, the rotor must be fixed. No articles suchas alumium sheet, cloth strip of copper sheet betweengears.They prevents the crankshaft from rotating.
4-55
Assembling and adjustment of engine ENG
Clutch
1.
2.
gasket
Installation:Main driven gearRetaining washerClutch hubRetaining NutInstallation:Nut
Note:Fasten the clutch hub with clutch fixture ,lock thenut and bend the retaining gasket .
Clutch fixtrue90890-04086
Nut torque(60N.m)6.0kgf
3.
pieces
Installation:
Friction linertotal of 4
Clutch plate total of 3 pieces
Note:Apply the engine oil of 4 stroke engine on each plate of clutch,then install it.Install the clutch plate and friction liner alternativelyto the clutch hub, starting from friction liner and ending with friction liner.
4-56
Assembling and adjustment of engine ENG
4. Installation
Steel ball
5.
InstallationPush rod 1
Push plateWasher
Nut
6.Installation:
te Press pla
Spring
Screw
Screw installing torque0.6 kgf.m (6 N.m)
Note:Tighten up the bolts orderly according to the diago-nal order.
4-57
7.
→
Confirmation
The aligning identification of push rod assy and crank-
case
Turn the push rod assy counterclockwise to the end,
make sure the projecting part of push rod a is identified
with the aligning identification (convex part) b
If not identified adjust
8. :
After adjusting lock the nut
AdjustmentAligning identification of push rod 3 and crankcaseUnlock the nut , turn the push rod counter clockwiseto the end.
Turn the push rod 1 left and right,until a aligns withb
9.Installation
Paper gasket (new product)
Left crankcase cover
10.Installation:
Kick start rod
Nut fastening torque
0.8kgf.m ( 8 N.m )
Crankcase cover installing torque1.0kgf.m ( 10N.m )
Installing torque of kick start rod5.0kgf.m ( 50 N.m )
Assembling and adjustment of engine ENG
4-58
2
1
Timing chain
Guide plate of chainLocating shaft
Idle start gear Press plateWasherStarting gear 2
1112
Woodruff key
RotorStatorPaper gasketDowel pin
13Left crankcase cover
4-59
Assembling and adjustment of engine ENG
.
Rag, scrap, unsmoothness, abrasion→replace
→
*****************************************
1
2.
InspectionCheck the gear conditions of start gear 1 and 2( a b c )
InspectionStart gear 2(linking surface )Corrosive pitting, abrasion, damage replace
Install the starter gear to the clutch of starterand grip theclutch.When turn the starter gear clockwise A ,the starter cl-utch should be engaged with its gear. Otherwise, itindicates that there is some trouble with thestarterclutch and it should be replaced.When turn the starter gear counter clockwise B ,theclutch gear of starter should turn freely. Othewise itndicatesthat there is some throuble with starter clutch
and it should be replaced.
Inspection procedures:
i
*********************************************
Assembling and adjustment of engine ENG
Installation:Timing chainChain guide plate
Installation:Starting the idler pulley Pressure plate
1.
2.
Installing torque:1.0Kgf.m ( 10N.m )
The guide plate can be installed only after the timingchain has been installed.
Installing torque0.7Kgf.m ( 7N.m )
Note:
Rotor and stat mechanismr
Chain guide plate and idler pulley
Apply:Engine oil of 4 stroke(Apply the shaft neck and starter drive mechanism )
3.
4-60
Assembling and adjustment of engine ENG
4
5
.Installation:WasherStarting gear
.Installation:WoodruffRotor
Note:Before installing clean off the foreign matter and dirton the rotor.
6 .Locking:Nut
Fastening torque7.0Kgf.m(70N.m)
Note:Fasten the rotor with slide retaining tool , lockthe rotor with a nut with washer.
Slide retaining tool:90890-01701
7.Installation:Dowel pinPaper gasket(new product)Left crankcase cover
Fastening torque of crankcase cover:1.0Kgf.m(10N.m)
Note:The left crankcase can be installed only after the lo-cking nut of main drive gear of right crankcase has been installed.
4-61
Piston and piston ring
Note:
1.Installation of piston ringOily plateOil scraping plate2nd ring1st ring
When installing the 1st ring and 2nd ring,pay atte-ntion to the upper and lower directions.The surfacewith sign should be assemblied upward.When installing the ring ,first installing the lower oilscraping plate,then install the oily plate ,finallyinstall scraping plate .After assembling, make sure that the piston ringscan turn smoothly between each other.There should be a 120 angle difference for theinterfaces between the rings,the splits of upper andlower oil scraping plate of oil ring should straggerabout 20mm on the left and right sides of oily platesplit.
The arrow mark a on the piston should be tow-ard the front side of engine.Before installing the piston pin hoop,cover the cra-nkcase with clean towel or cloth so as to prevent thepiston pin hoop or other articles falling into the cr-ankcase.
2.I
3.
nstallation:PistonPiston pinPiston pin hoop
Installation:Dowel pinPaper pad
Note:
NEW
NEW
Assembling and adjustment of engine ENG
4-62
Assembling and adjustment of engine ENG
Cylinder and piston
CylinderO-ringPaper padDowel pinPiston ringPiston pin hoop
PistonPiston pin
4-63
Assembling and adjustment of engine ENG
Cylinder head
BoltCopper washer Inner hexagonal boltValve cover(Intake)O-ringValve cover(Exhaust)
Cylinder headDowel pinSteel padO-ringSide cover of cylinder headSpark plug
1112
4-64
Assembling and adjustment of engine ENG
Paper padTensionerChain guide plate(intake)Timing sprocketTiming chainChain guide plate(exhaust)
Cam shaft and locating key
4 65-
Chapter 5 Disassembling of carburetor
General drawing of carburetor ………………………………………………………………………………
Removal of carburetor ………………………………………………………………………………………
Adjustment of fuel level ……………………………………………………………………………………
5 — 1
5 — 2
5 — 5
CARB 5
Adjusting screw of throttle cable
Rubber sleeve Throttle cable guide pipeRubber washerTop cover capCirclipRubber washerPlunger springNeedle pressure plate
Carburetor
11 12 13 14 1516 17 18
CirclipNeedle washerNeedlePlungerCarburetor
SpringWasherRubber pad
Idle speed adjusting screw
19 20 21 22 23 24 25 26 27
Start spannerWave washerScrewRubber capGuide seatStarting plugerSpring plateFirm plateO-ring
28 29 30 31 32 33 34 35 36
Rubber pad WasherSpringPs adjusting screwIdling fuelNeedle valve jetMain jetO-ring Needle valve seat
37 38 39 40 41 42 43 44 45
Needle valveFirm clipBoltFloatFloat pinGasketFloat coverBoltSpring
46 O-ring
5
5-1
CARB 5Carburetor
1.Removal
Throttle cable
Caburetor
Disassembly
1. Loosen
Oil drain screw
2.
Removal
Plunger
3. Removal:
Starting wrench
Starting plunger
4. Removal
Float chamer
5-2
CARB 5Carburetor
5.Rmoval:
Float pin
Float
Needle valve
Needle valve seat
6. Removal:
Main jet
Needle valve jet
O-ring
7. Removal:
Idling fuel jet
8. Removal:
P.S adjusting screw
Inspection
1. Inspection
Mixing chamber case of carburetor
If polluted clean→
5-3
CARB 5Carburetor
3.Inspection:
Float
If damaged replace→
4. Inspection:
Needle valve
Needle valve seat O-ring
If worn or damaged replace→
Note:The needle valve and its needle valve seat should be replaced as a complete set.
5.
Inspection:
Main nozzle
1
2
3
4
Main jet
O-ring
Idling fuel jet
If polluted clean→
Note:Blow the jets with compressed air.
5-4
CARB 5Carburetor
Assembly
Conduct according to the reverse procedures of removal.
Note:Before reassembly, clean all parts with clean gas-oline.
Adjustement of fuel level
1. Measurement:
Fuel level a
Over the specification value adjust→
Measurement and adjustment procedures of fuel level
Rest the motorcycle on the flat ground and make sure
that the carburetor is in vertical condition.
Connect the fuel level dipstickwith oil drain pipe.
5-5
Fuel level a :6.67.6 mm
The fuel level should be at the middlepostion of the float chamber on the lower
side of the carburetor case edge.
Fule level dipstick
90890-01312
CARB 5Carburetor
Loosen the oil drain screw , run the engine for se-
veral minutes to raise the temperature.Keep the fuel level dipstick in vertical condition and
make it approach to the engrave line of float chamber.Measure the fuel level with fuel level dipstick.
Note:The records of the fuel level dipsiticks of the pipes on two sides of the carburetor should be equal.
If the fuel level is not correct,adjust it:
Remove the carburetor
Check the valve seat and needle valve
If they are all in good condition,adjust the fuel level by
bending the rear part of the float slightly.
Install the carburetor.
Check fuel level again.
5-6
Chapter 6 Chassis
Inspection of front and rear wheels …………………………………………………………………………
Front wheel
Inspection of front wheel
Speedometer gear assy
Front brake
Installation of front wheel
Rear wheel
Rear brake hub
Drive chain , sprocket
Drive chain
Inspection of drive chain
Inspection of clutch hub
Installation of drive chain
Removal of front fork
Inspection of front fork
Front fork assembly
Steering shaft and handle
Removal of handle
Inspection of handle
Inspection of front steering shaft
Install ing of steering shaft
Installation of handle bar
Rear shock absorbor and rear arm
Removal
Inspection
Front fork
……………………………………………………………………………………………………
……………………………………………………………………………………
………………………………………………………………………………………
……………………………………………………………………………………………………
……………………………………………………………………………………
……………………………………………………………………………………………………
…………………………………………………………………………………………………
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6-1
6-1
6-4
6-5
6-6
6-9
6-10
6-13
6-15
6-15
6-17
6-17
6-18
6-19
6-22
6-23
6-27
6-28
6-29
6-30
6-30
6-31
6-32
6-33
6-33
CHASInspection of front and rear wheels
Front wheelSelf-locking nut
Meter gear assy
Front wheel axle
Bushing
Front brake assy
Bushing
Front wheel
1
2
3 4
5
6
7 4,55Kgf.m (45,5 N.m)6- 1
6
Fron t wheelўЩSelf -locking nutўЪMet er gear assyўЫFron t wheel axle ўЬBush ingўЭFron t brake assyўЮBush ingўЯFron t wheel
12
3 4
5
6
7 4,55Kg f.m(45,5 N .m)6-1
6
Fro nt whee lўЩSe lf-locking n utўЪM eter gear ass yўЫFr ont wheel a xle ўЬBu shingўЭFr ont brake as syўЮBu shingўЯFr ont wheel
1
2
3
4
5
6
7
4,55 Kgf.m(45,5 N.m)
6
6-1
CHASInspection of front and rear wheels
Front wheelBrake padWasherMeter clutchMeter drive gearBrake armIndicatorCam axle
BushingWasherMeter driven gear
O-ringOil seal
11 12
1
23
4
5
67
89
10
1112
1,0Kgf.m(10 N.m)
6
6-2
CHASInspection of front and rear wheels
Removal
Warning1.Rest the motorcycle on the flat ground.2.Place the motorcycle on its central stand.3.Place the proper articles under the frame or eng
ine to lift the front wheel.-
2
1
2
1
Front brake
1 .emoval:
Front brake cable
R
Note:Before taking out the cable, release the brake.
Note:The clip should be taken out first.
3.Removal
Self-Locking nut
6-3
CHASInspection of front and rear wheels
Warning
Warning
4.Removal
Front wheel axle
Front brake assy
Bushin
Front wheel
g
Inspection of front wheel1.
F
Inspection
ront wheel axle(inspect with pencertage meter)
If bent→replace
Never attempt to straighten the bent front wheel axle.
The twist limit of front axle:0.25mm
2.Inspection
Wheel
If deformed,damaged of bent→replace
Never attempt to repair the wheel by yourself even the small repair.
3. Inspection and fastening of spoke
1.
2.
Inspection
Spoke
If bent and damaged→change
If the spoke is slack→tighten up
Fastening
Spoke
Note:After repairing ,be sure to adjust the slackness of the spoke evenly.
6-4
CHASInspection of front and rear wheels
4.
ver
Inspection
Turn the wheel rim slowly to inspect the radial and ax-
ial runout.
O of limit →replace
Rim runout limit
Radial: 1mm
Axial: 0.5mm
5.
windageunsmooth
Inspection
Wheel bearing
If the bearing inside the hub has
rotation, slackness, abnormal sound→replace
Oil seal
If worn or damaged→replace
Speedometer gear assy
1.
Removal
Cable head of speedometer
Driven chain of meter
The speedometer cable should be free from bending.
Meter clutch
1.Inspection
Meter clutch
If deformed/ damaged→ replace
6-5
CHASInspection of front and rear wheels
Drive chain of meter
Driven chain of meter
1.Inspection
Friction liner surface of brake pad
Smooth area→polish
Polish with rough sand
Front brake
Note:
After polish with sand,clean off the grainsof polishing
material.
2.
O
MeasurementFriction liner thickness of brake pad
ut of specification→replace
The friction liner thickness of brake a
Thickness a : 4mm
Limit: 2mm
Note:If any brake pad is found to be worn to the wear
limit ,replace the complete sets of brake shoes.
3.Measurement
Inner diameter of brake drum a
Out of specification→replace
Inner diameter of brake drum
Stardard value: 130mm
limit valve: 131mm
6-6
CHASInspection of front and rear wheels
Warning
4. :Inspection
There is oil stain or scraping mark on the inner surface
of brake drum→changeand repair
Oil stain
Wipe with a cloth dipped in the paint diluent or solvent.
Scrape
Polish slightly and evenly with a emery cloth
5. Inspection
Cam axle
Damaged→replace
When installing the cam axle and the central shaft,
apply a small amount of lubrication grease and clean
off the surplus lubrication grease.
1.
***********
.
*****************
y
Installation
Cam axle
Indicator
Let the convex part on the indicator a pass throughthe
concave groove on the cam axle b and install it well.
Align the indicating needle with wear indicator
Assembl
Procedures of installation
**********************************
****************************
2.
Installtion
Brake arm
:
1,0Kgf.m(10 N .m)
Installing bolt
6-7
CHASInspection of front and rear wheels
3.
Pad
Installation
Brake
Spring
NEW
Note :When installing , never use the pliers to deform or damage the hook of spring.Never apply the ludrication grease onthe friction liner of brake pad.
4.
t
Installation
Driven gear of meer
Installing meter cable
Speedometer cable head
5. Installation
Brake assy
.
Note:The convex part on the inner side of the gear assy
should be engaged with various surfaces each
other, the concex part of hub a should be jammed
into the clutch b
6-8
CHASInspection of front and rear wheels
Installation of front wheelInstallation
Front brake cable
Meter cable
Nut ( front wheel axle )
1.
Installation
Front wheel
2.
Note :The convex seat on the front fork should be engaged
with the locating slot of the brake padplate correctly.
Cable
The action of brake
If the action is not smooth→repair
3.
pad
3.5~5.6kgfm(35-56N.m)
Nut torsgue:
Installation
Meter cable
Clip
When installing the meter cable, don t bend it
4.
.
6-9
CHAS
S
Adjusting nut Driven chain gearPin Rear wheelSpring Rear brake assy
plit pin Shock absorberTension rod Oil sealSelf-locking nut BushingChain adjuster assy Bearing
Rear wheel
Inspection of front and rear wheels
1112
1413
NEW
6-10
CHASInspection of front and rear wheels
Rear wheelBrake shoe
Brake arm
Indicator
Cam axle
6-11
CHASInspection of front and rear wheels
Rear wheel
WarningRest the motorcycle firmly so as to avoid it turn over.
1
2
3 4
5
6
7 4,55Kgf.m (45,5 N.m)6- 1
6
Fron t wheelўЩSelf -locking nutўЪMet er gear assyўЫFron t wheel axle ўЬBush ingўЭFron t brake assyўЮBush ingўЯFron t wheel
2.Removal
Adjusting nut
Tension rod
Nut
Spring
Brake pull rod
Rear wheel nut
6
3.Removal
Rear wheel axle
bushing
Note:When removing the rear wheel axle,the bushing willfall down. Be careful not to lose it.
4.Removal
Rear wheel
Rear brake
Note:When removing the rear wheel axle,the clutch hub will fall down. Be careful of safety.
6-12
CHASInspection of front and rear wheels
5. Removal
Shock block
If damaged,deformed→replace
Rear brake hub
1. Inspection
Inner surface of brake drum
Oil stain or scrape→repair
Oil stain: Wipe a cloth dipped in the paint diluent or
solvent.
Scrape:Poslish slightly and evenly with a emery cloth.
Brake hub inner diameterStandard value:130mm
Limit value:131mm
2. Measurement
Brake hub inner diameter a
Out of specification replace→
6-13
CHASInspection of front and rear wheels
3.Installation
Rear wheel
Note:The convex part of clutch hub should be inserted intothe groove of the shock block.
4. Installation
Rear wheel axle
1
2
3 4
5
6
7 4,55Kgf.m (45,5 N.m)6- 1
6
Fron t wheelўЩSelf -locking nutўЪMet er gear assyўЫFron t wheel axle ўЬBush ingўЭFron t brake assyўЮBush ingўЯFron t wheel
Fastening rorque of rear wheel axle
9,1 Kgf.m(91 N.m)
6-14
CHASDrive chain and sprocket
Rear drive chain
Small sprocket(drive)
Chain press plate
Connector of chain
Chain (drive chain)
Big sprocket(driven)
Adjuster assy
Circlip
Retaining press plate
Sprocket cover1
6-15
CHASDrive chain and sprocket
1.Rest the motorcycle on the central stand.
Removal
WarningRest the motorcycle firmly to avoid turnover.
2.1
RemovalSprocket cover
3.RemovalDrive sprocket
4.RemovalChain joint clipPress plate of chainChainDriven chain
Inspection of drive chain1.Inspection
Drive chain jamIf jammed→Lubricate after cleaning or replace
2.
1/2
InspectionDrive chainDrive chainAs shown on the fig,the clearance after extruding right cannot exceed gear,If out →replace.
6-16
CHASDrive chain and sprocket
3.Measurement
The length of 10 links a (drive chain)Out of specification→replace
Length limit of 10 links
119.5mm
Note:Measure after pulling the chain with fingers As shown on the fig,measure the length of 10 links within the range from link roller to the inner sideof the roller Measure the length of 10 links at diffrient parts for 2~3 times.
11
5.CleaningClean with neutral detergent.After cleaning apply a plenty of chain lubrication oil ofSAE10 w-30w YAMAHA 4-stroke engine oil.
WarningNever clean with the volatile matters such as steam,gasoline,solvent,etc.
Inspection of clutch hub1.Inspection
Clutch hubIf worn,damaged,cracked→replace
1.InstallationDriven gearRetaining press plate Nut
Nut torque2.6K gf.m(26 N.m)
Note:Lock orderly.
6-17
CHASDrive chain and sprocket
2.Installation
Install as shown on the figBend the jaw part of limit prers plate in a or b as
shown on the left fig,after bend deformattion,stick the side of the nut firmly.
1
1.InstallationDrive chain
Chain tensioner
Chain press plate
Installation of drive chain
2.InstallationChain joint clip
Note:As shown on the fig,pay attention to the installing direction of chain joint clip.
3.
3
Adjustement
The slackness of drive chain
Refer to the section»Adjustment of drive chain,slack-ness»of chapter.
Note:If the slackness of drive chain is too small,it will cause
the engine and other main components to overload.The chain slackness should be kept within the sp-
ecified limit.
4.Installation
Axle nut
Bolt
6-18
Front fork CHAS
Bolt11 Washer12 Plug rod of oil stocking13 Damper rod 14 Inner pipe15 Spring16 Oil seal17 Outer
Front fenderPlugBoltO-ringSpacerSpring seatSpringDust coverClip pipe
NEW
NEW
6-19
Front fork CHAS
Take out the front fork
WarningRest the motorcycle firmly to avoid turnover.
Rest the motorcycle on the flat ground.1.
Place a proper bracket under the frame and the engine to surpport the front wheel.
2.
RemovalFront wheelFront fender
3.
LoosenLoosen the boltCover bolt
4.
Note:When removing the front fork,remove the 2 bolts forfastening the front fork.
Removal of front forkRemovalCover bolt(and O-ring)
1.
Oil drain2.
.RemovalSpacerSpring seatSpring
3
6-20
4.
5.
7.Removal
Removal
Dust cover
Clip
RemovalNut
Grip the shock absorber rod loosen the bolt with T and shock absorber fixture.
6.RemovalBoltWasher
Oil seal
Note:
Note:
Be careful not to damage the surface of inner pipe.
T flat handle90890-01294
When removing the oil seal,be careful not to scrape
the pipe wall of outer fork.
lever
6-21
Front fork CHAS
Front fork CHAS
Inspection of front fork1.Inspection
Bending of inner pipe
Bending limit
0.2mm
WarningNever attempt to straighten the bending inner piper,otherwise,the pipe will be damaged seriously.
2.Measurement
Free length of front fork spring a
Free length of front fork spring336.9mm
Min. free play
330mm
→Out of specification replace
3.InspectionDamper rod
Shock aborbor piston
Scraped,damaged,bent→replaceSpring
Plug rod of oil stocking
Worn,damaegd→replacePollutant→blow off all oil holes with compressed air.
Note:Never attempt to straighten the bending damper rod,
otherwise the damper rod will be damaged seriously.
6-22
Front fork CHAS
Assembling of front forkConduct according to the reverse procedures of «disass-
embling»,pay attention to the following items.
Note:When reassembling the front fork ,use the follow-
ing new components.
Oil sealDust coverBefore reassembling,make sure that all compon-
ents are cleaning.
1.Installation
Spring
Shock absorber piston
2.Lubrication
Inner pipe(Outer surface)
Shock absorbor oil 10W or equal.
3.InstallationShock absorber rod
Plug rod of oil stocking
Inner pipeOuter pipe
4.Installation
Washer
Bolt(shock absorber rod)
6-23
Front fork CHAS
5.Fastening
Bolt(damper rod)
Bolt
2.3Kgf.m(23N.m)
Fasten the bolt of damper rod with T handle wr-
ench and damper rod fixture.
Note:
“T”tool90890-01326
Shock absorber rod fixture:90890-01294
6.Installation
Oil seal
7.Installation
ClipOuter pipe
6-24
Front fork CHAS
8.Inspection
Stretch of inner pipe
If the stretch is not smooth Inspect again after disase-
mbling.
→
9.Measuring glassOil filling
Oil amount:156mm
10W shock absorber oil
10.After filling oil,move the front fork up and down slo-
wly so as to let the oil spread into the pipe.
11.Installation
Spring
When installing,let the end of front fork spring with
small play to toward the cover bolt side.Install the O-ring on the cover bolt.
Note:
12.Installation
Cover boltO-ring
Be careful not to damage the surface of inner pipe.
Note:
6-25
Front fork CHAS
Installation of front forkConduct according to the reverse procedures of «removal
1.Installation
Front forkTighten up the fixing bolt tempotarily.
Note:When installing , align the inner pipe end with bolt
head end.
2.Fastening
BoltBolt
Cover bolt
Torque of position:2.8Kgf.m(28N.m)
Torque of pisition:Kgf.m(23N.m)
Cover bolt torque:2.3Kgf.m(23N.m)
6-26
Steering axle and handle bar CHAS
Handle bar holderHandle barRight handle bar assyHandle bar seatLimit clipRing nutRing rubber padRing nut
Dust coverSteering axle
Bearing race(upper)Roller holding bracket(upper)Roller holding bracket(lower)Bearing race2(middle)Bearing race(Lower)
1112 13 1415
The inner diameter of two bearing races are different
6-27
Steering axle and handle bar CHAS
Handle bar1.Removal
Remove left and right lever switches
2.Removal
Handle bar holder
Handle barHandle bar seat
Removal
Front wheel
3.
4.RemovalFront fork
6-28
Steering axle and handle bar CHAS
5.Removal
Limit clip
Ring nut
Ring rubber pad
6.Removal
Ring nutRemove with steering nut wrench
Steering nut wrench90890-01403
WarningRemove only with wrench.
7.Removal
Bearing race 2
Roller race 2Roller
Steering axle
Roller holding bracket(Lower)
holding bracket(upper)
1.Inspection
Handle barIf bent,cracked,damaged→replace
Inspection of handle bar
WarningDo not attempt to straighten the bending handle bar,
otherwise,it will decrease the operation function of
the handle bar,causing danger.
6-29
Steering axle and handle bar CHAS
Inspection of front steering axle
Procedres for replacement:
Note:
1.
2.
******************
Clean the roller holding bracket and bearing race.
Inspection
Roller holding bracketBearing race
Worn,damaged→replace
As shown on the fig,remove the bearing race with a longrod and hammer,take it out from the cencave groove
of fork pipe of steering joint.
As shown on the fig,remove the bearing race of steeringrod with plain chisel and hammer.
Install the new dust seal parts, roller holding bracket
and bearing race.
The roller holding bracket,bearing race and dust
seal parts are always replaced as a complete set.
If the roller holding bracket and bearing race areinstalled at a slant,the frame will be worn, so install
them in horizontal condition.
Never beat the roller and rod surface.
************************
******************************************
Installation of steering axle
1.
2.
3
Conduct installation according to the reverse procedures
of «Removal».
Oil fillingRoller holding bracket(upper and lower)
Bearing race
Lithium base lubrication grease
Installation
Ring nut (lower)
Ring rubber padRing nut (upper)
Limit clipConduct adjustment after installing, the adjustment
method is conducted as stated in chapter .
6-30
Steering shaft and handle bar CHAS
Installation of the handle bar1.Install
Handle bar
Handle bar clamp
Coupling torque2.3Kgf.m(23N.m)
Note: The bolt ahead must be fastened first.
When assembling the steering, the projection of
handle bar clamp is in front of installation direction.
2.Install:
Front brake leverClutch lever
3.Install
Lever switch
When installing,locating pin a of the lever switch sh-ould be inserted into the locating hole b of the handlebar.
6-31
CHASRear shock absorber and rear arm
Rear shock absorberNutRear rocker armConnecting rod
Chain shield
6-32
CHASRear shock absorber and rear arm
Removal1.Rear shock absorber
The motorcycle should be supported firmly to avo-
id turning.
Warning
2.Remove
Left-right rear shock absorber
3.Remove
Rear wheel
4.Remove
Chain
5.Remove
NutConnecting rod
Chain shieldRear rocker arm
Inspection1.Check
Slackeness of rocker armIf it is loose→screw up the axle nut or replace bush
Vertical movement of rocker arm
If it is unflexiblebend and there is rough part→replace the bush
2.Check
Rear shock absorberIf it is leak,deformation→replace it
6-33
Chapter 7 Circuit
General drawing of circuit …………………………………………………………………………………………
Electric components…………………………………………………………………………………………………
Inspection of socket connector ……………………………………………………………………………………
Inspection of switch ………………………………………………………………………………………………
Ignition system ……………………………………………………………………………………………………
Starting system ……………………………………………………………………………………………………
Starting motor ……………………………………………………………………………………………………
Charge system ………………………………………………………………………………………………………
Lighting system ……………………………………………………………………………………………………
Signal system ………………………………………………………………………………………………………
7-1
7-3
7-5
7-6
7-8
7-12
7-17
7-22
7-26
7-31
Circuit ELEC
Circuit Drawing
7
7-1
Circuit ELEC
14
15
16
17
18
19
20
21
Instrument
Fuel signal sender
Horn
Left lever switch
Flash relay
Front brake switch
Rear brake switch
Neutral switch
Headlamp
Tail lamp
Front left turning lamp
Front right turning lamp
Left-right turning lamp
Right-left turning lamp
22
23
24
25
26
27
B
Br
Dg
G
L
Or
Sb
P
R
Y
W
B/W
B/R
Br/W
G/W
G/Y
W/L
W/R
B/Y
L/W
L/B
R/W
Black
Brown
Russet
Deep green
Green
Blue
Orange
Sky blue
Pink
Red
Yellow
White
Black/White
Black/Red
Brown/White
Green/White
Green/Yellow
White/Blue
White/Red
Black/Yellow
Blue/White
Blue/Black
Red/White
11
12
13
Magneto
Rectified adjuster
Battery
Starting relay
Starting motor
Positive wire
Negative wire
Main switch
Right lever switch
Clutch switch
CDI unit assy
Ignition coil
Diode
Ru
7
7-2
Circuit ELEC
Electric components
5.
6.
7.
8.
Rectifying adjuster
Fuel sensor
Three keys assy
Main cable
1.
2.
3.
4.
Battery
Rear brake switch
Starting relay
Fuse plate
7-3
Circuit ELEC
Electric components
4.Flash relay assy1.
2.
3.
Ignition coil assy
Spark plug cap assy
Neutral switch assy
5.CDI unit
6.Horn
7-4
Inspection of socket connector ELEC
Inspection of socket connector
The dirt,rust and moisture on the socket connector should be removed.
Remove
Socket connector
Dry every connector with air.
1.
2.
3.r
4.
5.
—
.
.
binding t
Evey socket connector should be connected and dis
charged for 2/3 times
Check if the wire is come off with hand
post is pulled out by hand,bend he
pin and insert the binding post into the socket co-nnector again.
If the
6.
7. .
Connect
Socket connector
Check if the circuit is conducted with multitester
I
binding post.
Note:f the non-conduction of circuit is found,clear
everyWhen checking the bale of wire,the procedure
of inspection must be done according to above
1/7 steps
When replacing the CDI ,every socket connecter
mustbe checked
The inspection should be done by inserting the multitester to the socket connector seefigure.
.
.
7-5
Inspection of socket connector ELEC
Inspection of the switch
Inspection method of the switchCheck the conduction of terminals with multitester.
If any poor condition is found, replace the switch imediately.
-m
Multitesler
90890-03112
Note:
Start the switch several times to cheak.Before checking,turn the multitester to “O” .
When checking, the used voltage gauge should
be set to proper position for check. The conduction
inspection of every switch should be done by Ω×1.
Every switch terminal in the manualInner connecting terminal abbreviated drawing of switch
(such as: main switch, handlebar switch, brake switch anlighting switch etc.), see left figure, often appear in this
manual. The switch position is recorded in the left columnof terminal connection table,which the wire color connec-ting terminal is written down at the upper column.
“O-O”means the conduction between the terminals
is formed, that is the sealing conduction circuit of every switch is formed on it’s position,conduction is formed at
“ON”position which is between the“Brown” term-
inal and the“Red”one.
7-6
Ignition System ELEC
Circuit of ignition system
MaganetoCDI unitIgnition coil/spark plugMain switch
11 12 8
4
7-7
Inspection of socket connector ELEC
Ignition system failure(No spark or discontinuous spark)
Exclusion of trouble shooting
1.2.3.4.
Inspection procedureSpark plugChecking sparkResistance of the spark plug capIgnition coil
5.6.7.8.C
Resistance of pulse coilResistance of spark charging coilMain switch
ircuit terminal(loop of ignition system)
Remark
Before excluding the troubleshooling,the following parts side cover cushion fuel tank should be removed
The following specific tool should be used before excluding.
Ignition tester
90890-06754
Min multitester
90890-03112
Spark plug type CR6HSA
Spark plug clearance0.6~0.7mm
Spark plug cap→High-pressure coil voltage gauge
Voltage gauge wire of high-pressure coil→Spark plug
2.Inspection of the spark
Turn the main switch to “ON”for checking if the spark gets to the normal value above.When pressing the starting switch,check if the spark a gets to normal value above.
Min.spark clearance of spark plug: 6mm
Normal
Abnormal
Correct and replace
The spark gets to normal value above
Ignition system normalNo spark
1.Spark plug
Check the spark plug condition.
Check the spark plug type.
Check the spark plug clearance.
Refer to the 3 chapter“Inspection of the spark plug”.
7-8
Inspection of socket connector ELEC
3.Resistance of spark plug cap
Remove the spark plug capConnect the multitester(test frequency×1K)to spark plug cap
4.Resistance of primary coil of ignition coil
RemarkDon’t pull down the spark plug from the high-pressure wire.Turning in counter clockwise when removing.Turning in clockwise when installing.When assembling the spark plug cap,check the high-pressure wire first.Cut off the front end of high-pressure wire about 5mm before installing.
Resistance value of ignition coil(primary)0.3Ω±10%(20°C)
Remove the high-pressure coil (ignition coil)Connect the multitester(test frequencyΩ×1)to the terminal of ignition coil.
lead wire of voltage gauge→spark plug sidelead wire of voltage gauge→high-pressure wire side
out of specification
The spark plug is failure,replace it
Resistance of spark plug cap5K ± 20%(20°C)Ω
Lead wire of voltage gauge→orange terminallead wire of voltage gauge→ground wire
7-9
Inspection of socket connector ELEC
5.Resistance of secondary coil of ignition coil
Connect multitester(test frequency×1k) to terminal of high-pressure coil.
The resistance of twocoils meets the normal value
6.Resistance of pulse coil
Divide the adapter of the pulse coil with wire
Connect the multitester(testΩ×1000)to the adapter of
pulse coil for measure of coil resistance.
lead wire of voltage gauge→Red terminallead wire of voltage gauge→White terminal
Replace the pulse coil
Out of normal value
The ignition coil is failure,replace it
Abnormal
lead wire of voltage gauge→High-pressure wirelead wire of voltage gauge→Orange terminal
Resistance value of ignition coil
3.16 K 10%(20 C)Ω ± °
..
7-10
Inspection of socket connector ELEC
7.Resistance of ignition charge coilRemove the ignition charge coilConnect the multitester (test
to the terminal of charge coilΩ×1000)
Connecting method
Resistance of charge coil860Ω±20%(20 ° C)
NormalOut of normal value
Replace the ignition charge coil
Lead wire of voltage gauge→Green terminallead wire of voltage gauge→Brown terminal
..
Change CDI unit assy
7.Wire joint
Refer to the loop connection of ignition system
Normal Poor connection
Correct or replace
7-11
Starting system ELEC
Circuit of starting system
Battery
Starting relay
Starting motor
Main switch
Right lever switch
Clutch switch
21Neutral switch
7-12
Starting system ELEC
Exclusion of troubleshooting
No work of starting notor
Inspection procedureBatteryFuseStarting motorMain switch
1.2.3.4.
5.Starting relay6.7.8.
Starting switchNeutral switchClutch switch
Before excluding ,the following components should be removedSide cover Cushion
The following specific tool should be used when excluding.
Min.multitester90890-03112
Remark
1.Fuse
Remove fuse
Connect min.multitester(Ω×1)to the fuse
Check if the fuse is conducted
2.Battery
12.5V
1.280, at 20°C(68°F)
Check the battery condition
Refer to the third chapter “Battery”
Voltage
Electrolyte specific gravitySupplement the electrolyte
Clear the binding post of batteryCharge or replace the battery
If the fuse is broken,replace it
No conduction
Abnormal
Conduction
Normal
…
.
….
7-13
Starting system ELEC
3.Starting motor The capacity of the cross-bond must be equal to or
larger than that of the battery wire,otherwise, the
cross-bond will be burnt.
4.Starting relay
Check if the starting motor work.
If the starting motor is failure,replace it.
Connect the positive binding postof batteryto the cable of starting motor with cross-bond.
See figare.
Remove the adapter of starting relay from the bundle
conductor.
Connect the battery to the wire of starting relay with cross-bond. See figure.
Check if the starting motor work.
If the starting motor is failure,replace it
Out of work
Out of work
Work
Work
Warning
12
7-14
Starting system ELEC
5.Main switch
6.Neutral switch
Remove the wire of neutral switch from the bundle conductor.
Check if the switch is conducted between the“sky blue wireand the ground wire” .
Normal
Abnormal
If the main switch is failure,replace it
NormalIf the neutral switch is failure,replace it
Abnormal
Remove the branch-connetor of main switch from the bale of wire.
Check if the switch is conducted between the red and
the brown.
7-15
Starting system ELEC
7.Clutch switch
Abnormal
Remove the branch-connector of clutch switch from
the bale of wire.
Check if the clutch switch is conducted between
“the black”and “the black”
If the clutch switch is failure,replace it
Normal
R
8.Wire jointPoor connection,break
Correct or replace
Refer to the loop wire of starting system
7-16
Starting motor assyRear bracket
Electric brush spring
Electric brush assyO-ring
Magnet-wheelElectric button
Adjusting pad
Front bracketO-ring
Length limit value of electric brush3.5mm
7-17
A
B
C
D 0.017~0.021Ω20°CResistance value of electric button coil
Hexagon slotm1.5m
Wear limit value of commutator21.0mm
Starting motor
Starting system ELEC
Removal
Stripping
Inspection and repair
1.
1.
t
2.Remove
3.
1.Check
600 sand paper
2.
Remove
Wire of starting motorStarting motor assy
Before stripping, make the identifiable mark on the
frond and rear bracke to be easy to check when asse-
mbling.
The front bracketpad
The rear bracket
Remove
Electric buttonMagnet-wheel
Electric brush
Commutator
Dirt on the comutator→polish it with
Measure
Diameter of the commutator aOut of normal value→Repace the starting motor
7-18
Wear limit value of commutator21mm
Starting system ELEC
Starting system ELEC
3.Measure
The depth of mica sheet slot aOut of normal range→grind it with hand saw to make
it fits to normal value.
Depth of the mica slot
1.5mm
The insulated mica sheet of commutator must has slot ,which can sure the normal work of the com-
mitator.
Note:
4.
**********************************
Check
Electric coil(insulation,conduction)If there is default→replace the starting motor
Connect min.multitester for the test of conductionand
insulatiomMeasure the resistance value of the electric button.
**********************************
5.
If the resistance value is abnormal,replace the starting mot
Measure
Electric brush length a
Out of normal value→Replace the electric brush as a se
Inspection procedure
********
Resistance value of electric button coil
Conduction test
0.017~0.021Ω,at 20°C68 FInsulation test
more than 1MΩat 20 °C68 F
Lengh limit value of the electric brush3.5mm(0.14in)
********
t
When replacing the electric brush, pay more atte-ntion to one side which is welding.
Note:
7-19
Starting system ELEC
6.Measure
Elastic force of the electric brush spring Fatigue or out of the normal value→replace it as a set.
Elastic force of the electric brush spring560~840g
1.InstallElectric brush spring
Electric brush
According to the contary procedure of “RemovaAssemble
Note:When assembling the electric brush, the electric brush wire should, wrap the outer side of proje-
ction of electric brush spring clamp.
When assembling the eclectric brush, the binding post of electric brush wire should slightly touch theprojection lying in the side of electric brush springclamp.
2.Install
Electric button
Note:When installing the electric button, press down the electric brush with min. screw driver to avoid da-
maging the electric brush.
7-20
Starting system ELEC
3.
O-
Install
ring
Replace new oneNote
4.InstallMagnet-wheel
The matching mark on the magnet-wheel shoeld bealign with that on the rear bracket,then the installation
is done.
Note:
5.Install
Pad
Front bracket
The installation is done after the project of washer is align with the groove of front bracket
Make the matching mark on the magnetic yoke be
align with that of front-rear bracket.
Note:
Bolt0.5Kgf.m(5N.m)
1.Install
The starting motor
Installation
2.Install
The starting motor
Wire of starting motor
Botl
0.7Kgf.m(7N.m)
7-21
Charge system ELEC
Charge systemCircuit Diagram
CDI magneto
Rectifing adjustor
Battery
Starting relay
7-22
Charge system ELEC
Exclusion of trouble shooting
No charge on the battery
4.
5.
Lamp switch
Double-beam lamp switch
1.
2.
3.
Fuse
Battery
Main switch
Remark
Refore excluding,the following components should be removed.Side cover Cushion
The following specific tool should be applied
Multitester90890-03112
Check if the fuse is conducted
Replace the fuse
1.FuseNo conduction
Conduction
2.Battery
Abnormal
Supplement the electrolyte(distilled wate)Clear the binding post of battery Charge or replace the battery
Check the battery condition
VoltageSpecific gravity of electrolyte
12.5V
1.280at20 °C(68 °F)
Normal
7-23
Charge system ELEC
3.Charge voltage
Connect the induction tachymeter to the wire of the spark plug.Connect min.multitester (DC20V) to the batteryPositive wire of multitester→positive binding post of battery.Negative wire of multitester→Negative binding postof battery.
Check the charge voltage after the engine isaccelerated to 5000r/min.
Charge voltage14.0V,at 5000r/min
Remark
Battery charged fully should be applied.The charge circuit is normal
Normal value
Out of normal value
4.Resistance value of charge coil
Remove the branch-connector of charge coil from bundle conductor.
Connect the min. MultitesterΩ×1to the charge
coil.
Measure the resistance value of charge coil.
Positive wire of multitester→White wire
Negative wire of multitester→White wire
Resistance value of charge coil0.4Ω±20%(20 °C)
Two test value meet the normal value
Out of normal value
If the charge coil is failure,replace it
7-24
Charge system ELEC
5.Connecting condition of wire
Check the whole connecting condition of charge
system.
Refer to section “circuit Diagram”.
Normal
Reinstall the rectifier/adjuster
Poor connetion
Correct
7-25
Lighting system ELEC
Lighting systemCircuit diagram
BatteryRight lever switch22
23
Head lampTail lamp
7-26
Lighting system ELEC
Exclusion of troubleshooting
Headlamp, high-beam indicator of headlamp, tailamp and instrument garden light are not lit
RemarkBefore excluding ,the following components should be removed.Side coverCushionHood
The following specific tool should be applied when excluding.
Min.multitesterPart number90890-03112
1.Bulb and socket
Check if the bulb and socket are conducted.
2.Fuse
3.Battery
If the bulb or socket is failure,replace it
Supplement eletrolyte.(distilled water)Clear the binding post of battery.Charge or replace the battery.
If the fuse is broken,replace it
Remove the fuse
Connect the min·multitester to the fuse.
Check if the fuse is conducted.
Refer to“Inspection of fuse”section of the 3 chapter.
(Ω×1)
Check the battery condition.
Refer to“Inspection of battery”section of the3chapter.
Specific gravity of electrolyte1.280,at 20 °C 68 °F
No conduction
Abnormal
Conduction
No conduction
7-27
Lighting system ELEC
4.Main switch
5.»Garden light»switch
6.Dimmer switch of «headlamp»
If the main switch is failure,replace it
«Garden light»switch is failure,replace the handlebar switch(right)
«Headlamp»dimmer switch is failure,replace the handlebar switch(left)
Remove the branch-connector of main switch from
the bundle conductor.
Check if the switch between «the red «and «the
brown»is conducted.
Remove the branch-connector of handle bar sw-
itch (right) from the bundle conductor.
Connect min. Multitester(Ω×1)to the binding
post of handle bar switch (right).
Check if the switch between»the brown»and»the
blue/black»is conducted.
Remove the branch-connector of handle bar switch
(left)from the bundle conductor.
Connect min. Multitester(Ω×1)to the binding
post of handle bar switch(right).
Check if the switch between»blue/black and yellow»
and «blue/black and green»is conducted.
Abnormal
Normal
Normal
Normal
Abnormal
Abnormal
7-28
Lighting system ELEC
Inspection of lighting system1.Headlamp and high-beam indicator of headlamp are not lit.
Check if the bulb and socket are conducted.
2.Voltage
Headlamp:Positive guide wire of multitester→Yellow or green guide wire.Negative guide wire of multitester→Black guidewire»High beam indicator of headlampPositive guide wire of multitester→Yellow guidewire
Negative guide wire of multitester→Black guide wire
«
Turn the switch to «ON».Turn the «garden light»switch to»ON».Turn the dimmer switch of «headlamp» to «HI» or «LO».Check if the voltage of socket connector between the greenand the yellow wire gets to 12V.
Meet normal valur (12V)
This circuit is normal.
Poor lagout from main switch to the socket,The repair is needed.
1.Bulb and socket
Connect Min. multitester(DC20V)to branch-connector of headlamp and to that of indicator.
When the dimmer switch of headlamp lies in lowerbeam poisitionWhen the dimmer switch of headlamp lies in highbeam position
Replace the bulb or socket
No conduction
Conduction
2.
1.
The instrument light is not lit
Bulb and socket
Check if the bulb and the socket are conducted.
Replace bulb or socket.
No conduction
Conduction
7-29
Out of normal value
Lighting system ELEC
2.Voltage
Positive wire of multitester→Yellow binding postNegative wire of multitester→Black binding post
Turn the main switch to «ON» postition.
Turn the «garden light»switch to «ON» position.
Check if the voltage of «Brown»wire on socket cnnector
gets to 12V.
The circuit is normal
Connect min. Multitester(DC20V)to the branch-connector of socket.
3.The tail lamp
1.Bulb and socket
2.Voltage
Positive wire of multitester→blue binding postNegative wire of multitester→black binding post
Turn the main switch to «ON» position.
Turn the «garde light»switch to «ON» position.Check if the voltage of blue wire on socket
Meet normal value(12V)
If layout from the main switch to the socket connector is poor,repair it.
No conduction
Replace the bulb or the socket.
If the layout from the main switch to socketconnector is poor,repair it.
Check if the bulb and socket are conducted.
Conduction
Connect min. multitester(DC20V) to socket connector.
The circuit is normal
7-30
Signal system ELEC
Signal systemCircuit Diagram
Main switchStarting relayBattery
Front brake switchRear brake switchHorn
Left handle lever switch assy
19
Flash relay
2016
1718
23
2426
25 27
21
Tai lamp/brake lamp
Front left-right turning lamp
Rear left-right turning lamp
Fuel signal sender
Instrument assy
Neutral switch
15
14
7-31
Signal system ELEC
Exclusion of trouble shooting
Blinker, brake lamp or indicator are not lit and the horn does not work.
Inspecttion procedureFuseBattery
1.2.
3.4.
Main switchWire joint
When excluding,the following components should be removed Side coverCushion
When excluding,the following specialtol should be used:
Multitester90890-03112
Remark
1.Fuse
Check if the fuse is conducted.
2.Battery
Check the battery condition
3.Main switch
4.Reconnection condition of guide wire
Check every circuit condition signal systemRefer to «Inspection of signal system»section
Poor conduction
Replace the fuse
Supplement electrolyte(distilled water)Clear the binding post of battery.Charge of replace battery.
The main switch is failre,replace it
The correct should be done.
Voltage
Special gravity of electrolyte
12.5V
1.280,(20°C)
Check the socket connector of whole signal system.Refer to «circuit Diagram»section.
Abnormal
Normal
Normal
Normal
Conduction
Remove the branch connector of main switch from bundle conductorCheck if the switch between the «Red and the Brown» is conducted.
Abnormal
Abnormal
7-32
Signal system ELEC
Inspection of signal system
Remove the branch-connector of handle bar
switch(left)from the bundle conductor
Check if the switch between the Pink and the
Black.
2.Voltage
Connect min·multitester(DC20V) to guide wire of hornPositive guide wire of multitester→Brown guide wireNegative guide wire of multitester→Frame ground
Turn the main switch to «ON».Check the voltage at the binding post of horn brwon guide wire gets to12V.
Connect the min·multitester(DC20V)to «Pink»
binding post of horn.
Positive guide wire of multitester→Pink guide wire
Negative guide wire of multitester→Frame ground
Turn the main switch to «ON»
Check if the «Pink»guide wire voltage at the
binding post of horn gets to 12V.
No function of the horn
Adjust or replace horn
The horn switch is failure,the lever switch (left) should be replaced.
Out of normal value
If there is poor layout from the main switchto the horn binding post,repair is needed.
If the horn is failure,replace it.
1.No function of the horn
1.Horn switch
Out of normal value
Meet normal value (12V)
Abnoraml
3.Horn
7-33
Signal system ELEC
2.The brake lamp is not lit
1.Bulb and socket
Check if the bulb and the socket are conducted.
2.Brake switchRemove brake switch guide wire from the bundle connector.Check if the switch between the «Yellow &Brown»and «Black& Black» is conducted
3.VoltageConnect min. Multitester(DC20V) to socket connector.Positive guide wire of multitester→YellowguidewireNegative guide wire of multitester→Blackguidewire
Turn the main switch to «ON».Pull brake lever or step brake pedal.Check if the voltage of «Yellow»guide wire at thesocket connector gets to 12V.
Meet normal value
The circuit is normal
If the brake switch is failure,replace it
Out of normal value
There is poor layout from the main switch to the socket connector,repair is needed.
Abnormal
Replace bulb or socket
No conduction
7-34
Signal system ELEC
3.Blinker/turn signal lamp,indicator no work.
1.Bulb and socket
Check if the bulb and socket are conducted
2.Turn signal switch
3.VoltageConnect min. Multitester(DC20V) to the relay
on the blinker device.
Postitive guide wire of multitester→Brown guied wireNegative guide wire of multitester→Frame ground
Turn the switch to «ON».Check if the voltage of «Brown»guide wire at the relay binding post of blinker device gets to 12V.
4.Blinker relay
Connect multitester(test frequencyDC20V) to blinker relay
Guide wire→Brown/white terminalguide wire→Body ground
Turn the main switch to «ON».Turn the blinker to left or right,Measure the voltage of brown/white guide wire(12V).
Replace the bulb or the socket
The turn signal switch is failure,replace the handlebar switch(left)
There is poor layout from the main swotch to the relaybinding post of blinker device,the repair is needed.
Replace the blinker relay
Out of normal value
Remove the branch-connector of handlebar switch
(left)from bundle conductor
Check if the switch between»Brown/white& Dark
brown»and»Brown/white &Dark green»is conducted.
Meet normal value
Meet mormal value
Out of normal value
Condutction
Abnormal
Conduction
No conduction
7-35
Signal system ELEC
5.Turn indicator
Connect min. Multitester(DC20V) to socket connector
Connection at the left blinker
Negative guide wire of multitester→Frame grounPositive guide wire of multitester→Brown guide wire
Connection at the right blinkerPositive guide wire of multitive→Dark green guide wireNegative guide wire→Frame ground wire
Turn main switch to «ON».
Turn «turn signal» switch to left » «
12V.
or » «right position
Check if the voltage of brown guide wire of dark
geeen guide wire at socket connector gets to
Meet normal value
Layout of signal loop is normal
Out of normal value
6.Circuit joint
Check if there is break at connection part of loop of signal system.Refer to connection diagram of loop of signal system.
4.Neutral indicator no work
1.Bulb and socket
Check if the bulb and the socket are conducted.
Conduction
2.Neutral switchRemove guide wire of neutral switch from bundlecondctor.Check if the switch between the sky blue and the ground wire is conducted.
No conduction
Replace the bulb or socket
The neutral switch is failure,replace it.
Abnormal
Normal
7-36
Signal system ELEC
7-37
Signal system ELEC
2.Voltage
Out of normal value
Check all socket connectors of singal system
Connect min. Multitester(DC20V) to branchconn-nector of fuel gange.(at the side of bundle conductor)
Meet normal value
Check if the brown wire voltage at the fuel gaugebinding post (at the side of bundle conductor)getsto 12V.
3.Fuel gauge
Turn the main switch to «ON».Move the float to Max. upper postion or max. Lower position to check the fuel gallge needle’s action
Normal
The loop connection of signal system is normal
RemarkFirm the float bowl on the 1 or 2 position respectively
for over 3 minutes to confirm the needle of fuel gauge.
Poor function
Replace petrol gauge
Connect fuel level sensor to circuit jointMove the float upand down.
Position of float bowl Needle of fuel gauge
Upper float bowl Showing F
Lower float bowl Showing E
7-38
Troubleshooting of engine Trouble
Troubleshooting of engineElectric Appliance system
Main switchShort-circuit of main switch·
Spark plug
Ignition coil(refer to page ) 7-8
CDI unit assyDamage of CDI unit assy
Pulse coil(refer to page7-8)Damage of windingIncorrect ignition timing
Lighting coil/ignition charge coil(refer to page)7-7/7-22)-7/7-22
Damage of winding
*Check all socket connector of guide wire
Starter motor(rdfer to page)7-14
·Damage or failure of starter motor·Failure of starter relay·Failure of starter cultch·Failure breaking relay
·Damage of short-circuit of main coil or secondary coil
·Failure of high-pressure guide wire·Failure of spark plug cap
·Apparent carbon deposit
·Moisture of electrode
·Improper spark plug clearance
leads to damage of spark plug
8
·Break or short-circuit of guide wire
8-1
Troubleshooting of engine Trouble
Compressure system
Buckle/carbon deposit
Inadequate tight force
Damage
Carbon deposit
Buckle/wear/damage
Wear/scratch/damageWear/choke/damage
Wear/scratch
Wear/choke/damage
Damage
Wear/choke/damage
Damage
Damage
Damage
Damage
8-2
Troubleshooting of engine Trouble
Intake and exhaust system
8-3
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