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Yamaha SR125 1997 Service Manual

Manual is about: Yamaha SR125'97 3MW-AE1 Service manual

Summary of SR125 1997

  • Page 3

    Eb000000 sr125 service manual 1996 by yamaha motor co., ltd. 1st edition, september 1996 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited ..

  • Page 4: Notice

    Note: warning caution: eb001000 notice this manual was produced by the yamaha motor company primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maint...

  • Page 5: How To Use This Manual

    1 2 6 7 6 4 3 8 yp002000 how to use this manual manual organization this manual consists of chapters for the main categories of subjects. (see “illustrated symbols”) 1st title 1 : this is the title of the chapter with its symbol on the upper right corner of each page. 2nd title 2 : this title indica...

  • Page 6: Gen

    21 1 3 5 7 9 2 4 8 6 23 24 22 20 18 19 17 15 14 13 11 12 10 gen info spec eng carb elec chas insp adj trbl shtg 16 eb003000 illustrated symbols illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 general information 2 specifications 3 periodic inspec...

  • Page 7: General Information

    General information specifications periodic inspection and adjustment engine overhaul carburation chassis electrical troubleshooting gen info 1 spec 2 3 eng 4 carb 5 chas 6 elec 7 trbl shtg 8 insp adj index.

  • Page 9: Chapter 1.

    Chapter 1. General information motorcycle identification 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame serial number 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine serial number 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 11: Gen

    1-1 motorcycle identification gen info note: yp100000 general information motorcycle identification sr100020 frame serial number the frame serial number 1 is stamped into the right side of the frame. Eb100030 engine serial number the engine serial number 1 is stamped into the crankcase. Designs and ...

  • Page 12: Gen

    1-2 important information gen info eb101000 important information preparation for removal proce- dures 1. Remove all dirt, mud, dust and foreign mate- rial before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. Refer to the “special tools” section. 4. When disassembling the m...

  • Page 13: Gen

    1-3 or important information gen info caution: eb101030 lock washers/ plates and cotter pins 1. Replace all lock washers / plates and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. Eb101040 bearings and oil seals insta...

  • Page 14: Gen

    1-4 checking of connections gen info note: note: eb801000 checking of connections dealing with 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. 4. Pull the lead to check that it will...

  • Page 15: Gen

    1-5 how to use the conversion table gen info eb201000 how to use the conversion table all specification data in this manual are listed in sl and metric units. Use this table to convert metric unit data to imperial unit data. Ex. Metric multiplier imp ** mm 0.03937 = ** in 2 mm 0.03937 = 0.08 in conv...

  • Page 16: Gen

    1-6 special tools gen info eb102000 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, ...

  • Page 17: Gen

    1-7 special tools gen info tool no. Tool name / usage illustration 90890-03079 thickness gauge this tool is used to measure the valve clearance. 90890-03081 90890 -04082 compression gauge adaptor these tools are used to measure the engine compression. 90890-03112 pocket tester these instruments are ...

  • Page 18: Gen

    1-8 special tools gen info tool no. Tool name / usage illustration 90890-04101 valve lapper this tool is used for removing and installing the lifter and for lapping the valve. 90890-06754 ignition checker this instrument is necessary for checking the ignition system components. 90890-85505 yamaha bo...

  • Page 19: Chapter 2.

    Chapter 2. Specifications general specifications 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance specifications 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 21: Spec

    2-1 general specifications spec specifications general specifications model sr125 model code: 3mw6 dimensions: overall length overall width overall height seat height wheelbase minimum ground clearance minimum turning radius 1,915 mm 775 mm 1,080 mm 745 mm 1,280 mm 155 mm 2,100 mm basic weight: with...

  • Page 22: Spec

    2-2 general specifications spec model sr125 carburetor: type / quantity manufacturer y24p/ 1 teikei spark plug: type manufacturer spark plug gap dr8ea ngk 0.6 x 0.7 mm clutch type: wet, multiple-disc transmission: primary reduction system primary reduction ratio secondary reduction system secondary ...

  • Page 23: Spec

    2-3 general specifications spec model sr125 brake: front brake type operation rear brake type operation single disc brake right hand operation drum brake right foot operation suspension: front suspension rear suspension telescopic fork swingarm shock absorber: front shock absorber rear shock absorbe...

  • Page 24: Spec

    2-4 maintenance specifications spec head dia. Face width seat width margin thickness maintenance specifications engine item standard limit cylinder head: warp limit sss 0.03 mm cylinder: bore size taper limit out of round limit 57.00 x 57.02 mm sss sss 57.1 mm 0.05 mm 0.01 mm camshaft: cam dimension...

  • Page 25: Spec

    2-5 maintenance specifications spec item standard limit guide inside diameter in ex stem-to-guide clearance in ex stem runout limit valve seat width in ex 6.000 x 6.012 mm 6.000 x 6.012 mm 0.010 x 0.037 mm 0.025 x 0.052 mm sss 0.9 x 1.1 mm 0.9 x 1.1 mm 6.042 mm 6.042 mm 0.08 mm 0.10 mm 0.03 mm 1.6 m...

  • Page 26: Spec

    2-6 maintenance specifications spec item standard limit crankshaft: crank width “a” runout limit “c” big end side clearance “d” big end radial clearance small end free play “f” 55.95 x 56.00 mm sss 0.35 x 0.65 mm 0.010 x 0.025 mm 0.8 x 1.0 mm sss 0.03 mm 1.0 mm sss sss clutch: friction plate thickne...

  • Page 27: Spec

    2-7 maintenance specifications spec tightening torques engine th d tightening part to be tightened part name thread size q’ty g g torque remarks g size y nm m s kg cylinder head blind plug cylinder head and cylinder cylinder head (timing chain side) cam sprocket cover valve cover plate spark plug cy...

  • Page 28: Spec

    2-8 maintenance specifications spec part to be tightened part name thread size q’ty tightening torque remarks g size y nm m s kg drive sprocket shift cam (segment) shift pedal pick up coil neutral switch stator coil starter motor bolt screw bolt screw screw screw screw m6 m6 m6 m6 m10 m4 m6 2 1 1 4 ...

  • Page 29: Spec

    2-9 maintenance specifications spec tightening sequence cylinder head crankcase item standard limit.

  • Page 30: Spec

    2-10 maintenance specifications spec chassis item standard limit steering system: steering bearing type no. / size of steel balls (upper) (lower) ball bearing 22 pcs. 0.1875 in 19 pcs. 0.251 in sss sss sss front suspension: front fork travel fork spring free length fitting length spring rate (k1) (k...

  • Page 31: Spec

    2-11 maintenance specifications spec item standard limit front brake: type disc outside diameter disc thickness pad thickness (inner) (outer) master cylinder inside diameter caliper cylinder 1 inside diameter caliper cylinder 2 inside diameter brake fluid type single disc 267 mm 4 mm 6.2 mm 6.2 mm 1...

  • Page 32: Spec

    2-12 maintenance specifications spec note: tightening torques chassis part to be tightened thread size tightening torque remarks g nm m s kg handle crown and front fork handle crown and steering shaft handlebar holder (under and upper) steering ring nut master cylinder and cap (front brake) handleba...

  • Page 33: Spec

    2-13 maintenance specifications spec electrical item standard limit ignition timing: ignition timing (b.T.D.C.) advanced timing advanced type 9 _ at 1,300 r / min 29 _ at 5,500 r / min electrical type sss sss sss c.D.I.: pickup coil resistance / color source coil resistance / color c.D.I. Unit model...

  • Page 34: Spec

    2-14 maintenance specifications spec item standard limit starter relay: model / manufacturer amperage rating coil winding resistance ms5d-191 / jideco 100 a 3.9 x 4.7 Ω at 20 _ c sss sss sss horn: model / manufacturer maximum amperage yf-12 / nikko 2.5 a sss sss flasher relay: type model / manufactu...

  • Page 35: Spec

    2-15 general torque specifications spec general torque specifications this chart specifies torque for standard fasten- ers with standard i.S.O. Pitch threads. Torque specifications for special components or as- semblies are included in the applicable sections of this book. To avoid warpage, tighten ...

  • Page 36: Spec

    2-16 lubrication point and grade of lubricant spec lubrication point and grade of lubricant engine lubrication point symbol oil seal lips (all) bearing retainer (all) bolt (cylinder head) crank pin connecting rod (big end) piston pin piston/ piston ring buffer boss valve stem / valve guide (in, ex) ...

  • Page 37: Spec

    2-17 lubrication point and grade of lubricant spec chassis lubrication point symbol steering head pipe bearing (upper / lower) front wheel oil seal lips (left / right) rear wheel oil seal lips (left / right) rear wheel hub rear brake shoe plate, camshaft and pivoting pin pivoting points (brake pedal...

  • Page 38: Spec

    2-18 1 rocker arm (in) 2 rocker shaft 3 rocker arm (ex) 4 camshaft 5 oil pump 6 push lever lubrication diagram spec lubrication diagram.

  • Page 39: Spec

    2-19 1 oil pump 2 oil filter 3 crankshaft 4 main axle 5 drive axle 6 oil strainer lubrication diagram spec.

  • Page 40: Spec

    2-20 a clamp the handlebar switch lead, (left and right), front brake switch lead, clutch switch lead to the handlebar. B do not contact the horn and wire- harness. 12 clutch switch coupler 13 handlebar switch lead (left) 14 front flasher lead (left) 15 horn lead 16 flasher relay 17 handlebar switch...

  • Page 41: Spec

    2-21 a align the clamp to the white tape on the wireharness b pass the clutch cable through the outside of the throttle cable. C pass the brake hose and throttle cable through the slit of the headlight body. And pass them the right inside of the front fork. D pass the brake hose to the holder. E cla...

  • Page 42: Spec

    2-22 a clamp the speedometer cable to the steering bracket and pass the cable to the cable holder. B pass the brake hose through the brake hose holder. 14 rectifier / regulator 15 thermostatic switch 16 throttle cable 17 clutch cable 18 wireharness 19 speedometer cable 20 cable holder 21 brake hose ...

  • Page 43: Spec

    2-23 cable routing spec 1 air filter case 2 battery 3 swingarm 4 battery breather pipe 5 lid 6 air filter case drain pipe a pass the air filter case drain pipe inside the swingarm..

  • Page 44: Spec

    Spec.

  • Page 45: Chapter 3.

    Chapter 3. Periodic inspections and adjustments introduction 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic maintenance / lubrication intervals 3-1 . . . . . . . . . . . Side cover, seat and fuel tank 3-3 . . . . . . . . . . . . . . . . . ....

  • Page 47: Insp

    3-1 introduction/ periodic maintenance/lubrication intervals insp adj 10 11 12 13 14 15 16 17 eb300000 periodic inspections and adjustments introduction this chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if f...

  • Page 48: Insp

    3-2 periodic maintenance/lubrication intervals insp adj 18 19 20 21 note: every no. Item routine brake-in 1,000 km 6,000 km or 6 months 12,000 km or 12 months drive chain check chain slack / alignment. Adjust if necessary. Clean and lube. Every 500 km * chassis fasteners check all chassis fittings a...

  • Page 49: Insp

    3-3 order job name / part name q’ty remarks 1 2 3 4 5 side cover, seat and fuel tank removal side cover (left) side cover (right) seat fuel pipe fuel tank 1 1 1 1 1 remove the parts in order. Reverse the removal procedure for instal- lation. Disconnect the fuel pipe, set the fuel cock lever “off” po...

  • Page 50: Insp

    3-4 valve clearance adjustment insp adj note: *************************************** *************************************** sr03004 engine valve clearance adjustment valve clearance adjustment should be made with the engine cool, at room temperature. When the valve clearance is to be measured or a...

  • Page 51: Insp

    3-5 a b valve clearance adjustment/ idling speed adjustment insp adj *************************************** 14 nm (1.4 m kg) *************************************** 10 nm (1.0 m kg) new 10 nm (1.0 m kg) new 18 nm (1.8 m kg) 5. Adjust: valve clearance adjustment steps: loosen the locknut 1 . Turn th...

  • Page 52: Insp

    3-6 idling speed adjustment/ throttle cable adjustment insp adj *************************************** *************************************** note: *************************************** note: 3. Check: engine idling speed out of specification adjust. Engine idling speed: 1,250 1,350 r / min 4. A...

  • Page 53: Insp

    3-7 throttle cable adjustment/ spark plug inspection insp adj warning *************************************** caution: loosen the locknut 1 on the throttle cable. Turn the adjuster 2 in or out until specified free play is obtained. Turning in free play is increased. Turning out free play is decrease...

  • Page 54: Insp

    3-8 spark plug inspection/ ignition timing check insp adj 18 nm (1.8 m kg) note: note: *************************************** *************************************** note: 5. Install: spark plug before installing a spark plug, clean the gasket surface and plug surface. Yp303052 ignition timing chec...

  • Page 55: Insp

    3-9 compression pressure measurement insp adj note: caution: sr303060 compression pressure measurement insufficient compression pressure will result in performance loss. 1. Check: valve clearance out of specification adjust. Refer to “valve clearance adjust- ment” section. 2. Start the engine and le...

  • Page 56: Insp

    3-10 compression pressure measurement/ engine oil level inspection insp adj *************************************** warning 18 nm (1.8 m kg) note: compression pressure (at sea lev- el): standard: 1,200 kpa (12.0 kg / cm 2 , 12 bar) minimum: 1,100 kpa (11.0 kg / cm 2 , 11 bar) measurement steps: cran...

  • Page 57: Insp

    3-11 engine oil level inspection/ engine oil replacement insp adj caution: note: *************************************** *************************************** do not put in any chemicals additives or use oils with a grade of cd a or higher. Be sure not to use oils labeled “energy conserving ii” b ...

  • Page 58: Insp

    3-12 engine oil replacement insp adj 43 nm (4.3 m s kg) note: caution: *************************************** *************************************** 6. Install: s drain plug inspect the o-ring. If it is damaged, replace it with a new one. Before reinstalling the drain plug, do not for- get to fit ...

  • Page 59: Insp

    3-13 timing chaine tensioner adjustment/ clutch adjustment insp adj *************************************** *************************************** 5 nm (0.5 m s kg) sr******* timing chaine tensioner adjustment 1. Remove: s cap 1 2. Check: s rod check the rod end 1 is flush with the adjust- er end 2...

  • Page 60: Insp

    3-14 clutch adjustment/ air filter cleaning insp adj *************************************** note: *************************************** caution: 2. Adjust: s clutch cable free play adjustment steps: crankcase side s make sure that the adjuster 1 and locknut 2 are fully tightened. S loosen the loc...

  • Page 61: Insp

    3-15 air filter cleaning/ exhaust system inspection insp adj note: caution: warning 2. Inspect: s air filter element 1 damage replace. 3. Clean: s air filter element use solvent to clean the element. After cleaning, remove the remaining solvent by squeezing the element. Do not twist the filter eleme...

  • Page 62: Insp

    3-16 exhaust system inspection insp adj 1 2 2. Check: s tightening torque bolt : 12 nm (1.2 m s kg) nut : 20 nm (2.0 m s kg).

  • Page 63: Insp

    3-17 front brake adjust ment/ rear brake adjustment insp adj *************************************** caution: warning *************************************** eb304002 chassis front brake adjustment 1. Check: brake lever free play a out of specification adjust. Free play (brake lever): 2 5 mm at brak...

  • Page 64: Insp

    3-18 rear brake adjustment insp adj *************************************** *************************************** *************************************** caution: *************************************** 2. Adjust: s brake pedal height adjustment steps: s loosen the locknut 1 . S turn the adjuster ...

  • Page 65: Insp

    3-19 brake fluid level inspection insp adj note: note: caution: warning eb304020 brake fluid level inspection 1. Stand the motorcycle on a level surface. S make sure the motorcycle is upright when in- specting the brake fluid level. S stand the motorcycle on its centerstand if it has one. If not, pl...

  • Page 66: Insp

    3-20 brake pad inspection/brake shoe inspection/ brake light switch adjustment insp adj note: *************************************** *************************************** eb304030 brake pad inspection 1. Operate the brake lever. 2. Inspect: brake pad (front) wear indicators 1 almost touch the bra...

  • Page 67: Insp

    3-21 air bleeding insp adj warning *************************************** note: eb304070 air bleeding (hydraulic brake system) bleed the brake system whenever: s the system is disassembled. S a brake hose is loosened or removed. S the brake fluid level is very low. S brake operation is faulty. Loss...

  • Page 68: Insp

    3-22 air bleeding/ drive chain slack adjustment insp adj note: warning *************************************** note: caution: warning j. Tighten the bleed screw. Bleed screw: 6 nm (0.6 m s kg) if bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the ble...

  • Page 69: Insp

    3-23 a b drive chain slack adjustment insp adj *************************************** note: *************************************** caution: 1. Check: s drive chain slack out of specification ! Adjust. Drive chain slack: 25 35 mm a check window b adjustable limit c usable limit d usable range 2. Ad...

  • Page 70: Insp

    3-24 steering head inspection insp adj warning note: *************************************** note: *************************************** sr304130 steering head inspection securely support the motorcycle so that there is no danger of it falling over. 1. Stand the motorcycle on a level surface. Stan...

  • Page 71: Insp

    3-25 front fork inspection/ rear shock absorber adjustment insp adj warning warning *************************************** a b eb304140 front fork inspection securely support the motorcycle so that there is no danger of it falling over. 1. Stand the motorcycle on a level surface. 2. Check: s inner ...

  • Page 72: Insp

    3-26 rear shock absorber adjustment/ tire inspection insp adj caution: *************************************** warning adjustment numbers: standard 1 minimum 1 maximum 5 s never turn the adjuster beyond the maxi- mum or minimum setting. S always adjust each shock absorber to the same setting. Eb3041...

  • Page 73: Insp

    3-27 tire inspection insp adj warning warning 2. Inspect: tire surfaces wear / damage replace. Minimum tire tread depth (front and rear): 1.6 mm 1 tread depth 2 side wall 3 wear indicator it is dangerous to ride with a worn-out tire. When the tire tread begins to show signs of wear, replace the tire...

  • Page 74: Insp

    3-28 spoke inspection and tightening/ wheel inspection insp adj note: note: warning eb304190 spoke inspection and tightening 1. Inspect: s spokes 1 bending / damage replace. Loose spoke retighten. 2. Tighten: s spokes be sure to tighten the spokes before and after break-in. Nipple: 2 nm (0.2 m s kg)...

  • Page 75: Insp

    3-29 battery inspection insp adj caution: note: caution: eb305001 electrical battery inspection 1. Remove: s side covers (left and right) refer to “side cover, seat and fuel tank” section. 2. Inspect: s electrolyte level electrolyte level should be between the up- per 1 and lower 2 level marks. Elec...

  • Page 76: Insp

    3-30 battery inspection insp adj *************************************** *************************************** caution: warning replace the battery if: s battery voltage will not rise to a specific value or bubbles fail to rise during charging. S sulphation of one or more cells occurs, (as in- dic...

  • Page 77: Insp

    3-31 battery inspection/fuse inspection insp adj caution: caution: *************************************** note: *************************************** 7. Install: battery 8. Connect: battery leads connect the positive lead 1 first and then connect the negative lead 2 . 9. Connect: breather hose be...

  • Page 78: Insp

    3-32 fuse inspection/ headlight beam adjustment insp adj *************************************** warning *************************************** 3. Replace: s blown fuse replacement steps: s turn off the main switch. S install a new fuse with the proper current rat- ing. S turn on switches to verify...

  • Page 79: Chapter 4.

    Chapter 4. Engine overhaul engine removal 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust pipe, starting motor and wire read 4-1 . . . . . . . . . Carburetor, clutch cable and drive chain 4-2 . . . . . . . . . . Engine 4-3 . . . . . . . . . . . . ....

  • Page 80

    Balancer gear 4-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancer driven gear removal 4-38 . . . . . . . . . . . . . . . . . . . . . . . Drive gear inspection 4-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancer drive gea...

  • Page 81: Eng

    4-1 order job name / part name q’ty remarks 1 2 3 4 5 6 7 exhaust pipe, starting motor and wire read removal side cover, seat and fuel tank rear foot rest (right) exhaust pipe ass’y exhaust pipe gasket ground lead starting motor read cdi magneto read plug cap 1 1 1 1 1 1 1 refer to “side cover, seat...

  • Page 82: Eng

    4-2 engine removal eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 carburetor, clutch cable and drive chain removal carburetor clutch cable crankcase breather hose shift pedal drive sprocket cover rear wheel axle nut sprocket holder drive sprocket / drive chain 1 1 1 1 1 1 1 / 1 remove the...

  • Page 83: Eng

    4-3 engine removal eng order job name / part name q’ty remarks 1 2 3 4 5 engine removal engine stay (top) front engine stay engine mount bolt (rear upper) engine mount bolt (rear under) engine 1 1 1 1 1 remove the parts in order. Securely support the motorcycle so there is no danger of it falling ov...

  • Page 84: Eng

    4-4 cylinder head eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 cam sprocket cover removal side cover, seat and fuel tank exhaust pipe assembly carburetor assembly engine stay (top) spark plug cam sprocket cover / o-ring valve cover (intake side) / o-ring valve cover (exhaust side) / o-r...

  • Page 85: Eng

    4-5 cylinder head eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 cylinder head removal timing chain tensioner cap / o-ring timing chain tensioner assembly cam sprocket / timing chain ignition coil cylinder head dowel pins gasket cylinder head gasket 1 / 1 1 1 / 1 1 1 3 1 1 remove the pa...

  • Page 86: Eng

    4-6 cylinder head eng note: note: t401030 cylinder head removal 1. Align: slit a on the magneto (with stationary pointer b on the crank case cover) turn the crank shaft counterclockwise with a wrench and align the “i” mark c with the cylinder head match mark d when the piston is at tdc on the compre...

  • Page 87: Eng

    4-7 cylinder head eng note: note: *************************************** note: *************************************** 5. Remove: cylinder head loosen the nuts in their proper loosening sequence. Start by loosening each nut 1 / 2 turn until all are loose. Yp402000 cylinder head inspection 1. Elimin...

  • Page 88: Eng

    4-8 cylinder head eng new new 22 nm (2.2 m kg) m8 (1 4) 20 nm (2.2 m kg) m8 (5 6 note: *************************************** note: caution: *************************************** sr******** cylinder head installation 1. Install: dowel pins 1 gasket 2 gasket (cylinder head) 3 2. Install: cylinder ...

  • Page 89: Eng

    4-9 cylinder head eng 60 nm (6.0 m kg) note: 4. Install: plate washer bolt (timing chain) timing chain tensioner assembly 5. Tighten: bolt (timing chain) install the bolt while holding the magneto mounting bolt with a wrench. 6. Check: magneto rotor slit align the stationary pointer with the crank- ...

  • Page 90: Eng

    4-10 cam shaft and rocker arms eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 cam shaft and rocker arm removal cylinder head lock washer plate collar cam shaft rocker arm shaft (intake side) rocker arm shaft (exhaust side) rocker arm o-ring nut / adjuster 1 1 1 1 1 1 2 1 2 / 2 remove ...

  • Page 91: Eng

    4-11 cam shaft and rocker arms eng note: note: sr****** rocker arm and rocker arm shaft removal 1. Remove: camshaft 1 collar (camshaft) 2 use 10 mm bolt 3 to remove the camshaft. 2. Remove: rocker arm shaft (intake) rocker arm shaft (exhaust) attach a rocker arm shaft puller bolt 1 and weight 2 to t...

  • Page 92: Eng

    4-12 cam shaft and rocker arms eng *************************************** *************************************** yp402060 rocker arms and rocker arm shafts inspection 1. Inspect: rocker arm shafts rocker arms wear / pitting/ scratches / blue discoloration replace. Inspection steps: inspect the two...

  • Page 93: Eng

    4-13 eng cam shaft and rocker arms note: caution: note: new 8 nm (0.8 m kg) note: 2. Apply: molybdenum disulfide oil (onto the rocker arm and rocker arm shaft) molybdenum disulfide oil 3. Install: rocker arm rocker arm shaft 1 apply engine oil onto the outside of the rocker arm shaft and apply molyb...

  • Page 94: Eng

    4-14 order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 valves and valve springs removal cylinder head rocker arm, camshaft valve cotters spring retainer valve spring (inner) valve spring (outer) valve (intake) valve (exhaust) valve guide (stem seal) spring seat 4 2 2 2 1 1 2 2 remove the parts...

  • Page 95: Eng

    4-15 valves and valve springs eng note: caution: a b *************************************** note: yp401150 valves and valve springs removal 1. Remove: valve cotters 1 attach a valve spring compressor and attach- ment 2 between the valve spring retainer and cylinder head to remove the valve cotters....

  • Page 96: Eng

    4-16 valves and valve springs eng note: *************************************** note: install the new valve guide using a valve guide installer 2 and valve guide remover 1 . After installing the valve guide, bore the valve guide using a valve guide reamer 3 to obtain proper stem-to-guide clearance. ...

  • Page 97: Eng

    4-17 valves and valve springs eng *************************************** *************************************** *************************************** note: caution: eb402020 valve seats inspection 1. Eliminate: carbon deposits (from the valve face and valve seat) 2. Inspect: valve seats pitting/...

  • Page 98: Eng

    4-18 valves and valve springs eng note: note: *************************************** apply molybdenum disulfide oil to the valve stem. Install the valve into the cylinder head. Turn the valve until the valve face and valve seat are evenly polished, then clean off all compound. Valve lapper: 90890-0...

  • Page 99: Eng

    4-19 valves and valve springs eng molybdenum disulfide oil new note: note: caution: 2. Apply: molybdenum disulfide oil (onto the valve stem 3 and oil seal 2 ) 3. Install: valve spring seat 1 valve stem seat 2 valve 3 (into the cylinder head) valve spring 4 spring retainer 5 install the valve spring ...

  • Page 100: Eng

    4-20 cylinder and piston eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 cylinder and piston removal cylinder head timing chain guide (exhaust side) cylinder / o-ring o-ring dowel pin cylinder gasket piston pin circlip piston pin piston piston ring set 1 1 / 1 1 2 1 2 1 1 1 remove the ...

  • Page 101: Eng

    4-21 cylinder and piston eng note: note: *************************************** note: yp****** piston and piston rings removal 1. Remove: piston pin circlip 1 piston pin 2 piston 3 before removing the piston pin circlip, cover the crankcase opening with a clean towel or rag to prevent the circlip f...

  • Page 102: Eng

    4-22 cylinder and piston eng *************************************** cylinder bore “c” 57.00 57.02 mm taper limit “t” 0.05mm out of round “r” 0.01mm “c” = maximum d “t” = (maximum d 1 or d 2 ) – (maximum d 5 or d 6 ) “r” = (maximum d 1 , d 3 or d 5 ) – (minimum d 2 , d 4 or d 6 ) if out of specifica...

  • Page 103: Eng

    4-23 cylinder and piston eng note: note: note: eb402110 piston ring inspection 1. Measure: side clearance out of specification replace the piston and the piston rings as a set. Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance. Side clearance: t...

  • Page 104: Eng

    4-24 cylinder and piston eng *************************************** b a *************************************** note: eb402120 piston pin inspection 1. Inspect: piston pin blue discoloration / grooves replace, then inspect the lubrication system. 2. Measure: piston pin-to-piston clearance measureme...

  • Page 105: Eng

    4-25 cylinder and piston eng new note: new note: engine oil new note: 2. Install: piston 1 piston pin 2 piston pin clip 3 apply engine oil onto the piston pins. The “ ” mark a on the piston must face the exhaust side of the cylinder. Before installing the piston pin clip, cover the crankcase opening...

  • Page 106: Eng

    4-26 clutch eng order job name / part name q’ty remarks 1 2 3 4 5 6 crankcase cover (right) removal drain the engine oil nut foot rest (right) clutch cable crankcase cover (right) crankcase cover gasket (right) dowel pins 1 1 1 1 1 2 remove the parts in order. Refer to “engine oil replacement” secti...

  • Page 107: Eng

    4-27 clutch eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 4 1 4 3 1 / 1 1 1 1 1 1 1 / 1 remove the parts in order. Refer to “engine removal” section. Refer to “clutch installation” section. Clutch removal sprocket cover clutch springs pressure plate friction plates clutch plate...

  • Page 108: Eng

    4-28 clutch eng order job name / part name q’ty remarks 12 13 14 15 16 17 18 push lever axle torsion spring circlip oil seal nut / washer push rod #1 / o-ring push plate 1 1 1 1 1 / 1 1 / 1 1 refer to “clutch installation” sec- tion. Refer to “clutch installation” sec- tion. Reverse the removal proc...

  • Page 109: Eng

    4-29 clutch eng note: sr401061 clutch removal 1. Remove: nut 1 (clutch boss) lock washer 2 clutch boss 3 straighten the lock washer tab 2 . Loosen the clutch boss nut 1 while holding the clutch boss with a clutch holding tool 4 . Clutch holding tool: 90890-04086 sr402181 clutch inspection 1. Inspect...

  • Page 110: Eng

    4-30 clutch eng note: new 12 nm (1.2 m kg) note: 6. Measure: free length (clutch spring) a out of specification replace the clutch springs as a set. Free length (clutch spring): 34.5 mm 7. Inspect: dogs on the primary driven gear 1 scoring / wear / damage deburr or re- place. Clutch boss splines 2 s...

  • Page 111: Eng

    4-31 clutch eng new 70 nm (7.0 m kg) note: note: new 6 nm (0.6 m kg) note: 3. Install: lock washer 1 nut 2 (clutch boss) install the clutch boss nut 2 while holding the clutch boss with a clutch holding tool 3 . Clutch holding tool: 90890-04086 4. Bend: lock washer tab (along a flat side of the end)...

  • Page 112: Eng

    4-32 clutch eng *************************************** caution: *************************************** 8 nm (0.8 m kg) 9. Check: push lever position push the push lever assembly in the arrow direction and make sure that match marks are be aligned adjust. A match mark on the push lever assembly b m...

  • Page 113: Eng

    4-33 oil pump eng order job name / part name q’ty remarks 1 2 3 4 5 6 oil pump removal clutch nut lock washer primary drive gear oil pump cover oil pump assembly gasket (oil pump cover) 1 1 1 1 1 1 remove the parts in order. Refer to “clutch” section. Refer to “primary drive gear removal/ installati...

  • Page 114: Eng

    4-34 oil pump eng order job name / part name q’ty remarks oil pump disassembly oil pump housing dowel pin oil pump driven gear dowel pins inner rotor outer rotor housing 1 1 1 2 1 1 1 disassemble the parts in order. Reverse the disassembly procedure for assembly. 7 nm (0.7 m kg) 1 1 1 1 1 1 1 1 1 1 ...

  • Page 115: Eng

    4-35 oil pump eng note: note: sr401070 primary drive gear removal straighten the lock washer tab. 1. Remove: nut (primary drive gear) 1 lock washer 2 primary drive gear 3 place a folded aluminium plate or copper wash- er a between the teeth of the balancer drive gear 4 and balancer driven gear 5 . T...

  • Page 116: Eng

    4-36 oil pump eng new 50 nm (5.0 m kg) note: sr404010 oil pump installation 1. Lubricate: oil delivery passage (crankcase right) oil pump assembly recommended lubricant: engine oil sr404140 primary drive gear installation 1. Install: primary drive gear 1 lock washer 2 nut (primary drive gear) 3 plac...

  • Page 117: Eng

    4-37 balancer gear eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 balancer gear removal clutch primary drive gear nut / lock washer balancer driven gear woodruff key claw washer balancer drive gear buffer boss compression spring dowel pins woodruff key plate washer 1 / 1 1 1 1 1 1 ...

  • Page 118: Eng

    4-38 balancer gear eng note: note: note: note: sr****** balancer driven gear removal straighten the lock washer tab. 1. Remove: nut (balancer driven gear) 1 lock washer 2 balancer driven gear 3 place a folded aluminium plate or copper wash- er a between the teeth of the balancer drive gear 4 and bal...

  • Page 119: Eng

    4-39 balancer gear eng note: new 50 nm (5.0 m kg) note: sr****** balancer gear installation 1. Install: balancer driven gear 1 install the balancer driven gear, then mesh the balancer driven gear match mark a and ba- lancer drive gear assembly match mark b . 2. Install: lock washer 1 nut (balancer d...

  • Page 120: Eng

    4-40 shift shaft and segment eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 shift shaft and segment removal clutch shift pedal shift shaft plate washer torsion spring stopper lever plate washer circlip torsion spring collar tension spring 1 1 1 1 1 1 1 1 1 remove the parts in order. R...

  • Page 121: Eng

    4-41 shift shaft and segment eng order job name / part name q’ty remarks 10 11 12 13 screw segment dowel pins (short length) dowel pins (long length) 1 1 4 1 reverse the removal procedure for installation. Refer to “segment installation” section. 12 nm (1.2 m kg).

  • Page 122: Eng

    4-42 shift shaft and segment eng note: note: sr****** shift shaft removal 1. Remove: shift shaft assembly 1 push the shift lever arm 2 and the stopper lever 3 to the arrow direction and remove them from the segment. T402200 shift shaft inspection 1. Inspect: stopper lever roller turns roughly replac...

  • Page 123: Eng

    4-43 shift shaft and segment eng note: 12 nm (1.2 m kg) *************************************** *************************************** 2. Install: segment 1 fit the dowel pin 2 (long length) on the seg- ment to the locating hole a on the sift cam and install the segment. 3. Tighten: screw 1 sr*****...

  • Page 124: Eng

    4-44 cdi magneto and starter clutch eng order job name / part name q’ty remarks 1 2 3 4 crankcase cover (left) removal drain the engine oil side cover drive sprocket cover dci magneto lead couplers neutral switch lead connector crankcase cover (left) gasket dowel pins 1 1 1 2 remove the parts in ord...

  • Page 125: Eng

    4-45 cdi magneto and starter clutch eng order job name / part name q’ty remarks 1 2 3 4 pickup coil and stator coil removal clamp (stator coil) clamp (pickup coil) pickup coil stator coil 1 1 1 1 remove the parts in order. Reverse the removal procedure for installation. 3 nm (0.3 m kg) 7 nm (0.7 m k...

  • Page 126: Eng

    4-46 cdi magneto and starter clutch eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 cdi magneto and starter clutch removal cdi magneto idle shaft / collar starter idle gear woodruff key starter wheel gear shim dowel pins (inner) spring caps compression springs dowel pins (outer) ...

  • Page 127: Eng

    4-47 cdi magneto and starter clutch eng note: note: *************************************** *************************************** yp401081 c.D.I. Magneto removal 1. Remove: bolt 1 (magneto) plain washer 2 loosen the bolt (magneto) 1 while holding the rotor with a sheave holder 3 . Do not allow the...

  • Page 128: Eng

    4-48 cdi magneto and starter clutch eng 30 nm (3.0 m kg) note: 3. Inspect: starter wheel gear (contacting surface) pitting/ wear / damage replace. Sr****** starter clutch installation 1. Install: starter clutch assembly 1 2. Unloosen the starter clutch assembly by us- ing the center punch. 3. Instal...

  • Page 129: Eng

    4-49 cdi magneto and starter clutch eng 50 nm (5.0 m kg) note: 3. Tighten: cdi magneto assembly 1 tighten the bolt while holding the cdi magneto assembly with the sheave holder 2 . Sheave holder: 90890-01701.

  • Page 130: Eng

    4-50 crankcase and crank shaft eng order job name / part name q’ty remarks 1 crankcase separation engine cylinder head cylinder and piston clutch primary drive gear / oil pump balancer weight drive gear shift shaft and segment cdi magneto / starter clutch timing chain guide (intake) 1 remove the par...

  • Page 131: Eng

    4-51 crankcase and crank shaft eng order job name / part name q’ty remarks 2 3 4 timing chain crankcase dowel pins 1 1 2 refer to “crankcase separation / installation” section. Reverse the removal procedure for installation. 8 nm (0.8 m kg) 7 nm (0.7 m kg).

  • Page 132: Eng

    4-52 crankcase and crank shaft eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 crankshaft and balancer weight removal balancer weight crankshaft assembly dowel pin plunger seal compression spring bearing (balancer weight) bearing (crankshaft right) 1 1 1 1 1 1 1 remove the parts in order. ...

  • Page 133: Eng

    4-53 crankcase and crank shaft eng note: note: caution: note: sr401132 crankcase separation 1. Remove: crankcase screws the numbers embossed on the crankcase in- dicate the tightening sequence. Loosen the screws in decreasing numerical order (see numbers on the illustration). Loosen each screw 1 / 4...

  • Page 134: Eng

    4-54 crankcase and crank shaft eng note: t****** crankshaft inspection 1. Measure: crankshaft runout out of specification replace crankshaft and / or bearing. Measure the crankshaft runout with the crank- shaft assembly turning slowly. Runout limit: 0.03 mm 2. Measure: big end side clearance out of ...

  • Page 135: Eng

    4-55 crankcase and crank shaft eng caution: note: 7 nm (0.7 m kg) note: sr****** plunger seal installation 1. Install: compression spring 1 plunger seal 2 dowel pin 3 2. Check the plunger seal smooth operation pushing the plunger seal by your finger. T***** balancer weight installation 1. Install: c...

  • Page 136: Eng

    4-56 transmission sift cam and shift fork eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 transmission, shift cam and shift fork removal crankcase separating shift fork guide bar 2 (short length) shift fork guide bar 1 (long length) shift cam shift fork 1 “c” (center) shift fork 2 “...

  • Page 137: Eng

    4-57 transmission sift cam and shift fork eng order job name / part name q’ty remarks drive axle and main axle disassembly second wheel gear first wheel gear fifth wheel gear circlip / washer third wheel gear forth wheel gear drive axle second pinion gear forth pinion gear third pinion gear circlip ...

  • Page 138: Eng

    4-58 transmission sift cam and shift fork eng warning sr****** transmission, shift cam and shift fork removal 1. Install: o-ring 1 to the drive sprocket groove. 2. Remove: drive axle assembly 1 main axle assembly 2 remove them at same the time. T402190 shift fork shift cam inspection 1. Inspect: shi...

  • Page 139: Eng

    4-59 transmission sift cam and shift fork eng note: note: note: 4. Check: shift fork movement (on the guide bar) unsmooth operation replace the shift fork and the guide bar. When damaged the shift fork and mission gear, replace the facing each gear as set. Sr****** transmission, shift cam and shift ...

  • Page 140: Eng

    Eng.

  • Page 141: Chapter 5.

    Chapter 5. Carburetion carburetor 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor assembly 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel level adjustment 5-5 . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 143: Carb

    5-1 carburetor carb order job name / part name q’ty remarks 1 2 3 4 carburetor removal side cover seat fuel tank heater unit lead carburetor joint clamp screw air filter joint clamp screw carburetor assembly carburetor top 1 1 1 1 remove the parts in order. Note: refer to “side cover, seat and fuel ...

  • Page 144: Carb

    5-2 carburetor carb order job name / part name q’ty remarks carburetor disassembly throttle cable throttle valve assembly throttle valve spring mixing chamber top / o-ring drain screw assembly float chamber gasket (float chamber) float pin / float needle valve assembly main jet main nozzle / o-ring ...

  • Page 145: Carb

    5-3 carburetor carb order job name / part name q’ty remarks pilot screw assembly pilot jet throttle stop screw assembly starter plunger assembly screw / gasket heater unit / washer 1 1 1 1 1 / 1 1 / 1 reverse the disassembly procedure for assembly. Refer to “carburetor assembly” section. 12 13 14 15...

  • Page 146: Carb

    5-4 carburetor carb caution: new sr****** carburetor assembly do not use a wire for cleaning. Before assembling, wash all parts in clean petroleum based solvent. Always use a new gasket. 1. Install: pilot jet 1 pilot screw assembly 2 pilot screw (turn out): 2 turns out 2. Install: o-ring main nozzle...

  • Page 147: Carb

    5-5 carburetor carb *************************************** *************************************** yp600060 fuel level adjustment 1. Measure: fuel level a out of specification adjust. Fuel level: 2.5 3.5 mm below the float chamber line measurement and adjustment steps: place the motorcycle on a lev...

  • Page 148: Carb

    Carb.

  • Page 149: Chapter 6.

    Chapter 6. Chassis front wheel and brake disc 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front wheel disassembly 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front wheel inspection 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake disc insp...

  • Page 150

    Steering installation 6-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear shock absorber and swingarm 6-43 . . . . . . . . . . . . . . . . . . . . Swingarm inspection 6-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

  • Page 151: Chas

    6-1 front wheel and brake disc chas order job name / part name q’ty remarks 1 2 3 4 5 6 7 front wheel and brake disc removal speedometer cable axle pinch bolt wheel axle front wheel assembly collar meter gear unit assembly brake disc 1 1 1 1 1 1 1 remove the parts in order. Loosen the axle pinch bol...

  • Page 152: Chas

    6-2 front wheel and brake disc chas front wheel disassembly oil seal bearing spacer spacer flange bearing order job name / part name q’ty remarks 1 1 1 1 1 disassemble the parts in order. Refer to “front wheel assembly” section. Refer to “front wheel disassembly/ assembly” section. Reverse the disas...

  • Page 153: Chas

    6-3 front wheel and brake disc chas caution: warning note: note: t****** front wheel disassembly 1. Remove: bearings 1 spacer remove the bearings using a general bear- ing puller 2 . Handle the wheel with care not to damage the brake disc. If the brake disc is damaged, replace. T700021 front wheel i...

  • Page 154: Chas

    6-4 front wheel and brake disc chas note: 5. Measure: front wheel runout over the specified limits replace. Front wheel runout limits: radial 1 : 2.0 mm lateral 2 : 2.0 mm 6. Inspect: front wheel bearings bearings allow free play in the wheel hub or the wheel does not turn smoothly replace. Oil seal...

  • Page 155: Chas

    6-5 front wheel and brake disc chas caution: 23 nm (2.3 m kg) note: note: note: do not strike the inner race of balls of the bearing. Contact should be made only with the outer race. 2. Install: brake disc 1 tighten the bolts (brake disc) in stage using a crisscross pattern. Sr700030 front wheel ins...

  • Page 156: Chas

    6-6 front wheel and brake disc chas 59 nm (5.9 m : kg) 20 nm (2.0 m : kg) caution: warning note: *************************************** *************************************** 4. Tighten: : front wheel axle : axle pinch bolt before tightening the wheel axle, stroke the front fork several times to c...

  • Page 157: Chas

    6-7 front wheel and brake disc chas *************************************** note: *************************************** *************************************** *************************************** 4. Adjust: : wheel static balance adjusting steps: : install a balancing weight 1 on the rim exact...

  • Page 158: Chas

    6-8 front brake chas order job name / part name q’ty remarks 1 2 3 brake pad removal bolt (caliper support bolt) brake pads pad support 1 2 1 remove the parts in order. Refer to “brake pad replacement” section. Reverse the removal procedure for installation. 23 nm (2.3 m kg) front brake brake pad.

  • Page 159: Chas

    6-9 front brake chas note: note: caution: 23 nm (2.3 m kg) sr702010 brake pad replacement it is not necessary to disassemble the brake cal- iper and brake hose to replace the brake pads. 1. Remove: bolt (caliper support bolt) 1 move the direction brake caliper 2 to the ar- row mark. 2. Remove: brake...

  • Page 160: Chas

    6-10 front brake chas order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 master cylinder removal drain the brake fluid rear view mirror (right) brake lever / compression spring brake switch union bolt plate washer brake hose bracket (master cylinder) master cylinder 1 1 / 1 1 1 2 1 1 1 remove t...

  • Page 161: Chas

    6-11 front brake chas master cylinder disassembly rubber boots circlip master cylinder kit spring order job name / part name q’ty remarks 1 1 1 disassemble the parts in order. Refer to “master cylinder assembly” section. Reverse the disassembly procedure for reassembly. 1 2 3 4.

  • Page 162: Chas

    6-12 front brake chas warning yp702040 master cylinder inspection 1. Inspect: master cylinder piston 1 wear / scratches replace the master cyl- inder kit. Master cylinder cup 2 cracks / damage replace. 2. Inspect: master cylinder scratches / wear / damage replace the master cylinder assembly. 3. Ins...

  • Page 163: Chas

    6-13 front brake chas a new 9 nm (0.9 m kg) caution: new new 30 nm (3.0 m kg) note: caution: 2. Install: circlip 1 install the circlip securely into the master cyl- inder groove. Rubber boot 2 yp****** master cylinder installation 1. Install: master cylinder 1 master cylinder bracket 2 install the m...

  • Page 164: Chas

    6-14 front brake chas warning use only designated quality brake fluid: otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance. Refill with the same type of brake fluid:mix- ing fluids may result in a harmful chemical reaction and lead to poor performance. Be care...

  • Page 165: Chas

    6-15 front brake chas order job name / part name q’ty remarks 1 2 3 4 5 6 caliper removal drain teh brake fluid brake hose holder union bolt plain washer brake hose caliper support bolt caliper assembly 1 1 1 1 1 1 remove the parts in order. Refer to “caliper installation” section. 23 nm (2.3 m kg) ...

  • Page 166: Chas

    6-16 front brake chas order job name / part name q’ty remarks caliper disassembly brake pad caliper piston dust seal piston seal bleed screw / cap 2 2 2 1 disassemble the parts i order. Refer to “brake pad” section. Refer to “brake caliper disassembly/ assembly” section. Reverse the disassembly proc...

  • Page 167: Chas

    6-17 front brake chas note: *************************************** warning *************************************** warning sr****** brake caliper disassembly before disassembling either brake caliper, drain the brake fluid from the brake hose, mas- ter cylinder, brake caliper and reservoir tank. 1....

  • Page 168: Chas

    6-18 front brake chas new new warning 40 nm (4.0 m kg) 23 nm (2.3 m kg) new 30 nm (3.0 m kg) caution: caution: 1. Install: piston seals 1 dust seal 2 always use new caliper piston seals. 2. Install: caliper piston 1 apply brake fluid to the outer surface and install. Yp****** caliper installation 1....

  • Page 169: Chas

    6-19 front brake chas warning use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. Refill with the same type of brake fluid: mixing brake fluids may result in a harmful chemical reaction and lead to poor brake p...

  • Page 170: Chas

    6-20 rear wheel, rear brake and drive chain chas order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 rear wheel and rear brake removal adjuster brake rod pin compression spring cotter pin tension bar chain case axle nut chain puller wheel axle collar 1 1 1 1 1 1 1 1 2 1 1 remove the part...

  • Page 171: Chas

    6-21 rear wheel rear brake and drive chain chas order job name / part name q’ty remarks 12 13 14 15 16 17 18 rear wheel assembly collar shoe plate nut (driven sprocket) circlip washer driven sprocket 1 1 1 4 1 1 1 reverse the removal procedure for installation. Refer to “rear wheel assembly” section...

  • Page 172: Chas

    6-22 rear wheel, rear brake and drive chain chas order job name / part name q’ty remarks rear wheel disassembly bearing collar spacer oil seal bearing 1 1 1 1 1 disassemble the parts in order. Refer to “rear wheel disassembly/ assembly” section. Reverse the disassembly procedure for reassembly. 1 2 ...

  • Page 173: Chas

    6-23 rear wheel, rear brake and drive chain chas order job name / part name q’ty remarks brake shoe plate disassembly brake shoe kit tension springs cam lever indicator plate camshaft 2 2 1 1 1 disassemble the parts in order. Refer to “brake shoe plate assembly” section. Reverse the disassembly proc...

  • Page 174: Chas

    6-24 rear wheel, rear brake and drive chain chas order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 drive chain removal chain case axle nut shift pedal sprocket cover sprocket holder clip plate chain joint drive chain drive sprocket 1 1 1 1 1 1 1 1 1 remove the parts in order. Refer to “rear ...

  • Page 175: Chas

    6-25 rear wheel, rear brake and drive chain chas warning t****** rear wheel disassembly 1. Remove: bearings 1 spacer 2 collar 3 refer to “front wheel”. Sr701020 rear wheel inspection 1. Inspect: rear wheel axle rear wheel rear wheel bearings oil seals refer to “front wheel”. 2. Inspect: clutch hub d...

  • Page 176: Chas

    6-26 rear wheel, rear brake and drive chain chas note: 5. Inspect: cam shaft face t701020 drive chain inspection 1. Inspect: drive chain stiffness stiffness clean and lubricate or replace. 2. Inspect: drive chain 1 driven sprocket 2 more than 1 / 2 tooth a wear replace the drive chain. Use new drive...

  • Page 177: Chas

    6-27 rear wheel, rear brake and drive chain chas *************************************** *************************************** 9 nm (0.9 m kg) note: new note: warning 4. Clean: drive chain put it in kerosene, and brush off as much dirt as possible. Then remove the drive chain from the kerosene and...

  • Page 178: Chas

    6-28 rear wheel, rear brake and drive chain chas note: caution: new 40 nm (4.0 m kg) new caution: sr****** rear wheel assembly 1. Install: bearing 1 spacer 2 collar 3 bearing 4 apply the lithium soap base grease on the bearing and oil seal lip when installing. Use a socket that matches the outside d...

  • Page 179: Chas

    6-29 front fork chas order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 front fork removal front wheel brake hose holder caliper front fender cover bolt/ washer bolt (under bracket) front fork assembly (left) front fork assembly (right) 1 1 1 1 1 / 1 1 1 1 remove the parts in order. Refer to “f...

  • Page 180: Chas

    6-30 front fork chas 10 order job name / part name q’ty remarks front fork disassembly cap bolt / o-ring collar / washer fork spring dust cover retaining clip washer (oil seal) inner tube assembly oil seal piston metal damper rod outer tube 1 / 1 1 / 1 1 1 1 1 1 1 1 1 1 drain the fork oil. Note: ref...

  • Page 181: Chas

    6-31 front fork chas caution: *************************************** caution: *************************************** warning sr****** front fork disassembly 1. Remove: cap bolt 1 collar 2 washer 3 fork spring 4 2. Remove: dust cover 1 retaining clip 2 (using a slotted-head screwdriver) washer (oil...

  • Page 182: Chas

    6-32 front fork chas caution: note: note: 2. Measure: fork spring a front fork spring free length: 326.1 mm 321 mm over the specified limit replace. 3. Inspect: rod assembly 1 bends / damage replace. The front fork has a built-in piston rod and a very sophisticated internal construction which are pa...

  • Page 183: Chas

    6-33 front fork chas new new note: caution: new note: 2. Install: piston metal 1 oil seal 2 use the fork seal driver weight 3 and the at- tachment 4 . Before installing the oil seal 2 , apply lithium soap base grease onto the oil seal lips. Make sure that the oil seal numbered side faces upward. For...

  • Page 184: Chas

    6-34 front fork chas note: note: new 65 nm (6.5 m kg) note: 48 nm (4.8 m kg) 30 nm (3.0 m kg) 7. Measure: oil level a out of specification adjust. Oil level: 165 mm (from the top of the inner tube fully compressed and without the fork spring) hold the fork in an upright position. 8. Install: front f...

  • Page 185: Chas

    6-35 handlebar chas order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 handlebar removal headlight assembly handlebar switch lead (left and right), front brake switch lead and clutch switch lead master cylinder bracket master cylinder housing (throttle grip) throttle cable throttle grip as...

  • Page 186: Chas

    6-36 handlebar chas order job name / part name q’ty remarks 11 12 13 14 15 handlebar switch (left) grip (left) lever holder (left) upper holder handlebar 1 1 1 2 1 refer to “handlebar removal” section. Refer to “handlebar installation” section. Reverse the removal procedure for installation. 9 nm (0...

  • Page 187: Chas

    6-37 handlebar chas *************************************** *************************************** warning 20 nm (2.0 m kg) note: note: warning yp****** handlebar removal 1. Remove: grip (left) removal steps: remove the grip end (left). Blow with compressed air between the hadle- bar and adhesive s...

  • Page 188: Chas

    6-38 handlebar chas 9 nm (0.9 m kg) note: 3. Install: master cylinder 1 master cylinder bracket 2 install the master cylinder bracket with the “up” mark facing upward. 4. Adjust: throttle cable free play brake operation. Refer to “throttle cable adjust- ment / brake lever adjustment” section in chap...

  • Page 189: Chas

    6-39 steering chas order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 under bracket removal front fork handlebar flasher light assembly (left) flasher light assembly (right) cover meter cable / meter lead meter assembly / handlebar crown horn ring nut ball race cover under bracket 1 1 1 1 / 1...

  • Page 190: Chas

    6-40 steering chas order job name / part name q’ty remarks 10 11 12 13 14 ball race (upper) ball ball ball race (center) ball race (lower) 1 22 19 1 1 reverse the removal procedure for installation. Refer to “steering removal/ installation” section. 40 nm (4.0 m kg) 1st step: 38 nm (3.8 m kg)2nd ste...

  • Page 191: Chas

    6-41 steering chas warning warning *************************************** *************************************** note: caution: yp704010 steering removal securely support the motorcycle so that there is no danger of it falling over. Stand the motorcycle on a level surface. 1. Remove: ring nut 1 us...

  • Page 192: Chas

    6-42 steering chas 7 nm (0.7 m kg) eb704030 steering installation reverse the “removal” procedure. Note the following points. 1. Lubricate: bearings (upper and lower) ball races recommended lubricant lithium-soap base grease 2. Install: ring nut 1 refer to “steering head inspection” section in chapt...

  • Page 193: Chas

    6-43 rear shock absorber and swingarm chas order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 rear shock absorber and swingarm removal rear wheel chain case drive chain rear shock absorber nut footrest assembly (right) pivot shaft footrest assembly (left) swingarm tension bar cover (swingarm)...

  • Page 194: Chas

    6-44 rear shock absorber and swingarm chas t***** swingarm inspection 1. Inspect: swingarm side play free play exists check side clearance. Swingarm up and down movement unsmooth movement / bending / rough spots grease or replace bearings, solid bushes and collars..

  • Page 195: Chapter 7.

    Chapter 7. Electrical electrical components 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch inspection 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection steps 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 197: Elec

    7-1 electrical components elec 15 c.D.I. Unit 8 neutral relay 9 thermo switch 10 sidestand switch 11 rear brake switch 12 neutral switch 13 spark plug cap 14 ignition coil 1 horn 2 flasher relay 3 main switch 4 starter relay 5 rectifier / regulator 6 battery 7 fuse holder assembly eb800000 electrica...

  • Page 198: Elec

    7-2 switch inspection elec note: yp-n switch inspection inspection steps using pocket tester, check switches for continu- ity between their terminals to determine wheth- er they are correctly connected. Replace the switch component if any of the combinations does not produce the correct reading. Poc...

  • Page 199: Elec

    7-3 1 clutch switch 2 turn switch 3 dimmer switch 4 horn switch 5 main switch 6 front brake switch 7 engine stop switch 8 start switch 9 rear brake switch 10 neutral switch 11 sidestand switch 12 fuse 13 thermo switch switch inspection elec switch continuity inspection refer to “switch inspection” a...

  • Page 200: Elec

    7-4 1 c.D.I. Magneto 6 main switch 10 engine stop switch 12 c.D.I. Unit 13 ignition coil 14 spark plug 15 sidestand switch ignition system elec eb802000 ignition system circuit diagram.

  • Page 201: Elec

    7-5 ignition system elec note: 1. Spark plug check the spark plug condition. Check the spark plug type. Check the spark plug gap. Refer to “spark plug inspection” sec- tion in chapter 3. Spark plug gap: 0.6 0.7 mm standard spark plug: dr8ea/ ngk out of specification repair or replace the spark plug ...

  • Page 202: Elec

    7-6 ignition system elec s remove the spark plug cap. S connect the pocket tester ( Ω 1k) to the spark plug cap. S when removing the spark plug cap, do not pull the spark plug cap from high tension cord. Remove turning counterclockwise. Connect turning clockwise. S check the high tension cord when c...

  • Page 203: Elec

    7-7 ignition system elec tester (+) lead spark plug lead tester (–) lead orange terminal s disconnect the ignition coil connector from the wireharness. S connect the pocket tester ( Ω 1) to the ignition coil. S check if the primary coil has the specified re- sistance. 4. Ignition coil resistance : s...

  • Page 204: Elec

    7-8 tester (+) lead white terminal tester (–) lead red terminal tester (+) lead brown terminal tester (–) lead green terminal s disconnect the pickup coil coupler from the wireharness. S connect the pocket tester ( Ω 100) to the pickup coil coupler. 5. Pickup coil resistance : replace the pickup coi...

  • Page 205: Elec

    7-9 ignition system elec refer to “switch inspection” section. 8. Engine stop switch : replace the handlebar switch (right). No continuity continuity refer to “switch inspection” section. 9. Sidestand switch replace the sidestand switch no continuity continuity s check the connection of the entire i...

  • Page 206: Elec

    7-10 3 starter relay 4 battery 5 fuse 6 main switch 10 engine stop switch 11 start switch 15 clutch switch 16 sidestand switch 17 neutral relay 24 neutral switch 38 starter motor electric starting system elec eb80300 electric starting system circuit diagram.

  • Page 207: Elec

    7-11 electrical starting system elec sr****** starting circuit operation the starting circuit on this model consists of the starter motor, starter relay, and the neutral relay. If the engine stop switch and the main switch are both closed, the starter motor can operate only if: the transmission is i...

  • Page 208: Elec

    7-12 electrical starting system elec note: 1. Fuse refer to “switch inspection” section. Continuity no continuity replace the fuse. 2. Battery check the battery condition. Refer to “battery inspection” section in chapter 3. Specific gravity: 1.280 at 20 c correct refill the battery fluid. Clean batt...

  • Page 209: Elec

    7-13 electrical starting system elec s connect the battery positive terminal and starter motor cable using a jumper lead *. S check the starter motor operation. : * 1 : 3. Starter motor 2 3 moves does not move repair or replace the starter motor. 4. Starter relay s disconnect the relay unit coupler ...

  • Page 210: Elec

    7-14 electrical starting system elec : 1 : 2 3 4 5. Neutral relay s remove the relay from the frame. S connect the pocket tester ( Ω 100) to the battery and the relay connecter. Tester (+) lead terminal 1 tester (–) lead terminal 3 battery (+) lead terminal 2 battery (–) lead terminal 4 check the te...

  • Page 211: Elec

    7-15 electrical starting system elec : 10.Clutch switch refer to “switch inspection” section. Continuity no continuity replace the clutch switch. 11. Start switch refer to “switch inspection” section. Continuity no continuity replace the handlebar switch (right). 12.Wiring connection s check the con...

  • Page 212: Elec

    7-16 order job name / part name q’ty remarks 1 2 3 starter motor removal drain the engine oil crankcase cover (right) starter motor lead starter motor o-ring 1 1 1 remove the parts in order. Refer to “engine oil replacement” section in chapter 3. Refer to “clutch removal” section in chapter 4. Rever...

  • Page 213: Elec

    7-17 electrical starting system elec note: a b yp803034 inspection and repair 1. Inspect: commutator dirt clean it with #600 grit sandpaper. 2. Measure: commutator diameter a commutator wear limit: 27 mm out of specification replace the starter motor 3. Measure: mica undercut a mica undercut: 0.7 mm...

  • Page 214: Elec

    7-18 electrical starting system elec note: new 3 nm (0.3 m kg) note: 6. Measure: brush spring force fatigue / out of specification replace as a set. Brush spring force: 540 x 660 g 7. Inspect: oil seal wear / damage replace. Yp****** assembly reverse the “disassembly” procedure. Note the following p...

  • Page 215: Elec

    7-19 1 c.D.I. Magneto 2 rectifier / regulator 4 battery 5 fuse charging system elec yp804000 charging system circuit diagram.

  • Page 216: Elec

    7-20 charging system elec note: 1. Fuse refer to “switch inspection” section. Continuity no continuity replace the fuse. 2. Battery check the battery condition. Refer to “battery inspection” section in chapter 3. Specific gravity: 1.280 at 20 c correct incorrect refill the battery fluid. Clean batte...

  • Page 217: Elec

    7-21 charging system elec tester (+) lead battery (+) terminal tester (–) lead battery (–) terminal : 1 2 : 3. Charging voltage s connect the engine tachometer to the spark plug lead. S connect the pocket tester (dc20v) to the battery. S measure the battery terminal voltage. S start the engine and a...

  • Page 218: Elec

    7-22 5. Wiring connection check the entire charging system for connec- tions. Refer to “circuit diagram” section. Correct replace the rectifier / regulator. Poor connection correct. Charging system elec yp******.

  • Page 219: Elec

    7-23 4 battery 5 fuse 6 main switch 22 high beam indicator light 23 meter light 26 tail / brake light 30 auxiliary light 34 lights switch 36 dimmer switch 39 headlight lighting system elec eb804000 lighting system circuit diagram.

  • Page 220: Elec

    7-24 lighting system elec note: 1. Fuse refer to “switch inspection” section. Continuity no continuity replace the fuse. 2. Battery check the battery condition. Refer to “battery inspection” section in chapter 3. Specific gravity: 1.280 at 20 c correct incorrect refill the battery fluid. Clean batte...

  • Page 221: Elec

    7-25 headlight: tester (+) lead green or yellow lead tester negative (–) lead black lead high beam indicator light: tester (+) lead yellow lead tester (–) lead black lead when the dimmer switch is on low beam. When dimmer switch is on high beam. : 1 3 4 5 : b a 4. Lights switch refer to “switch insp...

  • Page 222: Elec

    7-26 lighting system elec tester (+) lead blue terminal tester (–) lead black terminal : s turn the main switch to on position. S turn the lights switch to on position. S turn the dimmer switch to low beam or high beam. S check for voltage (12 v) on the lead at bulb socket connectors. 1 2 meets spec...

  • Page 223: Elec

    7-27 tester (+) lead blue / red terminal tester (–) lead black terminal 2 tester (+) lead blue terminal tester (–) lead black terminal 1 2 1 1. Bulb and bulb socket refer to “switch inspection” section. Continuity 2. Voltage connect the pocket tester (dc20v) to the bulb socket connector. Turn the ma...

  • Page 224: Elec

    7-28 4 battery 5 fuse 6 main switch 7 thermo switch 8 heater unit 19 neutral indicator light 20 turn indicator light (left) 21 turn indicator light (right) 24 neutral switch 25 rear flasher lights 26 tail / brake light 27 front brake switch 28 rear brake switch 29 front flasher lights 31 flasher rel...

  • Page 225: Elec

    7-29 signal system elec note: : 1. Fuse refer to “switch inspection” section. Continuity no continuity replace the fuse. 2. Battery s check the battery condition. Refer to “battery inspection” section in chapter 3. Specific gravity: 1.280 at 20 _ c correct incorrect s refill the battery fluid. S cle...

  • Page 226: Elec

    7-30 signal system elec : 4. Wireharness s check the connections of the entire signal system. Refer to “circuit system wiring dia- gram” section. Correct check condition of each of the signal sys- tem’s circuits. Refer to “signal system check” section. Poor connection correct. Yp******.

  • Page 227: Elec

    7-31 tester (+) lead pink terminal tester (–) lead frame ground tester (+) lead brown terminal tester (–) lead frame ground 1 1 1. Horn switch refer to “switch inspection” section. Continuity 2. Voltage connect the pocket tester (dc20v) to the horn lead. Turn the main switch to on. Check for voltage...

  • Page 228: Elec

    7-32 tester (+) lead yellow terminal tester (–) lead black terminal 1 2 1. Bulb and bulb socket refer to “switch inspection” section. Continuity 2. Brake switch (front / rear) refer to “switch inspection” section. 3. Voltage connect the pocket tester (dc20v) to the bulb socket connector. Turn the ma...

  • Page 229: Elec

    7-33 tester (+) lead brown/white terminal tester (–) lead frame ground tester (+) lead brown terminal tester (–) lead frame ground 1 1 : 1. Bulb and bulb socket refer to “switch inspection” section. Continuity 2. Turn switch refer to “switch inspection” section. Continuity 3. Voltage s connect the p...

  • Page 230: Elec

    7-34 at flasher light (right) tester (+) lead dark green lead tester (–) lead black terminal at flasher light (left) tester (+) lead chocolate lead tester (–) lead black terminal : 1 3 2 3 : 5. Voltage s connect the pocket tester (dc20v) to the bulb socket connector. S turn the main switch to on. S ...

  • Page 231: Elec

    7-35 tester (+) lead black terminal tester (–) lead black terminal : 1 2 1 2 : cool down heat up a b 3. Voltage s connect the pocket tester (dc20v) to the fuel gauge coupler. Tester (+) lead brown terminal tester (–) lead sky blue terminal s turn the main switch to on position. S select the gear pos...

  • Page 232: Elec

    7-36 signal system elec tester (+) lead terminal tester (–) lead terminal : 1 2 2. Heater unit resistance s remove the heater unit from the carburetor. S connect the pocket tester ( Ω 1) to the heater unit. S check the heater unit for specificated resis- tance. Heater unit resistance: 6 x 10 Ω (20 _...

  • Page 233: Chapter 8.

    Chapter 8. Trouble shooting starting failure/ hard staring 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Poor idle speed performance 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Poor medium and high speed performance 8-3 . . . . . . . . . . . . . Poor speed performance 8-3 ....

  • Page 235: Trbl

    8-1 starting failure/hard starting trbl shtg note: eb90000 troubleshooting 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 relative procedure in this manual for inspection, adjustment and repl...

  • Page 236: Trbl

    8-2 poor idle speed performance trbl shtg ignition system battery improperly charged battery faulty battery fuse burnt out, improper connection spark plug improper plug gap worn electrodes wire between terminals broken improper heat range faulty spark plug cap ignition coil broken or shorted primary...

  • Page 237: Trbl

    8-3 poor medium and high speed performance trbl shtg eb902000 poor medium and high speed performance poor medium and high speed performance refer to “starting failure/ hard starting” section. (fuel system, electrical system, compres- sion system and valve train) carburetor improperly adjusted fuel l...

  • Page 238: Trbl

    8-4 faulty clutch/faulty gear shifting trbl shtg eb904000 clutch slipping/dragging clutch slipping clutch improperly adjusted clutch cable loose clutch spring fatigued clutch spring worn friction plate / clutch plate incorrectly assembled clutch engine oil improper oil level improper quality / (low ...

  • Page 239: Trbl

    8-5 over heating/faulty brake trbl shtg sr905000 over heating or over-cool- ing over heating ignition system improper spark plug gap improper spark plug heat range faulty c.D.I. Unit fuel system improper carburetor setting improper fuel level adjustment clogged air filter element compression system ...

  • Page 240: Trbl

    8-6 front fork malfunction/instable handling trbl shtg sr907000 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 outer ...

  • Page 241: Trbl

    8-7 starter motor does not operate trbl shtg sr****** starter motor does not operate starter motor does not operate battery insufficient battery capacity faulty battery fuse burnt out, improper connection switch faulty main switch faulty starter switch faulty clutch switch faulty neutral switch faul...

  • Page 242: Trbl

    8-8 faulty signal and lighting system trbl shtg yp909000 faulty signal and lighting system headlight dark improper bulb too many electric accessories hard charging faulty rectifier / regulator faulty battery improperly connected coupler, connector, wireharness improperly grounded faulty main switch ...

  • Page 243

    Color code b black . . . . . Br brown . . . . Ch chocolate . . . Dg dark green . . . G green . . . . L blue . . . . . O orange . . . . Sb sky blue . . . . P pink . . . . . R red . . . . . Y yellow . . . . . W white . . . . Br / l brown / blue . . Br / w brown / white . G / y green / yellow . . L/ b ...