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Yamaha JYM125 Service Manual

Summary of JYM125

  • Page 1

    Ybr125(jym125/125-2) chongqing jianshe·yamaha motor co.,ltd first edition jan.2003 all rights reserved.Copy in any manner, in whole or part,or use without written authorization of company,prohibited..

  • Page 2

    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...

  • Page 3

    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 chapte second title :this title is shown in ...

  • Page 5

    Index § 1 general information § 2 specification § 3 periodic inspection and adjustment § 5 carburetor § 6 chassis § 7 electrical system § 4 engine 8 § 8 troubleshooting 7 6 5 4 3 2 1 gen info adj.

  • Page 6

    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...

  • Page 7

    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 ……………………………………………………………… ……………………………………………………………………………………… ………………………………………………………………………...

  • Page 8

    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...

  • Page 9

    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 ...

  • Page 10

    Chapter 1 general information motorcycle identification ………………………… motorcycle identification code points for attention in maintenance special tool …………………… ……………… ……………………………………….

  • Page 11

    Gen info 1 motorcycle identification general information motorcycle identification motorcycle identification code motorcycle identification code is stamped on the right side of steering bar.It consists of three portions.First portion (the first 3 digits) is the identification code of world manufact-...

  • Page 12

    1 gen info.

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    1 gen info.

  • Page 14

    Note: do not use compressed air to spin the bearings dry. This will damage the bearing surfaces. 1 ge n info.

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    1 gen info.

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    1 gen info.

  • Page 17

    Main specification inspection specification engine …………………………………………………2-1 ……………………………………………2-4 …………………………………………………………2-4 chassis electrical system main tighten torque specification pos ition to be ap plied lu bricati ng-oil and kind s of lu bricati ng-oil …………………………………………………………2-6 ………………………………………………...

  • Page 18

    2 2 2 yamalube,four-strokesae20w40sf’’or “sae10w30sf” machine oil machine oil type: engine oil.

  • Page 19

    2 vm22sh mikuni cr6hsa 0.6mm 0.7mm wet,multi-piece spur gear chain drive constant mesh 5-speed shift left 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) diamond 26.4 with tube 2.75-18(42p) 90/90-18(51p) 175kpa(1.75kgf/cm) 196kpa(2.0kgf/cm) 2...

  • Page 20

    2 wheelbase position neutral light highbeam indicator steering indicator steering light bulb(voltage/watt×quantity): headlight brake light/tail light meter light headlinght type headlight bulb type electrical system ignition system generator system battery type battery capacity shock absorber: front...

  • Page 21

    2 0.08~0.12mm 0.10~0.14mm.

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    5.000 5.012mm 5.000 5.012mm 0.010 0.037mm 0.025 0.052mm 2.

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    2.

  • Page 24

    2 rear wheel type rim dimension rim material rim runout (radial) (lateral) did1480h 118 20 30mm clutch lever clutch lever free play brake lever and brake pedal: free play of front brake free play rear brake type model of brake drum inside diameter of brake drum thickness of brake block free length o...

  • Page 25

    2 7 n.

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    2 tighten torque tighten torque engine 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-...

  • Page 27

    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-f51...

  • Page 28

    Tighten torque 2 for noraml tighten torque,tighten screw and nut can decide tighten torque according to diameter of thread(width of two faces)and space of thread except appointed tighten torque.(see the table in the right side). Dia of screw(width of two faces) space of thread × tighten torque m5(8m...

  • Page 29

    2 position 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 st...

  • Page 30

    2 position to be applied lubricant 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 position to be applied lubricant symbol surroundings 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 fa...

  • Page 31

    2 rocker arm(intake) arm(exhaust) cam shaft rocker arm shaft rocker lubrication diagram centrifugal filter oil pump pushing rod filtering web 2 - 14.

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    2.

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    2 layout of cable pipline e wire of starting generator shall pass through the inte rior ofbattery f flowing guide tube of battery shall pass through the interior of battery g fix the wire of magneto and brake switch at the wire clip h pass the brake cable and flexible shaft of meter though guide fra...

  • Page 34

    2 layout of cable pipline drum type without fairing.

  • Page 35

    Drum type without fairing 2 layout of cable pipline a pass the wire of the cable,brake cable,brake switch and handle bar switch through guide frame. B pass the wire of clutch cable,handle bar switch and clutch switch through guide frame. C fix the wire of left handle bar switch and clutch switch wit...

  • Page 36

    2 layout of cable pipline disc type with fairing.

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    2 layout of cable pipline disc type without fairing.

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    2 layout 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 4 5 6 7 8 9 2 - 21.

  • Page 39

    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 o...

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    3 insp adj ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ routine run-in period or 1 month 1,000 (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* ...

  • Page 41

    3 insp adj routine run-in period or 1 month 1,000 (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...

  • Page 42

    3 insp adj removal and installation of cushion, fuel tank and cove alike 1.Side cover(left) open with 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 position with screwdriver,then pull out set p...

  • Page 43

    3 insp adj 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.Installation conduct as per reverse procedure of removal operation pay attention to the following 1.Instal...

  • Page 44

    3 insp adj inspection and adjustment of air valve clearance engine inspection and adjustment of air valve clearance note: the valve clearance must be adjusted when the engine is cool. Adjust the air valve clearance when the piston is at the top dead center(t.D.C) on compression stroke. 1.Remove the ...

  • Page 45

    3 insp adj inspection and adjustment of air valve clearance 4.Turn the rotator counter-clockwise,align the t.D.C mark 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:0.08 0.12 mm ex:0.10 0.14 mm co...

  • Page 46

    3 insp adj idle 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 ...

  • Page 47

    3 insp adj drainage and adjustment of freeplay of throttle cable 5.Remove the following parts rpm meter of engine adjustmet of co content at idle speed n 1. 2. Install the following measuring meter:measuring meter with detector for normal temperature and rpm meter of engine. Warm the engine until th...

  • Page 48

    3 insp adj adjustment of frdd play of throttle cable and check of spark plug note: when the adjustment could not done by the steel cable at throttle handle bar,it could be done by the adjuster at the carburetor. Second step(carburetor) loosen the locking screw adjust the adjuster screw in→increase t...

  • Page 49

    3 insp adj check of compression pressure note: insufficient compression pressure wil result in the performance loss. 1. 2. 3. 4. 5. Check: air valve clearance→adjust refter to "adjustment of air valve" start and warm the engine for several minutes. Stop the engine remove:spark plug install: pressure...

  • Page 50

    3 insp adj check of lubricant quantity of engine/recommended lubricant oil/replace engine lubricant oil check of lubricant quantity of engine note: when inspecting,the motorcycle should be rested at flat position and in vertical condition. 1.Conduct the following check lubricant quantity of engine r...

  • Page 51

    3 insp adj re place ment of engine lubricating- oil/ check of lubricating -oil pressure replacement of engine oil note: do not add any chemical additives.Engine oil also lubricates the clutch and additives could cause clutch slippage.Do not allow foreign material to enter the crankcase. 1. 2. 3. 4. ...

  • Page 52

    3 insp adj adjustment ofclutch/adjustment of front brake adjustment of clutch 1.Check: freeplay of clutch cable a out of specified range →adjust free play: 10 15mm measure at end portion of clutch lever 2.Adjust: free play of clutch cabl 1. 2. 3. E confirm that adjusting device and locking nut have ...

  • Page 53

    Clear of air filter clear of air filter 1.Remove side cover(right) cushion case of air filter 2.Remove core of air filter 3 - 14 install filter core 2 on filter core. 1 2 note: there is check hose at the bottom of the air filter.If dust or water collects in this hose,clean the air filter core and ca...

  • Page 54

    3.Check: clean of air filter 3 insp a dj 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 n...

  • Page 55

    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...

  • Page 56

    Check of front brake 3 insp a dj check of front brake(disk-type) wrning if feeling loose and soft braking,the bad brake effect may be caused by oil leakage or mixing with air.You should check brake liquid capacity,and lock brake steel cable,or eliminate air. 1. 2. Conducting following check: if ther...

  • Page 57

    Check the brake liquid quantity/exhausting air 3 insp a dj check the brake liquid quantity 1.Conduct following checking brake liquid level check the liquid level when the brake liquid level cover is in horizonal state.The liquid level should be above in figure. If the liquid level is below the lower...

  • Page 58

    3 insp a dj exhausting air/replacing brake liquid warning grip the brake hadlebar to check brake liquid leakage, wipe off the brake liquid sprayed on brake disk, tire and rim. Warning 6.Refit the diaphragm of brake liquid vat. 7.Refit the cover of brake liquid vat. Replacing brake liquid: 1.Make the...

  • Page 59

    Checking,adjusting rear brake/check of rear brake shoe 7. 8. Operate the brake handlebar until no bubble sends out from the small hole of brake liquid vat and the brake handlebar is felt powerful. Release air. Assemble according to reverse procedures after adjus- ting . 9. 3 insp a dj check and adju...

  • Page 60

    3 insp a dj checking rear brake light switch/checking,adjusting driving chain checking rear brake switch 1. 20 30mm. Conduct following checking brake light check if the brake light comes on when treading down the brake pedal brake light does not come on adjustment (rotate the adjusting nut for adjus...

  • Page 61

    3 insp a dj checking,adjusting driving chain/check of fronk fork checking,adjust driving chain note: there is graduation mark on chain adjuster.When adjusting,should ensure the identical graduation value on driving chain adjusters of two sides of rear arm. After the left and right adjuster is adjust...

  • Page 62

    3 insp a dj 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 →...

  • Page 63

    3 insp a dj check of tire warning 1.Measure tire pressure exceeding specified valueadjustment → front wheel rear wheel pressure of cold tire 175kpa (1.75kgfcm ) 2 196 (2.0 kpa kgf/cm ) 2 196kpa (2.0kgf/cm ) 2 245 (2.5 kpa kgf/cm ) 2 load below 0~90 kg * max,load 100kg * * load means total weight of ...

  • Page 64

    3 insp a dj 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 front fork 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 tu...

  • Page 65

    3 insp a dj check of battery check of battery 1. 2. Disassemble: side cover(left) reter to section “disassembly of side cover” check: electrolyte level the electrolyte level must be between upper mark line if the electrolyte level is too low, supply the electrolyte properly. And lower mark line . No...

  • Page 66

    Warning 5. 6. Connet: airflow hose must confirm firm connection and correct way of air flow hose. Check: specific gravity smaller than1.08 recharge → charging current:0. 5 a / 10 h specific gravity:1.28 at 20 68o f replace the battery when finding following condition. During charging,the votage can ...

  • Page 67

    Warning method 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 pro...

  • Page 68

    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 disa...

  • Page 69

    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 ………………………...

  • Page 70

    Eng disassembly 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 pip...

  • Page 71

    Eng disassembly 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 chain loosen nut of rear wheel shaft 1. 2. 3. : : disassemble shift p e dal disassemble small chain gear driving chain kick s...

  • Page 72

    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 engine cylinder cover, cylinder and pi...

  • Page 73

    Eng disassembly of engine 4. 5. 6. Disassemble: air valve cover(intake) : air valve cover ( exhaust) disassemble side cover of cylinder co v er timing adjustment make the mark “ ” on rotator aiming at the fixing needle on crankcase cover. 3 ******************************* *********** timing adjustin...

  • Page 74

    Eng disassembly 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 eac...

  • Page 75

    Eng disassembly 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 a piece of clean cloth on crankcase t...

  • Page 76

    Eng disassembly of engine disassembling tool of piston pin : 90890-01304 left crankcase cover,starting motor disconncct 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. Dis...

  • Page 77

    Eng disassembly of engine 3. : disassemble bolt clutch spring pressing pan friction wafer clutch wafer pushing rod 1 steel ball note: firstly loosen each bolt 1 /4 turn according to order of opposite angle, then remove all bolts. 4. Flatten: smoothen the tongue of lock washer 5. Loosen: nut note: wh...

  • Page 78

    Eng disassembly 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 copper bar etc . Between main driven gear and primary driving gear ( see a ). Fix with sle...

  • Page 79

    Eng disassembly 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...

  • Page 80

    Eng disassembly 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. 90890-01701 rotator jig: 2. Disassemble: rotator half-round key note: push the fly wheel backward with disassembling t...

  • Page 81

    Eng disassembly of engine 3. Disassemble : s tarting idle gear 1 4. : washer disassemble pressing plate of gear starthing idle gear 2 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 ...

  • Page 82

    Eng disassembly 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 of crankcase . Balance device , transmission and shift rod 1. Disassemble: guide rod of...

  • Page 83

    Eng disassembly of engine 1. Disassemble main axle inner pushing rod of cl u tch 2 dri v ing axle washer pushing rod of clutch 3. : disassemble idle switch disassembly of crank and balance 1. Disassem : le b balance block crank disassemble with disassembling tool of crank . 90890-01135 disassembling...

  • Page 84

    Eng disassembly of engine rocker arm and camshaft 1. Disassemble: lock pressure plate 2. Disassemble : c amshaft ( with bearing note : disassemble the camshaft with 8 mm bolt . 3. Disassemble: rocker shaft rocker arm note : disassemble the rocker arm with sliding hammer bolt and weight block . Slidi...

  • Page 85

    Eng disassembly of engine valve before disassembling the inner parts of cylinder head (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 secti...

  • Page 86

    Eng disassembly 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 them to oringinal position. 4 - 17.

  • Page 87

    Eng check 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 damagement of the spark plug thread and air valve seat. 2. Check: cylinder head scratched marks damage→replacement 3. Measure: the tilt of cylind...

  • Page 88

    Eng check 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 a...

  • Page 89

    Eng check 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 ...

  • Page 90

    Eng check 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...

  • Page 91

    Eng check 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 toler...

  • Page 92

    Eng check 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 →r...

  • Page 93

    Eng check and repair length of convex part of cam: exhaust: a standard: 25.841 25.941 mm limitation: 25.811 mm b standard: 21.050 21.150 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 adju...

  • Page 94

    Eng check and repair 3. Measure: outer diameter b of rocker shaft outer diameter of rocker shaft: standard value:9.981 9.991 mm limitation:9.95 mm timing chain,sprocket,guide plate of chain and chain tensioner 1. Check: timing chain hardening or crack→replace the whole set of timing chain and chain ...

  • Page 95

    Eng check 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 ...

  • Page 96

    Eng che 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 of cylinder outer dia- meter of pis...

  • Page 97

    Eng check 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 sp...

  • Page 98

    Eng check and repair 3.Measure: end clearance note: when measuring the oil ring end clea ran ce,do not m easur e at p art in g slip of cup r in g of oil r in g .O nly can measure the end cle aran ce of upper and lower guard rails. If the clearance is too large, replace all the rings. Three end clear...

  • Page 99

    Eng check 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,unsta...

  • Page 100

    Eng check 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→replaci...

  • Page 101

    Eng check and repair 3. Measure: thickness of friction wafer exceeding specified value range→replacing the whole set 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→replaci...

  • Page 102

    Eng check 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 shi...

  • Page 103

    Eng check 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 ...

  • Page 104

    Eng check 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 ...

  • Page 105

    Eng check 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...

  • Page 106

    Eng check and repair 2.Check: centrifugal eigine oil filter → → crazine, damage replacement dirty washing 3.Check engine oil filter net crazine, damage replacement dirty washing → → crankcase 1. 2. 3. Rinse the combinating face of the crankcase thoroughly with a little warm solvent. Wash all matchin...

  • Page 107

    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 itself through blowing in compressed air.Otherwise will cause damage of bearing surface. 2. Check: o...

  • Page 108

    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...

  • Page 109

    Assembling and adjustment of engine eng assembly of engine and adjustment of air valve 1.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...

  • Page 110

    Assembling and adjustment of engine eng 4.Mount: lock piece of air valve note: when mounting the air valve lock piece,compress the spring 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 ...

  • Page 111

    Assembling and adjustment of engine eng 3.Mount: camshaft 4.Mount: pressing plate bolt 4-42.

  • Page 112

    Assembling and adjustment of engine eng crank and balance device crank bearing crank pin semi-round key crank(left) connecting rod balancer balancer bearing roller bearing of end side 4-43.

  • Page 113

    Mount of crank and balance axle 1.Mount: crank shielding hood of crank assembly: 90890-04081 sleeve of crank assembly 90890-01274 bolt of crank assembly 90890-01275 template pipe joint 90890-01378 assembling and adjustment of engine eng note: keep the connecting rod on dead piont. When mounting, nev...

  • Page 114

    Assembling and adjustment of engine eng transmission assembly 16 17 18 main axle circlip bearing 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-5gear drive gear-2gear driv...

  • Page 115

    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.

  • Page 116

    Assembling and adjustment of engine eng installation of thransmission,change cam and change 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...

  • Page 117

    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) cha...

  • Page 118

    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.

  • Page 119

    Crankcase(right) 1. Application seal gum (apply to the linking surface of left and right crankcase) 2. 3. Installation: dowel pin installation 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 hole ...

  • Page 120

    Assembling and adjustment of engine eng shift shafl,pedal spindle and pedal idle speed gear shift shaft retainer reset spring tortion spring star wheel start shaft assy 11 circlip washer idler pulley washer circlip 4-51.

  • Page 121

    Assembling and adjustment of engine eng shiftcam 1. Installation: dowel pin 2. Installation star wheel note: when installing the star wheel ,pay attention to install the pin hole on the star wheel and the pin hole a on the cam correctly. 3. Installation: retainer spring bolt (retainer) 1.0kgf.M (10n...

  • Page 122

    Assembling and adjustment of engine eng pedal shaft and pedal idle speed gear 1. Installation : drive shaft hoop s pring n: ote the 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 wash...

  • Page 123

    19paper pad of oil 1 push plate push rod friction liner clutch plate spring press plate clutch hub retaining washer main driven gear steel ball push rod push rod assy 11 12 13 14 15 16 17 18 drive gear oil filter dowel pin drive gear of oil pump drive gear of oil pump oil pump case clutch,oil pump a...

  • Page 124

    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...

  • Page 125

    Assembling and adjustment of engine eng clutch 1. 2. Gasket installation: main driven gear retaining washer clutch hub retaining nut installation: nut note: fasten the clutch hub with clutch fixture ,lock the nut and bend the retaining gasket . Clutch fixtrue 90890-04086 nut torque (60n.M)6.0kgf 3. ...

  • Page 126

    Assembling and adjustment of engine eng 4. Installation steel ball 5. Installation push rod 1 push plate washer nut 6. Installation : te press pla spring screw screw installing torque 0.6 kgf.M (6 n.M) note: tighten up the bolts orderly according to the diago- nal order. 4-57.

  • Page 127

    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 adj...

  • Page 128

    2 1 timing chain guide plate of chain locating shaft idle start gear press plate washer starting gear 2 11 12 woodruff key rotor stator paper gasket dowel pin 13 left crankcase cover 4-59 assembling and adjustment of engine eng.

  • Page 129

    . Rag, scrap, unsmoothness, abrasion→replace → ***************************************** 1 2. Inspection check the gear conditions of start gear 1 and 2 ( a b c ) inspection start gear 2(linking surface ) corrosive pitting, abrasion, damage replace install the starter gear to the clutch of starteran...

  • Page 130

    Assembling and adjustment of engine eng 4 5 .Installation: washer starting gear .Installation: woodruff rotor note: before installing clean off the foreign matter and dirt on the rotor. 6.Locking: nut fastening torque 7.0kgf.M(70n.M) note: fasten the rotor with slide retaining tool , lock the rotor ...

  • Page 131

    Piston and piston ring note: 1.Installation of piston ring oily plate oil scraping plate 2nd ring 1st ring when installing the 1st ring and 2nd ring,pay atte- ntion to the upper and lower directions.The surface with sign should be assemblied upward. When installing the ring ,first installing the low...

  • Page 132

    Assembling and adjustment of engine eng cylinder and piston cylinder o-ring paper pad dowel pin piston ring piston pin hoop piston piston pin 4-63.

  • Page 133

    Assembling and adjustment of engine eng cylinder head bolt copper washer inner hexagonal bolt valve cover(intake) o-ring valve cover(exhaust) cylinder head dowel pin steel pad o-ring side cover of cylinder head spark plug 11 12 4-64.

  • Page 134

    Assembling and adjustment of engine eng paper pad tensioner chain guide plate(intake) timing sprocket timing chain chain guide plate(exhaust) cam shaft and locating key 4 65 -.

  • Page 135

    Chapter 5 disassembling of carburetor general drawing of carburetor ……………………………………………………………………………… removal of carburetor ……………………………………………………………………………………… adjustment of fuel level …………………………………………………………………………………… 5 - 1 5 - 2 5 - 5.

  • Page 136

    Carb 5 adjusting screw of throttle cable rubber sleeve throttle cable guide pipe rubber washer top cover cap circlip rubber washer plunger spring needle pressure plate carburetor 11 12 13 14 15 16 17 18 circlip needle washer needle plunger carburetor spring washer rubber pad idle speed adjusting scr...

  • Page 137

    Carb 5 carburetor 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.

  • Page 138

    Carb 5 carburetor 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.

  • Page 139

    Carb 5 carburetor 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 po...

  • Page 140

    Carb 5 carburetor 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...

  • Page 141

    Carb 5 carburetor 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 l...

  • Page 142

    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 insta...

  • Page 143

    Chas inspection of front and rear wheels front wheel self-locking nut meter gear assy front wheel axle bushing front brake assy bushing front wheel 1 2 3 4 5 6 7 4,55k gf.M (45,5 n .M ) 6-1 6 f ron t w heel ўЩ s elf -locking nut ўЪ m eter gear assy ўЫ f ront w heel axle ўЬ b ushing ўЭ f ront brake a...

  • Page 144

    Chas inspection of front and rear wheels front wheel brake pad washer meter clutch meter drive gear brake arm indicator cam axle bushing washer meter driven gear o-ring oil seal 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1,0kgf.M(10 n.M) 6 6-2.

  • Page 145

    Chas inspection of front and rear wheels removal warning 1.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...

  • Page 146

    Chas inspection of front and rear wheels warning warning 4.Removal front wheel axle front brake assy bushin front wheel g inspection of front wheel 1. 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...

  • Page 147

    Chas inspection 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. Windage unsmooth inspection wheel bearing if the bearing inside the hub has rotation, slackness, abnormal so...

  • Page 148

    Chas inspection 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 measurement friction liner thicknes...

  • Page 149

    Chas inspection 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 dama...

  • Page 150

    Chas inspection 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 speed...

  • Page 151

    Chas inspection of front and rear wheels installation of front wheel installation 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 ...

  • Page 152

    Chas s adjusting nut driven chain gear pin rear wheel spring rear brake assy plit pin shock absorber tension rod oil seal self-locking nut bushing chain adjuster assy bearing rear wheel inspection of front and rear wheels 11 12 14 13 new 6-10

  • Page 153

    Chas inspection of front and rear wheels rear wheel brake shoe brake arm indicator cam axle 6-11.

  • Page 154

    Chas inspection of front and rear wheels rear wheel warning rest the motorcycle firmly so as to avoid it turn over. 1 2 3 4 5 6 74 ,55k gf.M (45,5 n .M ) 6-1 6 f ron t w heel ўЩ s elf -locking nut ўЪ m ete r gear assy ўЫ f ront w heel axle ўЬ b ushing ўЭ f ront brake assy ўЮ b ushing ўЯ f ront w hee...

  • Page 155

    Chas inspection 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...

  • Page 156

    Chas inspection of front and rear wheels 3.Installation rear wheel note: t he convex part of clutch hub should be inserted into the groove of the shock block. 4. Installation rear wheel axle 1 2 3 4 5 6 74 ,55k gf.M (45,5 n .M ) 6-1 6 f ron t w heel ўЩ s elf -locking nut ўЪ m ete r gear assy ўЫ f ro...

  • Page 157

    Chas drive 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 cover 1 6-15.

  • Page 158

    Chas drive chain and sprocket 1.Rest the motorcycle on the central stand. Removal warning rest the motorcycle firmly to avoid turnover. 2. 1 removal sprocket cover 3.Removal drive sprocket 4.Removal chain joint clip press plate of chain chain driven chain inspection of drive chain 1.Inspection drive...

  • Page 159

    Chas drive 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 side o...

  • Page 160

    Chas drive chain and sprocket 2.Installation install as shown on the fig bend 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.Installation drive chain chain tensioner chain press plate installation of drive chain 2.In...

  • Page 161

    Front fork chas bolt 11 washer 12 plug rod of oil stocking 13 damper rod 14 inner pipe 15 spring 16 oil seal 17 outer front fender plug bolt o-ring spacer spring seat spring dust cover clip pipe new new 6-19.

  • Page 162

    Front fork chas take out the front fork warning rest 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. Removal front wheel front fender 3. Loosen loosen the bolt cover bolt 4. Note...

  • Page 163

    4. 5. 7.Removal removal dust cover clip removal nut grip the shock absorber rod loosen the bolt with t and shock absorber fixture. 6.Removal bolt washer oil seal note: note: be careful not to damage the surface of inner pipe. T flat handle 90890-01294 when removing the oil seal,be careful not to scr...

  • Page 164

    Front fork chas inspection of front fork 1.Inspection bending of inner pipe bending limit 0.2mm warning never 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 spring 336.9mm min. Fr...

  • Page 165

    Front fork chas assembling of front fork conduct 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 seal dust cover before reassembling,make sure that all compon- ents are clea...

  • Page 166

    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”tool 90890-01326 shock absorber rod fixture:90890-01294 6.Installation oil seal 7.Installation clip outer pipe 6-24.

  • Page 167

    Front fork chas 8.Inspection stretch of inner pipe if the stretch is not smooth inspect again after disase- mbling. → 9. Measuring glass oil 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.Ins...

  • Page 168

    Front fork chas installation of front fork conduct according to the reverse procedures of "removal 1.Installation front fork tighten up the fixing bolt tempotarily. Note: when installing , align the inner pipe end with bolt head end. 2.Fastening bolt bolt cover bolt torque of position :2.8kgf.M(28n....

  • Page 169

    Steering axle and handle bar chas handle bar holder handle bar right handle bar assy handle bar seat limit clip ring nut ring rubber pad ring nut dust cover steering axle bearing race(upper) roller holding bracket(upper) roller holding bracket(lower) bearing race2(middle) bearing race(lower) 11 12 1...

  • Page 170

    Steering axle and handle bar chas handle bar 1.Removal remove left and right lever switches 2.Removal handle bar holder handle bar handle bar seat removal front wheel 3. 4.Removal front fork 6-28.

  • Page 171

    Steering axle and handle bar chas 5.Removal limit clip ring nut ring rubber pad 6.Removal ring nut remove with steering nut wrench steering nut wrench 90890-01403 warning remove only with wrench. 7.Removal bearing race 2 roller race 2 roller steering axle roller holding bracket(lower) holding bracke...

  • Page 172

    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 bracket bearing race worn,damaged→replace as shown on the fig,remove the bearing race with a long...

  • Page 173

    Steering shaft and handle bar chas installation of the handle bar 1.Install handle bar handle bar clamp coupling torque 2.3kgf.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: fron...

  • Page 174

    Chas rear shock absorber and rear arm rear shock absorber nut rear rocker arm connecting rod chain shield 6-32.

  • Page 175

    Chas rear shock absorber and rear arm removal 1.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 nut connecting rod chain shield rear rocker arm inspection 1.Check slackeness ...

  • Page 176

    Chapter 7 circuit general drawing of circuit ………………………………………………………………………………………… electric components………………………………………………………………………………………………… inspection of socket connector …………………………………………………………………………………… inspection of switch ……………………………………………………………………………………………… ignition system …………………………………………………………………...

  • Page 177

    Circuit elec circuit drawing 7 7-1.

  • Page 178

    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 ...

  • Page 179

    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.

  • Page 180

    Circuit elec electric components 4.Flash relay assy 1. 2. 3. Ignition coil assy spark plug cap assy neutral switch assy 5.Cdi unit 6.Horn 7-4.

  • Page 181

    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 che...

  • Page 182

    Inspection of socket connector elec inspection of the switch inspection method of the switch check the conduction of terminals with multitester. If any poor condition is found, replace the switch im ediately. - m multitesler 90890-03112 note: start the switch several times to cheak. Before checking,...

  • Page 183

    Ignition system elec circuit of ignition system maganeto cdi unit ignition coil/spark plug main switch 11 12 8 4 7-7.

  • Page 184

    Inspection of socket connector elec ignition system failure (no spark or discontinuous spark) exclusion of trouble shooting 1. 2. 3. 4. Inspection procedure spark plug checking spark resistance of the spark plug cap ignition coil 5. 6. 7. 8.C resistance of pulse coil resistance of spark charging coi...

  • Page 185

    Inspection of socket connector elec 3.Resistance of spark plug cap remove the spark plug cap connect the multitester(test frequency×1k) to spark plug cap 4.Resistance of primary coil of ignition coil remark don't pull down the spark plug from the high-pressure wire. Turning in counter clockwise when...

  • Page 186

    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 two coils meets the normal value 6.Resistance of pulse coil divide the adapter of the pulse coil with wire connect the multi...

  • Page 187

    Inspection of socket connector elec 7.Resistance of ignition charge coil remove the ignition charge coil connect the multitester (test to the terminal of charge coil Ω×1000) connecting method resistance of charge coil 860Ω±20%(20 ° c) normal out of normal value replace the ignition charge coil lead ...

  • Page 188

    Starting system elec circuit of starting system battery starting relay starting motor main switch right lever switch clutch switch 21neutral switch 7-12.

  • Page 189

    Starting system elec exclusion of troubleshooting no work of starting notor inspection procedure battery fuse starting motor main switch 1. 2. 3. 4. 5.Starting relay 6. 7. 8. Starting switch neutral switch clutch switch before excluding ,the following components should be removed side cover cushion ...

  • Page 190

    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 post of ...

  • Page 191

    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 wire and the ground wire” . Normal abnormal if the main switch is failure,replace it normal if the neutral switch is failure,replace ...

  • Page 192

    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 joint poor connection,break correct or replace ref...

  • Page 193

    Starting motor assy rear bracket electric brush spring electric brush assy o-ring magnet-wheel electric button adjusting pad front bracket o-ring length limit value of electric brush 3.5mm 7-17 a b c d 0.017~0.021Ω20°c resistance value of electric button coil hexagon slot m 1.5m wear limit value of ...

  • Page 194

    Removal stripping inspection and repair 1. 1. T 2.Remove 3. 1.Check 600 sand paper 2. Remove wire of starting motor starting motor assy before stripping, make the identifiable mark on the frond and rear bracke to be easy to check when asse- mbling. The front bracket pad the rear bracket remove elect...

  • Page 195

    Starting system elec 3.Measure the depth of mica sheet slot a out 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. ******************...

  • Page 196

    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 spring 560~840g 1.Install electric brush spring electric brush according to the contary procedure of “ remova assemble note: when asse...

  • Page 197

    Starting system elec 3 . O- install ring replace new one note 4.Install magnet-wheel the matching mark on the magnet-wheel shoeld be align 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...

  • Page 198

    Charge system elec charge system circuit diagram cdi magneto rectifing adjustor battery starting relay 7-22.

  • Page 199

    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 multitester 90890...

  • Page 200

    Charge system elec 3.Charge voltage connect the induction tachymeter to the wire of the spark plug. Connect min.Multitester (dc20v) to the battery positive wire of multitester→positive binding post of battery. Negative wire of multitester→negative binding post of battery. Check the charge voltage af...

  • Page 201

    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.

  • Page 202

    Lighting system elec lighting system circuit diagram battery right lever switch 22 23 head lamp tail lamp 7-26.

  • Page 203

    Lighting system elec exclusion of troubleshooting headlamp, high-beam indicator of headlamp, tailamp and instrument garden light are not lit remark before excluding ,the following components should be removed. Side cover cushion hood the following specific tool should be applied when excluding. Min....

  • Page 204

    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 ma...

  • Page 205

    Lighting system elec inspection of lighting system 1.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 guide wire "high beam...

  • Page 206

    Lighting system elec 2.Voltage positive wire of multitester→yellow binding post negative 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 i...

  • Page 207

    Signal system elec signal system circuit diagram main switch starting relay battery front brake switch rear brake switch horn left handle lever switch assy 19 flash relay 20 16 17 18 23 2426 25 27 21 tai lamp/brake lamp front left-right turning lamp rear left-right turning lamp fuel signal sender in...

  • Page 208

    Signal system elec exclusion of trouble shooting blinker, brake lamp or indicator are not lit and the horn does not work. Inspecttion procedure fuse battery 1. 2. 3. 4. Main switch wire joint when excluding,the following components should be removed side cover cushion when excluding,the following sp...

  • Page 209

    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 horn positive guide wire of multitester→brown guide wire negati...

  • Page 210

    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 switch remove brake switch guide wire from the bundle connector. Check if the switch between the "yellow &brown" and "black& black" is conducted 3.Voltage connect min. Multitester...

  • Page 211

    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.Voltage connect min. Multitester(dc20v) to the relay on the blinker device. Postitive guide wire of multitester→brown guied wire negative guide wire of...

  • Page 212

    Signal system elec 5.Turn indicator connect min. Multitester(dc20v) to socket connector connection at the left blinker negative guide wire of multitester→frame groun positive guide wire of multitester → brown guide wire connection at the right blinker positive guide wire of multitive→dark green guid...

  • Page 213

    Signal system elec 7-37.

  • Page 214

    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 gauge binding post (at the side of bundle ...

  • Page 216

    Troubleshooting of engine trouble troubleshooting of engine electric appliance system main switch short-circuit of main switch · spark plug ignition coil(refer to page ) 7-8 cdi unit assy damage of cdi unit assy pulse coil(refer to page7-8) damage of winding incorrect ignition timing lighting coil/i...

  • Page 217

    Troubleshooting of engine trouble compressure system buckle/carbon deposit inadequate tight force damage carbon deposit buckle/wear/damage wear/scratch/damage wear/choke/damage wear/scratch wear/choke/damage damage wear/choke/damage damage damage damage damage 8-2.

  • Page 218

    Troubleshooting of engine trouble intake and exhaust system 8-3.