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Yamaha Fazer Service Manual

Summary of Fazer

  • Page 1

    Service manual.

  • Page 2: Fazer

    L-1 fazer service manual yamaha motor india pvt. Limited all rights reserved. Any reprinting or unauthorised use without the written permission of yamaha motor india pvt. Limited is expressly prohibited..

  • Page 3: Foreword

    R-1 foreword this workshop manual has been prepared for use by the yamaha motor india private ltd. Authorised dealerships and their service personnel to attend to servicing of fazer motorcycles. It is not possible to include entire service education into this manual. It is assumed that persons using...

  • Page 4

    L-2 eng engine assembly and adjustments piston pin replacer tool ysst - 607 engine assembly 1 3 how to use this manual manual organisation this manual consists of chapters for the main categories of subjects. (see “illustrated symbols”) 1st title 1 : this is the title of the chapter with its symbol ...

  • Page 5

    R-3 10.Lubricant illustrated symbols illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number and content. Gen info spec insp adj eng carb chas elec trbl shtg illustrated symbols 16 to 21 in the exploded diagrams indicate the types of lubricants and lubrication points. ...

  • Page 6: Index

    Index general information gen info 1 trouble shooting trbl shtg 8 electrical elec 7 chassis chas 6 carburetion carb 5 engine eng 4 periodic inspection and adjustments insp adj 3 specifications spec 2.

  • Page 7

    Gen info chapter 1 general information motorcycle identification frame serial number ......................................................... 1-1 engine serial number ....................................................... 1-1 important information preparation for disassembly .........................

  • Page 8

    Gen info frame serial number the frame serial number ¿ is stamped into the right side of the steering head pipe. Engine serial number the engine serial number À is stamped on the top portion of rh crankcase. ( engine serial number does not contain year and month of production) note : designs and sep...

  • Page 9

    Gen info preparation for disassembly 1. Remove all dirt, mud, dust and foreign ma- terial before disassembly. 2. Use proper tools and cleaning equipment. Refer to “yamaha special service tools”. 3. When disassembling the motorcycle, keep mated parts together. This includes gears, cylinder, piston an...

  • Page 10

    Gen info important information 1-3 warning if the circlip is fitted the wrong way it would cause it to jump off its groove and damage related components. Warning caution: do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. All replacement parts 1. Use only...

  • Page 11

    Gen info yamaha special service tools yamaha special service tools 1-4 the appropriate yamaha special service tools are necessary for proper maintenance of the motorcycle. Using the correct yamaha special service tool will help to prevent damage caused by the use of improper tools or improvised tech...

  • Page 12

    Gen info yamaha special service tools 1-5 18. T.F.F. Oil seal installation tool ysst-275 this tool is used to remove the crank shaft from the crank case. 9. Crank shaft removal tool. Ysst - 265 this tool is used for scraping the sealent from crankcase surface. 14. Scraper ysst - 612 these tools are ...

  • Page 13

    Gen info special service tools 1-6 this tool is used to loosen or tighten the speedometer gear nut. 21. Spanner - speedometer gear nut. Ysst - 237 this fixture is used to hold the engine for its disassembly and assembly. 22. Engine stand this tool is used to remove/install the center plug from crank...

  • Page 14

    Gen info service instruments the following service instruments are necessary for complete and accurate tune up of motorcycle service instruments 1-7 5. Vernier calliper (150 mm) this instrument is used for measuring length, width & thickness of components this instrument is used for checking the eng...

  • Page 15

    Gen info service instruments 1-8 9. Tyre pressure gauge 10. Vaccum gauge 11. Torque wrench (10-50 ft-lb) (20-100 ft-lb) 12. Feeler gauge this instrument is used for checking the tyre pressure this instrument is used for checking intake vaccum. This tool is used to tighten the nuts/bolts at a specifi...

  • Page 16

    Spec chapter 2. Specifications general specifications .................................................... 2-1 maintenance specifications engine ...................................................................................... 2-4 chassis ...........................................................

  • Page 17

    Spec description specification model : fazer model code : 5yy1 engine model code: 5yy1 dimensions: overall length 2065 mm overall width 730 mm overall height 1060 mm seat height 800 mm wheelbase 1300 mm minimum ground clearance 160 mm minimum turning radius 2065 mm dry weight : 115 kg basic weight :...

  • Page 18

    Spec description specification clutch type : wet, multiple disc transmission : primary reduction system helical gear primary reduction ratio 68/19 (3.579 : 1) secondary reduction system chain drive secondary reduction ratio 45/14 (3.214 : 1) transmission type constant mesh 4-speed operation left foo...

  • Page 19

    Spec description specification brake : front brake type drum brake (dia 150 mm) operation right hand operation rear brake type drum brake (dia 130 mm) operation right foot operation suspension : front suspension telescopic fork rear suspension swingarm shock absorbser : front shock absorber coil spr...

  • Page 20

    Spec description specification cylinder : bore size 54.000 ~ 54.018 mm (in five grades) piston : piston to cylinder clearance 0.020 ~ 0.027 mm piston size “d” 53.977 ~ 53.996 mm cylinder piston grading (in five grades) measuring point “h” 4.5 mm piston offset 0.5 mm piston offset direction intake si...

  • Page 21

    Spec description specification cylinder head : * lines indicate straightedge measurement. Camshaft : drive method chain drive cam dimensions intake “ a ” 25.881 ~ 25.981 mm “ b “ 21.195 ~ 21.295 mm “ c “ 4.931 mm exhaust “ a “ 25.841 ~ 25.941 mm “ b “ 21.05 ~ 21.15 mm “ c “ 0.03 mm rocker arm/ rocke...

  • Page 22

    Spec description specification stem outside diameter in 5.975 ~ 5.990 mm ex 5.960 ~ 5.975 mm in ex guide inside diameter in 6.000 ~ 6.012 mm ex 6.000 ~ 6.012 mm in ex stem to guide clearance in 0.010 ~0.037 mm ex 0.025 ~ 0.052 mm in ex stem runout limit 0.010 mm valve seat width in 0.9 ~ 1.1 mm ex 0...

  • Page 23

    Spec description specification clutch : friction plate thickness 2.90 ~ 3.10 mm quantity 5 pcs. Clutch plate thickness 1.6 ± 0.15 mm quantity 4 pcs. 0.05 mm clutch spring free length 32 mm quantity 4 pcs. Minimum length 30.5 mm clutch release method inner push, cam push carburetor : i. D. Mark 5yy1 ...

  • Page 24

    Spec 2-8 maintenance specifications tightening torque (engine) part to be tightened parts thread q’ty tightening torque remark name size nm m.Kg ft.Lb cylinder head bolt m8 4 22 2.2 17 bolt m6 2 10 1.0 7.2 spark plug - m10 1 12.5 1.25 9 cylinder head side cover bolt m6 2 10 1.0 7.2 valve cover - m45...

  • Page 25

    Spec tightening sequence 2-9 maintenance specifications cylinder head crankcase right - hand left - hand t tightening torque (engine) part to be tightened parts thread q’ty tightening torque remark name size nm m.Kg ft.Lb stopper lever bolt m6 1 10 1.0 7.2 sensor assembly bolt m6 2 10 1.0 7.2 neutra...

  • Page 26

    Spec description specification steering system : steering bearing type retainer ball cage no./size of steel balls (upper) 19 pcs. / 1/4 in (lower) 16 pcs. / 1/4 in front suspension : front fork travel 120 mm fork spring free length 316.9 mm 311.9 mm spring rate (k1) 7.4 n/mm (k2) 10.8 n/mm stroke (k...

  • Page 27

    Spec description specification front drum brake : type leading, trailing brake drum inside diameter 150mm lining thickness 4.0 mm shoe spring free length spring 1 57.0 mm spring 2 63.0 mm rear drum brake : type leading, trailing brake drum inside diameter 130mm lining thickness 4.0 mm shoe spring fr...

  • Page 28

    Spec tightening torque (chassis) maintenance specifications 2-12 parts to be tightened thread tightening torque size nm m.Kg ft.Lb front engine stay and mount m 8 x 1.25 38 3.8 27.5 front engine stay and frame m 10 x 1.25 55 5.5 40 rear engine mount and frame m 8 x 1.25 38 3.8 27.5 upper engine stay...

  • Page 29

    Spec description specification voltage : 12v ignition system : ignition timing (b.T. D. C) 7º ± 2º btdc at 1400 rpm. Advancer type electrical type cdi : digitally controlled magneto model/manufacturer 5yy/denso sensor coil (color) 240 Ω ± 20% cdi unit model/manufacturer 5ka/ denso ignitioncoil : mod...

  • Page 30

    Spec maintenance specifications circuit breaker : type fuse amperage for individual circuit x quantity : main 10a x 1pc. Reserve 10a x 1pc. 2-14.

  • Page 31

    Spec general torque specifications this chart specifies torque for standard fasteners with standard i.S.O. Pitch threads. Torque speci- fication for special components or assemblies are included in applicable section of this book. To avoid warpage, tighten multi-fastener assemblied in a criss-cross ...

  • Page 32

    Spec engine lubrication points (part name) lubricant type oil seal lips (all) bearing retainer (all) bolt (cylinder head) o-ring (cylinder head side cover and valve cover) crank pin connecting rod (big end) piston pin valve stem and valve guide oil seal (valve stem end) rocker arm shaft and rocker a...

  • Page 33

    Spec lubrication points and lubricant type chassis lubrication points (part name) lubricant type gear unit (gear meter and drive) oil seal lips (all) pivot shaft (swingarm) pivoting points (brake pedal shaft and frame) ball and ball race (steering head) tube guide (right grip) pivoting points (brake...

  • Page 34

    Spec engine lubrication route engine lubrication route 2-18 warning caution: do not damage crank case surfaces, otherwise oil leakage will start.

  • Page 35

    Spec engine lubrication route engine lubrication route 2-19 warning caution: for improved performance, always use yamalube oil.

  • Page 36

    Spec engine bearings engine bearings 2-20

  • Page 37

    Spec cable routing ¿ handlebar switch (left) À clutch cable Á starter wire speedometer à tachometer Ä brake cable front Å throttle cable Æ brake switch lead Ç speedometer cable È wireharness cable routing É flasher light lead (left) Ê flasher light Ë flasher light lead (right) a pass the clutch cabl...

  • Page 38

    Spec cable routing 2-22 ¿ headlight assembly À handlebar switch lead Á speedometer cable cable guide à clutch cable Ä horn Å fuse Æ cdi unit Ç clamp battery È stop/tail light É flasher light lead (lh) Ê flasher light Ë battery Ì battery breather hose Í neutral switch lead Î brake cable Ï h.T. Coil Ð...

  • Page 39

    Spec cable routing ¿ throttle cable È a.I.S. Unit À high tension cord É starter wire Á ignition coil Ê carburettor breather band - c.D.I. Pipe à brake cable front Ä speedometer Å brake switch lead Æ clutch cable Ç rr brake switch a pass the high tension cord À through the cable guide and starter wir...

  • Page 40

    Spec cable routing ¿ c.D.I. Unit À rectifier regulator Á flasher relay flasher light lead a clamp the wire harness lead. B pass the wire harness between frame and rear fender à stop/tail light lead Ä wireharness Å carburettor air vent Æ tail light assembly ¿ À Å Ä Á Æ Ã Ä a b 2-24.

  • Page 41

    Insp adj chapter 3 periodic inspection and adjustments periodic maintenance / lubrication intervals ....... 3-1 side cover, seat and fuel tank removal ................................................................................... 3-3 installation ...................................................

  • Page 42

    Insp adj introduction/ periodic maintenance/lubrication intervals 3-1 s. No. Item operation services free paid 1 valves check valve clearances, adjust if necessary 2 spark plug check condition, gap clean and reset if necessary 3 carburetor 4 *air filter clean, inspect & lubricate.(replace if necessa...

  • Page 43

    Insp adj periodic maintenance/lubrication intervals 3-2 s. No. Item operation services free paid 18 drive chain check chain stack, alignment, adjust if necessary clean and lubricate. 19 nuts, bolts check all chassis fittings and fasteners for and fasteners looseness. Tighten as per specification. 20...

  • Page 44

    Insp adj removal side cover (lh) 1. Remove • side cover (lh) ææææææææææææææææææææææææææææææææææ removal steps : • open the lock ¿ using main switch key. • pull the lug À / lug Á towards you to remove it from the fuel tank. • slide the side cover towards the front side of the motorcycle for removing ...

  • Page 45

    Insp adj side covers, seat and fuel tank 3-4 2. Remove • bolt (fuel tank) ¿ • plate À • damper rubber Á • fuel tank removal fuel tank 1. Disconnect • fuel hose • scoop bracket - 2 nos bolts note : • position the fuel cock lever Á to the ‘off’, disconnect the fuel hose. • place a rag cloth under the ...

  • Page 46

    Insp adj installation reverse the removal procedure. Note the following points. 1. Install • fuel tank ¿ • damper rubber À • plate Á • bolt • fuel hose side covers, seat and fuel tank 3-5 5. Install • side cover (rh) À 6. Tighten • screw Á bolt (fuel tank) 20 nm (2.0 mkg; 14.4 ft.Lb) bolt (seat) 3.8...

  • Page 47

    Insp adj valve clearance checking and adjustment valve clearance checking and adjustment note : valve clearance checking and adjustment should be made with the engine in cold condi- tion, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead cen-...

  • Page 48

    Insp adj valve clearance checking and adjustment ææææææææææææææææææææææææææææææææææ checking steps : measurement steps : • rotate the crankshaft anticlockwise to align the slit ç third mark on the rotor with the sta- tionary pointer è on the crankcase cover lh when the piston is at top dead center (...

  • Page 49

    Insp adj idling co. Measurement and adjustment idling co. Measurement and adjustment 1. Start the engine and let it warm up by run- ning the motorcycle approx. 3~4 kms. 2. Attach : • inductive tachometer to the spark plug lead. 3. Check : • engine idling speed (standard) out of specification Ÿ adjus...

  • Page 50

    Insp adj idling ‘co’ measurement and adjustment/ throttle cable adjustment 5. Adjust : • ‘co’ concentration ææææææææææææææææææææææææææææææææææ adjustment steps : • turn the pilot screw ¿ in or out until the speci- fied ‘co’ concentration is obtained. Note : for adjusting the engine idling speed use ...

  • Page 51

    Insp adj throttle cable adjustment/ spark plug inspection • loosen the locknut ¿ on the throttle cable. • turn the adjuster À in or out until the specified free play is obtained. • tighten the locknut ¿. Spark plug inspection 1. Remove : • spark plug cap • spark plug 2. Check : • spark plug type / n...

  • Page 52

    Insp adj spark plug inspection/ ignition timing checking procedure 3-11 6. Install : • spark plug note : • before installing a spark plug, clean the gas- ket surface and plug surface. • if a torque wrench is not available, a good estimate of the correct tightening torque is to finger tighten ¿ the s...

  • Page 53

    Insp adj ignition timing checking procedure 3. Check : • ignition timing ********************************************* checking steps : • start the engine and let it warm up for sev- eral minutes or run the motorcycle for approx. 4 kms. • maintain the engine idling speed • confirm that the stationar...

  • Page 54

    Insp adj compression pressure measurement compression pressure measurement note : insufficient compression pressure will result in performance loss. 1. Check : • valve clearance out of specification Ÿ adjust. Refer to “valve clearance adjustment” section. Page no 3-6 2. Start the engine and let it w...

  • Page 55

    Insp adj engine oil level inspection/ engine oil replacement engine oil level inspection 1. Stand the motorcycle on a level surface us- ing the center stand. Note: make sure the motorcycle is upright when inspecting the oil level. 2. Start the engine and let it warm up for a few minutes. 3. Turn off...

  • Page 56

    Insp adj engine oil replacement/ exhaust system inspection 4. Install : • drain plug ¿ with washer 5. Fill : • oil in crankcase 6. Check : • engine oil level refer to “engine oil level inspection” section page no 3-14 7. Install • dip stick (oil level gauge) exhaust system inspection 1. Inspect : • ...

  • Page 57

    Insp adj air filter cleaning 1. Remove: • side cover (r.H.) • air filter case cap ¿ - unscrew 4 nos. Screws • spring wire À • air filter element Á • element guide 2. Inspect: • air filter element Á damaged Ÿ replace. 3. Clean: • air filter element Á use kerosene to clean the element. Note : after cl...

  • Page 58

    Insp adj clutch cable adjustment clutch cable adjustment 1. Check : • clutch cable free play ç out of specification Ÿ adjust, 2. Adjust: • clutch cable free play ææææææææææææææææææææææææææææææææææ adjustment steps: lever side • loosen the locknut ¿ • turn the adjuster À in or out until the speci- fi...

  • Page 59

    Insp adj front brake adjustment/ rear brake adjustment chassis 3-18 ç turning in ç Ÿ free play is increased. Turning out è Ÿ free play is decreased. Turning in ç Ÿ free play is decreased. Turning out è Ÿ free play is increased warning caution: make sure that there is no brake drag after adjusting th...

  • Page 60

    Insp adj rear brake adjustment/ brake shoe inspection ææææææææææææææææææææææææææææææææææ adjustment steps : • turn the adjuster ¿ in or until the specified free play is obtained. ææææææææææææææææææææææææææææææææææ 3. Adjust : • brake light switch refer to “brake light switch adjustment”. As given be...

  • Page 61

    Insp adj drive chain slack adjustment drive chain slack adjustment note: • before checking and adjusting, rotate the rear wheel several revolutions and check the slack at several points to find the tight- est point. • check and if necessary adjust the drive chain slack with the rear wheel in this “t...

  • Page 62

    Insp adj drive chain slack adjustment 3-21 warning caution: do not loosen the axle nut after tightening the torque. If the axle nut grooves is not aligned with the cotter pin hole, align the groove with the hole by tightening up the axle nut. Warning always use a new cotter pin. ææææææææææææææææææææ...

  • Page 63

    Insp adj steering head inspection 3-22 warning securely support the motorcycle so that there is no danger of it falling over. Steering head inspection 1. Stand the motorcycle on a level surface. Note : stand the motorcycle on its center stand. 2. Elevate the front wheel by placing a suit- able stand...

  • Page 64

    Insp adj steering head inspection • check the steering stem by turning it lock to lock. If there is any binding, remove the steer- ing stem assembly and inspect the steering bearings. Refer to “steering head and handle- bar” section in chapter 6 page no 6-29 • install the damper rubber Á and ring nu...

  • Page 65

    Insp adj front fork inspection front fork inspection 1. Stand the motorcycle on a level surface. 2. Check: • inner tube scratches/damage ➔ replace. • oil seal ¿ excessive oil leakage ➔ replace 1. Hold the mitorcycle upright on level surface and apply the front brake 2. Check: • operarion push down h...

  • Page 66

    Insp adj rear shock absorber adjustment ææææææææææææææææææææææææææææææææææ adjustment steps: • turn the adjuster ring ¿ in or out. ææææææææææææææææææææææææææææææææææ tyre inspection 1. Measure : • tyre inflation pressure out of specification Ÿ adjust. 3-25 adjustment numbers: standard 2 minimum 1 ma...

  • Page 67

    Insp adj tyre inspection 2. Inspect : • tyre surfaces wear/damage Ÿ replace ¿ tread depth À side wall Á wear indicator • be sure to install the correct tube when using tube type tyres. • while installing tyre on wheel always check that the tyre lining is seated uniformly with respect to wheel rim. 2...

  • Page 68

    Insp adj spoke inspection and tighteneing 3-27 warning never attempt to make any repairs to the wheel rim. Wheel inspection 1. Inspect : • wheels damage/bends Ÿ replace. Note : always balance the wheel when a tyre or wheel has been changed or replaced. Spokes inspection and tightening 1. Inspect : •...

  • Page 69

    Insp adj battery inspection electrical 3-28 warning caution: when inspecting the battery, make sure that the breather hose is routed correctly. If the breather hose is positioned in such a way as to allow battery electrotyte gas to come into contact with the frame, this could dam- age the motorcycle...

  • Page 70

    Insp adj battery installation replace the battery if: • battery voltage does not rise to a specific value or bubbles fail to rise during charging. • sulphation of one or more cells occurs, (as indicated by the plates turning white, or ma- terial accumulating in the bottom of the cell ). • specific g...

  • Page 71

    Insp adj fuse inspection fuse inspection 1. Remove: • side cover (left) refer to “seat, side covers and fuel tank” section page no 3-3 • fuse holder ¿ 2. Inspect : • fuse ææææææææææææææææææææææææææææææææææ inspection steps : • connect the multimeter to the fuse and check it for continuity. Note : se...

  • Page 72

    Insp adj headlight beam adjustment/ headlight bulb replacement headlight beam adjustment 1. Loosen: • bolt ¿ 2. Loosen: • screw À - 2 nos. 3. Adjust : • headlight beam (vertical) note : punch mark is given on the adjuster bracket for reference to tighten the bolt ¿. Headlight bulb replacement 1. Rem...

  • Page 73

    Eng chapter 4 engine overhaul engine removal side covers, seat and fuel tank removal ................ 4-1 engine oil drain ................................................................... 4-1 battery .................................................................................... 4-1 carburet...

  • Page 74

    Eng circlips and washers ........................................................ 4-31 engine assembly and adjustment ................................ 4-32 crankshaft ........................................................................... 4-35 transmission ..........................................

  • Page 75

    Eng engine removal engine removal 4-1 it is not necessary to remove the engine in order to remove the following parts. • cylinder head • cylinder • piston • clutch • cdi magneto side covers, seat and fuel tank removal 1. Remove : • side covers (lh and rh) • seat • fuel tank refer to the “side covers...

  • Page 76

    Eng 3 engine removal 4-2 footrest assembly 1. Remove: • bolt (footrest) ¿ - 2 nos. (lh & rh) • bolt axle - lower rear mounting À • footrest assembly drive chain 1. Remove : • crankcase cover#1 (l.H.) ¿ • drive chain case upper À and lower Á 2. Slack off the drive chain refer to “drive chain slack ad...

  • Page 77

    Eng engine removal 4-3 shift pedal 1. Remove • bolt (shift pedal) ¿ • shift pedal À battery box 1. Remove • bolt (battery box) ¿ 3 nos • battery box À leads 1. Disconnect: • stator coil lead coupler ¿ • sensor coil lead coupler À 2. Remove : • spark plug cap engine removal 1. Remove : • engine mount...

  • Page 78

    Eng engine disassembly engine disassembly 4-4 cylinder head, cylinder and piston note: with engine mounted on motorcycle, the cyl- inder head, camshaft and cylinder can be maintained by removing the following parts. Warning caution: before engine disassembly clean the outer body of engine properly 1...

  • Page 79

    Eng engine disassembly 4-5 6. Remove : • bolt (cam sprocket) ¿ • plate washer (cam sprocket) À • cam sprocket Á note : hold the nut rotor with socket spanner for opening cam sprocket bolt. Fasten a safety wire to the timing chain to prevent it from fall- ing in the crankcase. 8. Remove : • guide sto...

  • Page 80

    Eng maintenance specifications 4-6 10. Remove : • piston pin circlip ¿ 2 nos • piston pin À , using piston pin replacer • piston Á note : before removing the piston pin circlip, cover the crankcase with a clean cloth to prevent the circlip from falling into the crankcase cavity. 9. Remove : • dowel ...

  • Page 81

    Eng engine disassembly 4-7 3. Remove: • pressure plate bolts ¿ - 4 nos • clutch springs À - 4 nos • pressure plate Á with push rod 1 • friction plates - 5 nos • clutch plates à - 4 nos note : loosen the pressure plate bolts in a crisscross pattern. 4. Remove : • ball Ä 5. Loosen : • straighten the l...

  • Page 82

    Eng engine disassembly 4-8 6. Remove : • clutch boss nut ¿ • lock washer À • clutch boss Á • thrust washer • clutch housing à • spacer Ä 1. Remove : • gear pump drive ¿ • screw (oil pump-2 nos) À • oil pump assembly Á • gasket (oil pump) • oil strainer 8. Remove • nut • plate washer • primary drive ...

  • Page 83

    Eng engine disassembly 4-9 kick starter disassembly 1. Remove : • spacer ¿ • torsion spring À • shim Á • ratchet gear • shim à • ratchet gear with return spring Ä • kick axle Å shift shaft note : the shift shaft can be removed while the engine is mounted by removing the following parts. • shift peda...

  • Page 84

    Eng engine disassembly 4-10 cdi magneto removal 1. Remove : • nut (magneto) • plain washer note : • loosen the nut magneto while holding the magneto À with magneto holder ¿ 2. Attach • bush • magneto puller ¿ note : • place the bush on the crankshaft threaded end before using the magneto puller to a...

  • Page 85

    Eng engine disassembly 4-11 2. Remove : • bolts (crankcase lh-8 nos) note : • loosen the bolts in a crisscross pattern. • loosen each bolts 1/4 turn at a time and re- move them after all are loose. Warning caution: • do not use the flat head screw driver ex- cept at the separating slot. • separate t...

  • Page 86

    Eng engine disassembly: transmission and shifter 4-12 transmission and shifter 1. Remove : • shift fork guide bar ¿ (short) • shift fork guide bar À (long) • shift cam Á • shift fork -c • shift fork -r • shift fork - l 2. Remove : • axle drive assembly ¿ • axle main assembly À • push rod # 2 • washe...

  • Page 87

    Eng disassembly of cylinder head, rocker arms, camshaft and valves 1. Loosen : • valve adjuster locknuts ¿ • valve adjusters À 2. Remove : • stopper plate Á by opening allen bolt engine disassembly 4-13 3. Attach • rocker arm shaft puller ¿ 4. Remove : • rocker arm shafts by tightening the puller nu...

  • Page 88

    Eng engine disassembly 4-14 7. Attach valve spring compression tool ¿ 8. Remove : • valve cotters À note : valve spring compressor tool is to be attached between the valve spring retainer and the valve face (inlet and exhaust) one at a time. 9. Remove : • valve spring retainer ¿ • valve spring À • v...

  • Page 89

    Eng inspection and repair inspection and repair: cylinder head 4-15 cylinder head 1. Remove : • carbon deposits from combustion chambers using a rounded scraper. Note : do not use a sharp instrument to avoid dam- aging or scratching : • spark plug threads • valve seats 2. Inspect : • cylinder head s...

  • Page 90

    Eng inspection and repair:valve seats 4-16 4. Lap : • valve face • valve seat note : after refacing the valve seat or replacing the valve, the valve seat and valve face should be lapped. ææææææææææææææææææææææææææææææææææ measurement steps : • apply mechanic’s blueing dye (dykem) è to the valve face...

  • Page 91

    Eng inspection and repairs 4-17 ææææææææææææææææææææææææææææææææææ lapping steps : • apply coarse lapping compound ç to the valve face • apply molybdenum disulfide oil to the valve stem. • install the valve into the cylinder head. • turn the valve in one direction using the valve lapping tool until ...

  • Page 92

    Eng inspection and repair : valve springs and valves 4-18 2. Measure : • spring tilt ç out of specification Ÿ replace valve springs and valves 1. Measure : • valve spring free length ç out of specification Ÿ replace. 3. Check • spring contact face wear/pitting/scratches Ÿ replace 5. Measure : valve ...

  • Page 93

    Eng engine inspection and repair 4-19 stem-to-guide clearance limit : intake : 0.010 ~ 0.00370 mm exhaust : 0.025 ~ 0.052 mm 7. Measure : • runout (valve stem) out of specification Ÿ replace out of specification Ÿ replace the cylinder head 6. Calculate : stem guide clearance stem-to-guide clearance ...

  • Page 94

    Eng engine inspection and repair 4-20 rocker arms and rocker arm shafts inspection 1. Inspect : • cam lobe contact surface ¿ • adjuster surface À wear/pitting/scratches/blue discoloration Ÿ replace ææææææææææææææææææææææææææææææææææ inspection steps : • inspect the two contact areas on the rocker ar...

  • Page 95

    Eng engine inspection and repair 4-21 timing chain, sprockets and chain guides 1. Inspect : • timing chain wear out/stiffness/damage Ÿ replace the chain and the sprockets as a set. 2. Inspect : • cam sprocket wear/damage Ÿ replace the cam sprocket and the timing chain as a set. 3. Inspect : • guide ...

  • Page 96

    Eng engine inspection and repair 4-22 cylinder and pistons 1. Inspect : • cylinder and piston walls vertical scratches Ÿ rebore or replace the cylinder and the piston 2. Measure : • piston-to-cylinder clearance ææææææææææææææææææææææææææææææææææ measurement steps : 1st step : • measure the cylinder ...

  • Page 97

    Eng 1 5mm engine inspection and repair 4-23 piston ring inspection 1. Measure : • side clearance out of specification Ÿ replace the piston and the piston rings as a set note : remove the carbon deposits from the piston ring grooves and rings before measuring the side clearance. 2. Position : • pisto...

  • Page 98

    Eng piston pin inspection 1. Inspect : • piston pin blue discoloration/grooves Ÿ replace and inspect the lubrication system 2. Measure : • piston pin-to-piston clearance ææææææææææææææææææææææææææææææææææ measurement steps. • measure the piston pin outside diameter ç using a micrometer. If out of sp...

  • Page 99

    Eng engine inspection and repair 4-25 5. Inspect : • crankshaft journal oil passage clogged Ÿ blow the oil passage with compressed air 4. Inspect : • crankshaft sprocket ¿ wear/damage Ÿ replace crankshaft • bearing À wear/crack/damage Ÿ replace crankshaft 3. Measure : • crank width ç out of specific...

  • Page 100

    Eng engine inspection and repair 4-26 primary drive gear inspection 1. Inspect : • primary drive gear teeth ¿ • primary driven gear teeth À wear/damage Ÿ replace both gears as a set. Note : refer the general specification for grading. Excessive noise during operation Ÿ replace both gears as a set. C...

  • Page 101

    Eng engine inspection and repair 4-27 push rod inspection 1. Inspect : • ball ¿ • push rod #1 À wear/damage/bend Ÿ replace 2. Inspect : • push rod # 2 ¿ wear/damage/bend Ÿ replace 6. Inspect : • dogs on the primary driven gear ¿ scoring/wear/damage Ÿ deburr or replace • clutch boss splines À scoring...

  • Page 102

    Eng engine inspection and repair 4-28 shift fork shift cam inspection 1. Inspect : • shift fork follower ¿ • shift fork pawl À scoring/bends/wear/damage Ÿ replace 2. Inspect : • shift cam grooves ¿ wear/damage/scratches Ÿ replace • shift cam segment À wear/damage Ÿ replace 3. Check : • shift fork mo...

  • Page 103

    Eng engine inspection and repair 4-29 5. Measure : • axle runout (main and drive) use a centering device and a dial gauge ¿ out of specifications Ÿ replace the bent axle 6. Inspect : • gear teeth blue discoloration/pitting/wear Ÿ replace • mated dogs rounded edges/cracks/missing portions Ÿ replace 7...

  • Page 104

    Eng engine inspection and repair 4-30 oil pump inspection 1. Measure : • tip clearance ç (between the inner rotor ¿ and the outer rotor À) using feeler gauge. • side clearance è (between the outer rotor À and the pump housing Á) using feeler gauge out of specification Ÿ replace the oil pump assembly...

  • Page 105

    Eng engine inspection and repair 4-31 circlips and washers 1. Inspect : • circlips ¿ • washers damage/looseness/bends Ÿ replace bearings and oil seals 1. Inspect : • bearings ¿ clean with solvent and lubricate with multigrade oil, then rotate the bearing using finger roughness/noise Ÿ replace 2. Ins...

  • Page 106

    Eng engine assembly and adjustments engine assembly and adjustments 4-32 valves, rocker arm and camshaft ¿ valve cotters À valve spring retainer Á valve springs valve stem seal à valve spring seat Ä valve (intake) Å valve (exhaust) Æ lock nut Ç adjuster È valve rocker arm É rocker arm shaft Ê camsha...

  • Page 107

    Eng engine assembly and adjustments 4-33 warning for engine assembly, replace the following parts with new ones : • o-rings • gaskets • oil seals • copper washers • lock washers • circlips valves and valve springs installation 1. Deburr : • valve stem end ¿ using an oil stone for smoothing. 2. Apply...

  • Page 108

    Eng engine assembly and adjustments 4-34 4. Install : • plate ¿ • bolt À 3. Install : • rocker arm as shown in figure • rocker arm shaft by pushing it in completely 2. Apply : • molybdenum disulfide oil on the rocker arm and rocker arm shaft camshaft and rocker arm installation 1. Lubricate : • cams...

  • Page 109

    Eng engine assembly and adjustments 4-35 crankshaft ¿ crank pin À crank shaft Á connecting rod big end bearing à crankshaft bearing Ä wood-ruff key Å gear balancer Æ balancer assy. Ç bearing.

  • Page 110

    Eng engine assembly and adjustments 4-36 crankshaft 1. Insert : • crankshaft in the crankcase (l.H.) 2. Attach : • crankshaft installing tool on crankshaft warning caution: to avoid scratching the crankshaft and to ease the installation procedure, apply engine oil onto each bearing and crankcase lh....

  • Page 111

    Eng engine assembly and adjustments 4-37 transmission ¿ drive sprocket À oil seal Á bearing 4th wheel gear à drive axle Ä 2nd wheel gear Å 3rd wheel gear Æ clutch dog Ç 1st wheel gear È bearing É bearing Ê 4th pinion gear Ë 3rd pinion gear Ì 2nd pinion gear Í main axle Î plate Ï bearing.

  • Page 112

    Eng engine assembly and adjustments 4-38 shifter ¿ shift fork guide bar (long) À shift fork # r Á shift fork # l shift cam à segment Ä shift fork guide bar (short) Å shift fork # c Æ torx screw Ç pin shaft cam.

  • Page 113

    Eng engine assembly and adjustments 4-39 transmission, shift cam and shift fork installation 1. Measure : • axle main assembled length ç 2. Install : • push rod # 2 ¿ in the axle main. 4. Check : • shift cam operation improper operation Ÿ reassemble/repair note : check the transmission and shift for...

  • Page 114

    Eng engine assembly and adjustments 4-40 crankcase ¿ crankcase #1 (lh) À dowel pins Á crankcase breather hose crankcase #2 (rh) Ã holder clutch cable tightening sequence ¿ Ä Æ Å Ã Á À È Ç.

  • Page 115

    Eng engine assembly and adjustments 4-41 crankcase lh 1. Apply : • sealant on the crankcase mating surfaces 2. Install : • dowel pins ¿ note : do not allow any sealant to come in contact with the oil galleries ç and è as shown in the fig- ure. Sealant yamaha bond no. 1215: 3. Install: • crankcase rh...

  • Page 116

    Eng engine assembly and adjustments 4-42 cdi magneto ¿ timing chain À guide stopper # 1 and # 2 Á cdi rotor assy wood-ruff key à stator assy. Ä gasket Å dowel pin Æ cover crankcase #1.

  • Page 117

    Eng engine assembly and adjustments 4-43 sprocket drive 1. Install • sprocket drive ¿ • drive sprocket washer À 2. Tighten • bolt Á (drive sprocket) using the sprocket holder. Timing chain and guide stopper#2 1. Install • timing chain ¿ 2. Install • guide stopper#2 À with spacer • tighten the bolt Á...

  • Page 118

    Eng engine assembly and adjustments 4-44 shift shaft and kick starter ¿ shift shaft À torsion spring Á stopper lever return spring à segment Ä kick starter assembly Å circlip Æ washer Ç kick idle gear È kick shaft assy. É cover crankcase # 2.

  • Page 119

    Eng engine assembly and adjustments 4-45 5. Install : • shift shaft assembly note : apply oil to the stopper pin and hook the spring ends on the stopper pin à 3. Install : • stopper lever ¿ • spring À 4. Tighten • bolt stopper lever Á note : hook the spring ends on the stopper lever ¿ and the crankc...

  • Page 120

    Eng engine assembly and adjustments 4-46 2. Install : following parts on the axle drive Ä • circlip ¿ • washer À • kick idle gear Á • washer • circlip à note : install circlips radius side towards the compo- nent refer chapter 1, page no 1-3 kick starter installation 1. Install : • kick axle ¿ • rat...

  • Page 121

    Eng engine assembly and adjustments 4-47 ¿ clutch spring À pressure plate Á push plate push rod #1 Ã friction plate Ä clutch plate Å clutch boss Æ thrust washer Ç primary driven gear È ball É push rod # 2 Ê push lever axle Ë primary drive gear Ì rotary filter clutch, primary drive gear and oil pump ...

  • Page 122

    Eng engine assembly and adjustments 4-48 primary drive gear installation 1. Install : • primary drive gear ¿ • key • washer À 2. Tighten : • nut Á note : hold the rotor with magneto holder then tighten the primary drive gear nut. 4. Install • rotary filter note : align the rotary filter dog ç with g...

  • Page 123

    Eng engine assembly and adjustments 4-49 4. Bend : • lock washer tab (along a flat side of the end) 5. Install : • friction plate ¿ 5 nos • clutch plate À 4 nos note : • install the clutch plates and friction plates al- ternately on the clutch boss, starting with a friction plate and ending with a f...

  • Page 124

    Eng aligned non aligned engine assembly and adjustments engine assembly and adjustments 4-50 6. Install : • ball ¿ 7. Install : • push rod # 1 ¿ • push plate À • plate washer Á • nut (push rod # 1) 8. Install : • pressure plate ¿ • compression springs À • bolts Á (clutch spring) note : match arrow m...

  • Page 125

    Eng engine assembly and adjustments 4-51 engine assembly and adjustments warning caution: take care not to overtighten the adjuster À and remove the freeplay between both push rods. • hold the adjuster to prevent it from moving and tighten the locknut to specification • tighten the locknut ¿ æææææææ...

  • Page 126

    Eng engine assembly and adjustments 4-52 ¿ cylinder À gasket cylinder Á dowel pins piston rings à piston pin circlips Ä piston Å pin piston Æ o’ ring cylinder and piston.

  • Page 127

    Eng engine assembly and adjustments 4-53 ¿ bolt flange À washer Á bolt valve cover (intake) Ã o-ring Ä valve cover (exhaust) Å cylinder head Æ dowel pin Ç gasket cylinder head È o-ring É cover cylinder head side # 3 Ê spark plug cylinder head.

  • Page 128

    Eng engine assembly and adjustments 4-54 cam sprocket and timing chain ¿ gasket À timing chain tensioner assembly Á guide stopper # 2 cam sprocket à timing chain Ä guide stopper # 1.

  • Page 129

    Eng engine assembly and adjustments 4-55 3. Install : • dowel pins ¿ - 2 nos. • gasket (cylinder) À piston ring, piston and cylinder installation 1. Install in following sequence • expander spacer (oil ring) ¿ • side rails (oil ring) À • 2nd ring Á • top ring note : • make sure to install the piston...

  • Page 130

    Eng engine assembly and adjustments 4-56 cylinder head installation 1. Install • dowel pins ¿ • gasket ( cylinder head) À • guide stopper#1 Á 4. Install : • piston rings ¿ note : offset the piston rings end gaps as shown. ç top ring end è oil ring end (lower) é oil ring end (upper) ê 2nd ring end 5....

  • Page 131

    Eng engine assembly and adjustments 4-57 2. Install : • cylinder head • bolt with washer (cylinder head) note : • apply engine oil onto the bolt thread • tighten the bolts starting with the lowest num- bered one. 3. Install : • cam sprocket À • timing chain ¿ ææææææææææææææææææææææææææææææææææ insta...

  • Page 132

    Eng engine assembly and adjustments 4-58 6. Check : • magneto rotor slit ç third mark in anticlockwise direction. Align with stationary pointer è in the crankcase cover #1 (lh) • cam sprocket “i” mark é align with stationary pointer ê on the cylinder head out of alignment Ÿ adjust 4. Install : • pla...

  • Page 133

    Eng engine assembly and adjustments 4-59 12. Install • o-ring (intake manifold) • intake manifold ¿ 13. Tighten • bolts (intake manifold) À 2 nos. 11. Install : • timing check plug (with o-ring) ¿ • center plug (with o-ring) À 10.Install : • valve covers (with o-ring) ¿ • cylinder head side cover (w...

  • Page 134

    Eng engine assembly and adjustments 4-60 14. Install : • spark plug 15. Install : • plug drain ¿ engine mounting when remounting the engine, reverse the re- moval procedure. Note the following points : 1. Install : • engine assembly (from the left side of the motorcycle) 2. Install • footrest assy 3...

  • Page 135

    Eng engine assembly and adjustments 4-61 5. Install : • gasket • exhaust pipe ¿ • bolts exhaust pipe À - 2 nos • bolt (muffler) Á 6. Install : • shift pedal ¿ 7. Tighten : • bolt shift pedal À 8. Install : • stay clutch cable ¿ 9. Install • clutch cable • adjust clutch cable free play at lever end r...

  • Page 136

    Eng engine assembly and adjustments 4-62 11. Install: • carburetor refer to “carburetor “ section in chapter 5 page no 5-7 12. Tighten: • air filter case screws 15. Install spark plug cap 16. Fill • crankcase refer to “engine oil replacement” section in chapter 3, page no 3-14 17. Adjust : • idle sp...

  • Page 137

    Carb chapter 5 carburetion carburetor view ................................................................ 5-1 removal ................................................................................... 5-2 disassembly ........................................................................... 5-3 ...

  • Page 138

    Carb carburetor carburetor 5-1 1 screw (top cover) 2 top cover 3 piston valve spring 4 holder (jet needle) 5 jet needle retainer spring 6 ring 7 jet needle e-ring 8 jet needle ring 9 washer 10 jet needle 11 piston valve assy 12 diaphragm (piston valve) 13 cap plunger 14 guide holder 15 o-ring 16 plu...

  • Page 139

    Carb carburetor 5-2 6. Remove • throttle cable - ¿ 7. Unscrew • clamp front/rear • remove carburettor from engine. 4. Disconnect : • air vent hose ¿ • fuel hose À • over flow hose Á 5. Remove : • starter wire nut - warning petrol is highly flammable. Avoid spilling fuel on the hot engine. R e m o va...

  • Page 140

    Carb disassembly 1. Open : • screw (pan head) 2-nos- ¿ 2. Remove : • cover À • spring Á • diaphragm with piston valve d i s a s s e m b ly note: the following parts can be cleaned and inspected without carburetor disassembly. • throttle cable • starter plunger assembly • fuel hose, air vent hose, ov...

  • Page 141

    Carb carburetor body 1. Inspect : • cracks/damage Ÿ replace • fuel passages blockage Ÿ clean with petrol and compressed air. • contamination in jet housings Ÿ clean disassembly/inspection 6. Remove : • needle valve- ¿ 7. Open : • main jet- À # 127.5 • main nozzle- Á • pilot jet- 8. Remove : • pilot ...

  • Page 142

    Carb inspection starter assembly 1. Inspect : • starter plunger movement • starter spring • starter wire piston valve 1. Check : • free movement insert the piston valve with diaphragm in carburetor body, and check for free movement hinderance Ÿ clean/replace float 1. Inspect : • damage/leakage Ÿ rep...

  • Page 143

    Carb assembly reverse the disassembly procedure. 1. Wash • all the parts in clean petroleum based solvent • always use new ‘o’ rings 2. Install : • pilot screw assembly ¿ assembly 7. Install • throttle stop screw assembly ¿ 6. Install • seal float chamber ¿ • float chamber À • screw - 3 nos. Á 5.Tig...

  • Page 144

    Carb installation 5-7 installation reverse the “removal” procedure 1. Carburettor inlet manifold and tighten air filter hose. Screw front/rear clamp 2. Install : throttle cable assembly ¿ on carburettor. 3. Starter cable assy À. 4. Connect : • over flow hose Á • air vent hose • fuel hose à 8. Instal...

  • Page 145

    Carb carburetor tuning 8. Adjust : • idling speed by throttle stop screw ¿ 5-8 turning in Ÿ rpm increases turning out Ÿ rpm decareses engine idling speed : 1300 - 1500 r.P.M. 9. Adjust : • throttle cable free play refer to “throttle cable adjustment” in chapter 3, page no 3-9 carburetor tuning ‘co m...

  • Page 146

    Carb warning caution: do not disturb settings of the carburetor if the engine performance is o.K. • if required, must record the existing set- ting (no. Of turns) of the pilot screw. • to counter check the setting of the pilot screw, follow the ‘co’ adjustement proce- dure. • ensure proper clamping ...

  • Page 147

    Carb carburetor tuning 5-10 by bending down Ÿ float height increase by lifting up Ÿ float height decrease • otherwise adjust float level by bending the float tang on the float slightly up or down as required. • install the carburetor • recheck the fuel level • adjust float height through float tang ...

  • Page 148

    Carb multimeter ytps + terminal of blue wire - terminal of black wire • check tps output voltage multimeter ytps + terminal of yellow wire - terminal of black wire if out of specifications, adjust ytps angle with in specifications by loosening ytps screw ¿ • check/adjust the idle rpm - 1300~1500 • r...

  • Page 149

    Carb carburetor tuning air induction system air injection the air induction system burns unburned exhaust gases by injecting fresh air(secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing seco...

  • Page 150

    Chas chapter 6 chassis front wheel and front brake ........................................ 6-1 front wheel ......................................................................... 6-1 front brake .......................................................................... 6-2 removal ..................

  • Page 151

    Chas front wheel ¿ cotter pin À axle nut Á speedometer cable assy. Wheel axle à spacer Ä brake shoe plate assy. Å dust seal/collar Æ front wheel front wheel and front brakes 6-1.

  • Page 152

    Chas front brake ¿ brake shoe assy. À oil seal Á gear drive lever camshaft à indicator plate Ä camshaft front wheel and front brakes 6-2 Å bush Æ plate washer Ç gear meter È o-ring ¿ Ç Æ Å È Ã Ä Á À.

  • Page 153

    Chas front wheel and front brakes warning • securely support the motorcycle on the centre stand so that there is no danger of it falling over. • park the motorcycle on a level surface 3. Disconnect • speedometer cable ¿ by removing the clip À 5. Remove • front wheel axle ¿ • brake shoe plate assembl...

  • Page 154

    Chas front wheel inspection : 1. Inspect • front wheel axle (by rolling it on a flat surface) bends Ÿ replace 2. Inspect : • front tyre wear/damage Ÿ replace refer to “tyre inspection” in chapter 3, page no 3-26 • front wheel refer to “wheel inspection” in chapter 3, page no 3-27 3. Check : • spokes...

  • Page 155

    Chas 5. Measure : • front wheel runout using a height gauge over the specified limits Ÿ correct/replace 6. Inspect : • front wheel bearings bearings allow free play in the wheel hub or the wheel does not turn smoothly Ÿ replace • oil seals wear/damage Ÿ replace 7. Inspect : • collar grooved wear Ÿ r...

  • Page 156

    Chas front wheel and front brakes front brake inspection 1. Inspect : • brake lining surface glazed areas Ÿ replace use coarse sand paper for polishing of brake lining note: after polishing , wipe the polished particles with a cloth. 2. Measure : • brake lining thickness ç out of specification Ÿ rep...

  • Page 157

    Chas front wheel and front brakes 6-7 warning after installing the brake camshaft, remove the excess grease 5. Install : • brake shoe plate assembly ¿ note : make sure that the wheel hub and the speed- ometer gear unit are installed with the two pro- jections ç meshed into the two solts è 6. Install...

  • Page 158

    Chas front wheel installation reverse the “removal” procedure note the following points 1. Lubricate : • axle front wheel • bearings • oil seal (lips) • drive/driven gear (speedometer) front wheel and front brakes 6-8 warning caution: before tightning the wheel axle, stroke the front fork several ti...

  • Page 159

    Chas 5 install : • meter cable ¿ • clip À • brake cable Á thru nozzle • bush • nut 6. Check : • front brake for proper operation improper operation Ÿ recheck or disassemble. 7. Adjust • brake lever free play refer to “front brake adjustment” section in chapter 3, page no 3-18 front wheel and front b...

  • Page 160

    Chas rear wheel ¿ adjuster À pin Á compressionspring cotter pin à tension bar Ä axle nut Å chain puller Æ spacer Ç rear wheel assembly È brake shoe plate assembly É damper Ê bearing Ë spacer/collar Ì bearing rear wheel and rear brake 6-10

  • Page 161

    Chas rear brake ¿ brake shoe kit À cam lever Á indicator plate camshaft à spring rear wheel and rear brake 6-11 Ã.

  • Page 162

    Chas rear wheel and rear brake 6-12 warning • securely support the motorcycle on centre stand so that there is no danger of it fall- ing over • stand the motorcycle on a level surface removal 1. Remove : • chain cover (upper ¿ and lower À) 2. Loosen • chain adjuster Á 3. Remove : • nut (rear brake) ...

  • Page 163

    Chas rear wheel and rear brake 6-13 rear wheel inspection 1. Inspect : • axle rear wheel • rear wheel • bearings rear wheel • oil seals refer to “front wheel inspection” page no 6-4 2. Measure : • rear wheel runout refer to “front wheel inspection ” page no 6-4 3. Inspect : • clutch hub damper wear/...

  • Page 164

    Chas rear wheel and rear brake 6-14 warning always use a new cottor pin rear wheel installation reverse the “removal” procedure 1. Install : • chain adjuster in rear swinging fork • rear wheel assembly in sprocket hub with spacer • brake shoe plate assembly • spacer between chain sprocket and frame ...

  • Page 165

    Chas drive chain and sprockets ¿ chain case À crankcase cover 3 Á drive sprocket clip chain joint à link plate Ä chain joint Å drive chain Æ spacer Ç driven sprocket assembly È chain tensioner adjuster É circlip Ê oil seal drive chain and sprockets 6-15.

  • Page 166

    Chas drive chain and sprockets 6-16 5. Remove : • rear wheel assy. Removal refer to rear wheel removal on page 6-12 • rear wheel sprocket assy. 4. Remove : • chain joint clip ¿ • link plate À • chain joint Á • drive chain warning securely support the motorcycle on centre stand so that there is no da...

  • Page 167

    Chas drive chain inspection 1. Inspect : • drive chain stiffness stiffness Ÿ clean and lubricate or replace drive chain and sprockets 6-17 4. Clean : • drive chain put it in kerosene and brush off as much dirt as possible. Then remove the drive chain from the ketosene and dry it. 3. Measure : • 10 l...

  • Page 168

    Chas 6-18 drive chain and sprockets clutch hub inspection 1. Inspect : clutch hub wear/damage/cracks Ÿ replace driven sprocket and drive chain installation 1. Install : • chain tensioner in rear swinging fork • driven sprocket spacer ¿ with drive sprocket assembly • axle rear wheel À with washer. 2....

  • Page 169

    Chas drive chain and sprockets warning caution: be sure to install the chain joint clip to the di- rection as shown 6-19 3. Install : • drive chain ¿ • chain joint À • plate Á • chain joint clip 4. Install : clip ¿ new 5. Install : • chain case (upper) • chain case (lower) • crank case cover - 3 ref...

  • Page 170

    Chas front fork 6-20 front fork ¿ front fender À cap bolt with gromet Á holder cable o ring à collar Ä spring seat Å fork spring Æ seal dust Ç ring snap È washer É bolt Ê gasket Ë spindle taper Ì cylinder comp front fork Í inner tube Î sub spring Ï oil seal Ð outer tube Á À.

  • Page 171

    Chas front fork 6-21 warning securely support the motorcycle so there is no danger of it falling over front fork disassembly 1. Remove • bolt upper -tff Á 2. Drain : • fork oil 3. Remove : • spacer ¿ • seat upper À • spring front fork Á 3. Remove : • front wheel • front fender refer to “front wheel ...

  • Page 172

    Chas front fork 6-22 warning caution: never reuse the oil seal 6. Remove : • ring snap • washer • oil seal ¿ using oil seal remover À 5. Remove : • bolt (damper rod) ¿ • washer À • cylinder complete fornt fork Á • spindle taper • spring sub à 4. Loosen : • bolt allen (damper rod) ¿ loosen the bolt (...

  • Page 173

    Chas front fork front fork inspection 1. Inspect : • inner tube bending scratches/bends/damage Ÿ replace 2. Measure : • fork spring length ç over the specified limit Ÿ replace 3. Inspect : • cylinder complete front fork ¿ • piston ring À wear/cracks/damage Ÿ replace • spring sub Á • spindle taper be...

  • Page 174

    Chas front fork 6-24 warning allow the cylinder complete to slide slowly down the inner fork tube until it protrudes from the bottom, being careful not to dam- age the inner fork tube 3. Install : • cylinder complete ¿ • spindle taper À • inner tube Á • outer tube front fork assembly reverse the “di...

  • Page 175

    Chas front fork 6-25 warning caution: make sure that the oil seal numbered side faces upward 7. Install : • washer ¿ • ring snap À • dust seal Á 5. Tighten : • bolt (cylinder complete) ¿ holding the cylinder complete with a t-handle À 6. Install : • oil seal ¿ new using tff oil seal installation too...

  • Page 176

    Chas front fork installation reverse the “removal procedure” note the following points 1. Install • front fork • temporarily tighten pinch bolt (underbracket) ¿ note: pull up the inner to until its end flushes with the top of the handle crown then temporarily tighten the bolts (underbracket) 2. Tigh...

  • Page 177

    Chas steering head and handlebar 6-27 steering head and handlebar ¿ bolt steering À holder handle bar upper Á handlebar grip assembly (right) Ã handle crown Ä lock washer Å ring nut (upper) Æ damper rubber Ç ring nut (lower) È ball race cover É under bracket Ê ball race (upper) Ë ball (upper) Ì ball...

  • Page 178

    Chas steering head and handlebar 6-28 warning securely support the motorcycle so that there is no danger of it falling over stand the motorcycle on a level surface removal 1. Remove : • band ¿ • brake cable (front) À • clutch cable Á • speedometer cable 2. Remove : • starter wire ¿ • switch handle À...

  • Page 179

    Chas steering head and handlebar 6-29 warning securely support the steering shaft so that there is no danger of it falling down warning do not attempt to straighten a bent handle- bar as this may dangerously weaken the handlebar ring nut wrench : ysst - 621 handlebar inspection 1. Inspect : • handle...

  • Page 180

    Chas 1 2 steering head and handlebar steering inspection 1. Wash the bearing and ball races with a sol- vent 2. Inspect : • bearing races ¿ • ball cage bearing À pitting/damage Ÿ replace ææææææææææææææææææææææææææææææææææ bearing race replacement steps : • remove the ball races on the head pipe us- ...

  • Page 181

    Chas steering head and handlebar 4. Install : • front fork refer to “front fork” section, page no 6-27 • front fender • front wheel refer to “front wheel” section, page no 6-8 handlebar installation 1. Install : • holder handelbar lower ¿ • handlebar ¿ • upper handlebar holder À note : • apply a lig...

  • Page 182

    Chas rear shock absorber and swing arm rear shock absorber and swingarm ¿ rear shock absorber À axle nut Á swing arm tension bar à seal guard 6-32.

  • Page 183

    Chas rear shock absorber and swing arm removal 1. Stand the motorcycle on a level surface. 2. Remove : • side covers (left and right) • seat • cover chaincase • chain case (upper and lower) refer to “side covers, seat, and fuel tank ” section in chapter 3, page no 3-3 3. Remove : • rear wheel • driv...

  • Page 184

    Chas rear shock absorber and swing arm inspection 1. Inspect : • swingarm looseness looseness exists Ÿ tighten the pivot shaft nut or replace bushes • swingarm up and down movement unsmooth movement/bending/rough spots Ÿ replace bushes 2. Inspect : • rear shock absorber oil leaks/damage Ÿ replace th...

  • Page 185

    Elec chapter 7 electrical circuit diagram ................................................................... 7-1 location of electrical components ......................... 7-2 checking of connections ............................................... 7-3 ignition system/charging system circuit diagra...

  • Page 186

    Elec circuit diagram 7-1.

  • Page 187

    Elec ¿ main switch À flasher relay assy Á c.D.I. Unit assy battery à fuse Ä stop switch rear Å neutral switch assy Æ rectifier / regulator assy Ç ignition coil assy È spark plug cap É horn Ê throttle position sensor (tps) location of electrical components electrical components 7-2 Ê.

  • Page 188

    Elec checking of connections dealing with wire pressed stains, rust, moisture etc. On the connector. 1. Disconnect • connector ¿ 2. Dry each terminal with an air blower 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. Checking of connec...

  • Page 189

    Elec ignition system/ charging system ignition system, charging system and tachometer system trouble shooting if the ignition system fails to operate. (no spark or intermittent spark) procedure check 1. Spark plug 2. Spark plug cap resistance 3. Ignition coil 4. Main switch 5. Sensor coil resistance...

  • Page 190

    Elec ignition system / charging system procedure steps 1. Spark plug • check the spark plug condition • check the spark plug type • check the spark plug gap • refer to “spark plug inspection“ section in chapter 3, page 3-10 standard spark plug cr7hsa - ngk out of specification adjust or replace the ...

  • Page 191

    Elec ignition system / charging system 3a. Ignition coil resistance (primary) • disconnect the ignition coil connector from the wire harness • connect the multimeter to the ignition coil. • check the primary coil resistance multimeter (+) lead Ÿ black/blue terminal ¿ multimeter (-) lead Ÿ green term...

  • Page 192

    Elec 5. Sensor coil resistance • disconnect the sensor coil coupler from the wiring harness • connect the multimeter ( Ω x 100) to the sensor coil coupler • check the sensor coil resistance replace the sensor coil assembly out of specification meets specification sensor coil is ok 6. Charging coil r...

  • Page 193

    Elec 7. Rectifier cum regulator unit • check the charging voltage procedure steps • connect the tachometer to spark plug lead • connect the multimeter ( dc 20v) to bat- tery red wire. Measure the battery voltage : 12v if less than specifications, charge the battery • start the engine and accelearte ...

  • Page 194

    Elec charging system trouble shooting procedure check 1. Fuse 2. Battery 3. Charging voltage 4. Charging coil resistance 5. Wiring system (entire charging system) note : remove the following parts before trouble shoot- ing. 1) side covers (lh ) • use service instruments as specified. 1. Fuse refer t...

  • Page 195

    Elec lighting system trouble shooting if the head light, hi beam indicator light, taillight and meter light do not work procedure check 1. Lighting coil resistance 2. Light switch 3. Dimmer switch 4. Lighting voltage 5. Wiring connections (entire lighting system) 6. Check individual lighting circuit...

  • Page 196

    Elec lighting system 1. Lighting coil resistance • remove the c.D.I. Magento coupler from the wiring harness • connect the multimeter ( Ω x 1) to the light- ing coil • measure the lighting coil resistance multimeter (+) lead Ÿ yellow terminal ¿ multimeter (-) lead Ÿ black terminal À replace the ligh...

  • Page 197

    Elec lighting system 5. Wiring connections • check entire lighting system for poor con- nections refer to “wiring diagram” page check the lighting coil resistance out of specification meets specification • repair or replace wireharness poor connections continuity • check the condition of individual ...

  • Page 198

    Elec lighting system 1. Bulb and bulb socket • check the bulb and bulb socket for continuity. C. If the tail light does not work replace bulb and/or bulb socket. No continuity 2. Lighting voltage • refer the lighting voltage section page no 7-12 continuity 1. Bulbs and bulb sockets • check the bulbs...

  • Page 199

    Elec signal system signal system circuit diagram : dc trouble shooting if the flasher light, brake light and indicator lights do not work if the horn does not work procedure check 1. Fuse 2. Battery 3. Main switch 4. Wiring connections (entire lighting system) 5. Check individual lighting circuits n...

  • Page 200

    Elec signal system 1. Fuse refer to “fuse inspection section “ in chapter 3, page 3-30 2. Battery • check the battery condition refer to “battery inspection sec- tion” in chapter 3, page 3-28 continuity no continuity replace fuse 3. Main switch • disconnect the main switch coupler from wireharness •...

  • Page 201

    Elec signal system 1. Horn switch • disconnect the handlebar switch coupler from wireharness. • check the continuity between the “pink” and “black” with switch in pressed position. A. If the horn does not work. No continuity 2. Voltage • connect the multimeter (dc20 v) to the horn lead • turn the ma...

  • Page 202

    Elec signal system 1. Bulb and bulb sockets • check the bulb and bulb sockets for con- tinuity. B. If the brake light does not work. Replace bulb and/or bulb socket. No continuity continuity replace the brake switch out of specification 3. Voltage • connect the multimeter “dc20v” to bulb socket conn...

  • Page 203

    Elec signal system 1. Bulb and bulb socket • check the bulb and bulb socket continuity c. If the flasher light and/or turn indicator light fails to blink. Replace the bulb and/or bulb socket 2. Turn switch • disconnect the handlebar switch (left) cou- pler from wireharness. • check the switch compon...

  • Page 204

    Elec signal system 5. Voltage • connect the multimeter (dc20v) to the bulb socket connector • turn the main switch to ‘on’ • turn the turn switch to left or right • check for voltage (12v) on the “chocolate” lead and “dark green” at the flasher light terminal. At flasher light (lh) multimeter (+) le...

  • Page 205

    Elec signal system check the connection of the entire signal system. Refer to “circuit diagram” page no 7-14. 1. Bulb and bulb socket • check the bulb and bulb socket for conti- nuity. 2. Neutral switch • disconnect the neutral switch lead. • check the continuity between the switch terminal and grou...

  • Page 206

    Trbl shtg chapter 8 trouble shooting starting failure/ hard starting .................................. 8-1 poor idle speed performance ...................................... 8-2 poor medium and high speed performance ............ 8-2 poor speed performance .............................................

  • Page 207

    Trbl shtg starting failure / hard starting note: the following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the related procedure in this manual for inspection, adjustment and replacement of parts. Compressi...

  • Page 208

    Trbl shtg poor idle speed performance ignition system spark plug • improper plug gap • worn electrodes • wire between terminals broken • improper heat range • faulty spark plug cap ignition coil • broken or shorted primary /secondary coil • faulty high tension cord • broken ignition coil body igniti...

  • Page 209

    Trbl shtg poor speed performance ignition system • dirty spark plug • improper heat range • faulty c.D.I. Unit • faulty sensor coil fuel system • partially clogged fuel tank cap breather hole • clogged air cleaner element • clogged jet • improperly adjusted fuel level compression system • worn cylin...

  • Page 210

    Trbl shtg faulty gear shifting / overheating faulty gear shifting hard shifting refer to “clutch dragging’’ page no 8-3 shift pedal does not move shift shaft • bent shift shaft shift cam shift fork • groove jammed with impurities • seized shift fork • bent shift fork guide bar transmission • seized ...

  • Page 211

    Trbl shtg front fork malfunction / unstable handling front fork malfunction oil leakage • bent damaged or rusty inner tube • damaged or cracked outer tube • damaged oil seal lip. • loose hexagon bolt • damaged cap bolt o-ring • improperly installed oil seal malfunction • bent inner tube • deformed o...

  • Page 212

    Trbl shtg faulty signal and lighting system faulty signal and lighting system headlight dim • improper bulb • too many electric accessories • hard charging • faulty rectifier/regulator • faulty battery • improperly connected coupler, connector wire harness • improperly grounded • faulty main switch ...

  • Page 213

    Yamaha motor india pvt. Limited 19/6, mathura road, faridabad - 121 006 india printed in india 5yy (fazer) 1y16(wm-01)-204-10-04-e.