Professional Documents
Culture Documents
YSR Service Manual PDF
YSR Service Manual PDF
YS R5OT
SERVICE MANUAL
01987 by Yamaha Motor Corporation, U.S.A.
1st Edition, March 1987
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
PINO. LIT-Il616-O6-05
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to put an entire mechanic's education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor-
cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle
repair technology. Without such knowledge, attempted repairs or service to this model may render
it unfit to use andlor unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all Authorized
Yamaha dealers and will, where applicable, appear in future editions of this manual.
TECHNICAL PU BLlCATlONS
SERVICE DIVISION
MOTORCYCLE OPERATIONS
YAMAHA MOTOR CO., LTD.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course
of action required will follow the symbol, e.g.,
Bearings
Pitting1Damage-, Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
ILLUSTRATED SYMBOLS
(Refer to the illustration)
I ENG 1 content.
a General information
@ Specifications
@ Periodic inspection and adjustment
@ Engine
@ Cooling system
@ Carburetion
a Chassis
@ Electrical
@ Troubleshooting
GENERAL INFORMATION
m
GEN
INFO
SPECIFICATIONS
Pf
PERIODIC INSPECTION em
AND ADJUSTMENT INSP
ADJ
@
+o,
ENGINE OVERHAUL
&O
CHASSIS
El
ELECTRICAL
ELEC
0
TROUBLESHOOTING
CONTENTS
CHAPTER 1 .
GENERAL INFORMATION
CHAPTER 2 .
SPECIFICATIONS
t N t i I N t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
.
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
THROTTLE CABLE FREE PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 3.5
AUTOLUBE PUMP CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 3.5
AUTOLUBE PUMP STROKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 3.6
AUTOLUBE PUMP AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
TRANSMISSION OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .3.11
TRANSMISSION OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
CARBURETOR JOINT INSPECTOIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Y.E.I.S. HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
BRAKE SHOE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
BRAKE LIGHT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
BRAKE HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
DRIVE CHAIN SLACK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
DRIVE CHAIN LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
STEERING HEAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CABLE INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 3.24
LEVER AND PEDAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
SIDESTAND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26 .
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28 .
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29 .
HEADLIGHT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
CHAPTER 4 .
ENGINE OVERHAUL
... .
w. w . . ....
L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .".
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
.
TRANSMISSION AND SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
.
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
..
AUTOLUBE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 .
CHAPTER 5.
CARBURETION
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-5-1 .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 .
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
CHAPTER 6.
CHASSIS
CHAPTER 7.
ELECTRICAL
CLUTCH SLIPPINGIDRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. .7
CLUTCH SLIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..7
CLUTCH DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 .
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
.
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
.
IAL N
The engine serial num
left side sf the en
. : : -
cThe first three di ts sf these numbers are for
model identificat ns; %heremainin
duction number.
specifications are su
without notice.
IMPORTANT INFORMATION I 1-
IMPORTANT INFORMATION
@ Bearing
SPEClAL TOOLS
ClRCLlPS
1-
1. All circlips should be inspected carefully be-
fore reassembly. Always replace piston pin
clips after one use. Replace distorted circlips.
When installing a circlip @, make sure that
the sharp edged corner @ is positioned op-
posite to the thrust @ it receives. See the
sectional view.
@ I
Shaft
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or improvised
techniques.
FOR TUNE UP
1. Inductive Timing Light
PIN. YM-33277
3. Flywheel Puller
PIN. YM-01189
1. Coil Tester
PIN. YU-33261
2. Pocket Tester
PIN. YU-03112
GENERAL SPECIFICATIONS
Model
Model Code Number:
Vehicle Identification Number:
Engine Starting Number
Dimensions:
Overall Length 1,630 mm (64.2 in)
Overall Width 635 mm (25.0 in)
Overall Height 930 mm (36.6 in)
Seat Height 660 mm (26.0 in)
Wheelbase 1,055 mm (41.5 in)
Minimum Ground Clearance 120 mm (4.7 in)
Basic Weight:
With Oil and Full Fuel Tank
Minimum Turning Radius: 2,400 mm (94.5 in)
Engine:
Engine Type Air cooled 2-stroke
Induction System Reed valve
Cylinder Arrangement Forward inclined single cylinder
Displacement 49.3 cm3
Bore x Stroke 40.0 x 39.2 mm (1.57 x 1.54 in)
Compression Ratio 7.4 : 1
Starting System Kick starter
Lubrication System:
TYpe Separate lubrication (Yamaha Autolube)
Engine Oil Type Yamalube " 2 or air cooled 2 stroke engine oil with
"BIA certified for service TC-W"
Transmission Oil Type Yamalube " 4 , SAE 10W30 type SE motor oil or
"GL" gear oil
Oil Capacity:
Engine Oil (Oil Tank) 0.73 L (0.64 Imp qt, 0.77 US qt)
Transmission Oil:
Periodic Oil Change 0.60 L (0.53 Imp qt, 0.63 US qt)
Total Amount 0.65 L (0.57 Imp qt, 0.69 US qt)
Air Filter
Type Wet type element
GENERAL SPECIFICATIONS I SPEC / pf I
Model
Fuel:
TYpe Regular gasoline
Fuel Tank Capacit I
Full Amount 8.0 L (1.76 Imp gal, 2.1 1 US gal)
Reserve Amount 1.5 L (0.33 Imp gal, 0.39 US gal)
Carburetor:
Type/ Quantity VM16SH/1 pc.
Manufacturer MIKUNI
Spark Plug:
TypeIQuantity B7HS or B8HS
Manufacturer NGK
Plug Gap - -
0.5 0.6 mm (0.020 0.024 in)
Clutch:
Type Wet, multiple disc
Transmission:
TYpe Constant mesh 5-speed
Primary Reduction System Helical gear
Primary Reduction Ratio 68/19 (3.579)
Secondary Reduction System Chain drive
Secondary Reduction Ratio 44/12 (3.667)
Operation Left foot operation
Gear Ratio
1st
2nd
3rd
4th
5th
Chassis:
Frame Type Double cradle
Caster Angle 25.3'
Trail 64 mm (2.52 in)
Tire:
TYpe Tubeless
Size
Front 3.50-12 2PR
Rear 4.00-12 2PR
Tire Pressure (Cold Tire):
Basic Weight:
With Oil and Full Fuel Tank
Maximum Load*
Cold Tire Pressure: FRONT
Zero - Maximum Load*
* Load is total weight of cargo, rider, and accessories.
2-2
GENERAL SPECIFICATIONS 1-
Model
Brake:
Front Brake Type Single disc brake
Front Brake Operation Right hand operation
Rear Brake Type Drum brake
Rear Brake Operation Right foot operation
Suspension:
Front Suspension Type Telescopic fork
Rear Suspension Type Swingarm (Monocross suspension)
Shock Absorber:
Front Shock Absorber Coil springloil damper
Rear Shock Absorber Coil springloil damper
Wheel Travel:
Front Wheel Travel 90 mm (3.5 in)
Rear Wheel Travel 75 mm (3.0 in)
Electrical:
Ignition System CDI Magneto
Generator System Flywheel magneto
Battery:
Type
Capacity
Headlight:
TYpe Sealed beem
Bulb Wattage (Quantity):
Headlight
TailIBrake Light
Flasher Light
Licence Light
Meter Light
"NEUTRAL" lndicator Light
"HIGH BEAM" lndicator Light
"TURN" lndicator Light
"OIL" Warning lndicator Light
(Light Emitting Diode)
MAINTENANCE SPECIFICATIONS I SPEC 1 p9 I
MAINTENANCE SPECIFICATIONS
ENGINE
Model
Cylinder Head: *
Warpage Limit 0.02 mm (0.001 in)
"Lines indicate straightedge measurement.
Cylinder:
Bore Size 40.00-40.02 mm (1.575- 1.576 in)
Taper Limit 0.05 mm (0.002 in)
Out of Round Limit 0.01 mm (0.0004 in)
Piston:
Piston Size "D" 39.96-39.98 mm (1.573- 1.574 in)
Measuring Point "a" 5 mm (0.20 in)
-
0.15 0.35 mm -
(0.006 0.014 in)
2nd Ring 0.15-0.35 mm (0.006-0.014 in)
Side Clearance Top Ring 0.03-0.05 mm (0.001 -0.002 in)
2nd Ring 0.03-0.05 mm (0.001 -0.002 in)
MAINTENANCE SPECIFICATIONS I SPEC 1 pp I
Model
Crankshaft:
Crank Width "A" 37.90-37.95 mm (1.492- 1.494 in)
Runout Limit "B" 0.03 mm (0.0012 in)
Big End Side Clearance "C" -
0.2- 0.7 mm (0.008 0.028 in)
< Limit > < 1.0 mm (0.04 in) >
Small End Free Play "D" 0.8- 1.0 mm (0.032-0.039 in)
< Limit >
- D
< 1.5 mm (0.06 in) >
Clutch:
Friction Plate:
Thickness 3.5 mm (0.138 in)
Quantity 2 pcs.
Wear Limit 2.7 mm (0.106 in)
Clutch Plate:
Thickness 2.0 mm (0.079 in)
Quantity 1 PC.
Warpage Limit 0.05 mm (0.002 in)
Clutch Spring:
Free Length 28.2 mm (1.11 in)
Quantity 4 pcs.
Minimum Free Length 26.2 mm (1.03 in)
Clutch Release Method Inner push, cam push
< Push Rod Bending Limit > 2 (0.008 in) >
~ 0 . mm
Transmission:
Main Axle Runout Limit 0.08 mm (0.003 in)
Drive Axle Runout Limit 0.08 mm (0.003 in)
-
Shifter:
TYpe Cam drum and guide bar
Guide Bar Bending Limit 0.025 mm (0.001 in)
Kick Starter:
TYpe Kick and Mesh type
MAINTENANCE SPECIFICATIONS 1-
Model
Air Filter:
Oil Grade Foam-Air-Filter oil or Yamalube "2"
Carburetor:
I.D. Mark 2AL 01
Main Jet # 120
Air Jet 42.5
Jet Needle-Position 3621-4
Needle Jet E-0
Cutaway 2.0
Pilot Outlet 40.9
Pilot Jet # 17.5
Air Screw 1-118
Valve Seat Size 41.5
Starter Jet # 20
Fuel Level 0 - 1 mm (0- 0.04 in)
Float Height -
21 -23 mm (0.83 0.91 in)
Idling Speed -
1,300 1,400 rlmin
Reed Valve:
Valve Thickness 0.15 mm (0.006 in)
Valve Stopper Height 6.7-7.3 mm (0.26- 0.29 in)
Valve Bending Limit 0.3 mm (0.012 in)
Lubrication System:
Autolube Pump
Color Code Green
Minimum Stroke - -
0.20 0.25 mm (0.008 0.010 in)
Maximum Stroke 1.85-2.05 mm (0.073-0.081 in)
Minimum Output 0.50-0.63 cm3 per 200 strokes
Maximum Output -
4.64 5.15 cm3 per 200 strokes
Pulley Adjusting Mark A t idle
MAINTENANCE SPECIFICATIONS I / p9 I
SPEC
TIGHTENING TORQUE
Spark plug
Cylinder head
Autolube pump
Intake manifold
Muffler (Front)
Muffler (Rear)
Crankcase
Crankcase cover
Transmission oil drain bolt
Autolube pump cover
Kick crank assembly
Primary drive gear
Clutch boss
Pressure plate
Stopper plate (Bearing)
Stopper plate (Shift cam)
Shift lever adjuster nut
Change pedal
Stator
CDI magneto
Neutral switch
MAINTENANCE SPECIFICATIONS pi+q
CHASSIS
Model
Steering System:
Bearing Type Ball Bearing
Bearing Size (Quantity)
Upper
Lower
Front Suspension:
Front Fork Travel 90 mm (3.54 in)
Fork Spring Free Length (Left side only) 374.2 mm (14.7 in)
< Limit > <367 mm (14.4 in) >
Spring Rate (K1) 8.2 N l m m (0.83 kglmm, 46.6 Iblin)
Stroke (KI) 0.0-90.0 mm (0.0 -3.5 in)
Optional Spring No.
LEFT RIGHT
Oil Capacity 126 cm3 (4.44 Imp oz, 164 cm3 (5.77 Imp oz,
4.26 US oz) 5.54 US oz)
Oil Level 146 mm (5.74 in) 51 mm (2.01 in)
From top of inner tube From top of inner tub(
fully compressed without compressed without
spring. spring.
Oil Grade Yamaha fork oil 10WT or t
equivalent
3ear Suspension:
Shock Absorber Travel 18.0 mm (0.71 in)
Spring Free Length 86 mm (3.4 in)
Fitting Length 82 mm (3.2 in)
Spring Rate (K1) 353 Nlmm (36 kglmm, 2,020 Iblin)
Stroke (K1) 0.0- 18 mm (0.0-0.71 in)
Optional Spring No.
Swingarm:
Free Play Limit (Swingarm end) 1.0 mm (0.039 in)
Move swingarm end side to side
Front Wheel:
TYpe Panel wheel
Rim Size MT2.50 x 12
Rim Material Steel
Rim Runout Limit
Vertical 2.0 mm (0.08 in)
Lateral 2.0 mm (0.08 in)
MAINTENANCE SPECIFICATIONS pqi$q
I Model
Rear Wheel:
Type Panel wheel
Rim Size MT2.50 x 12
Rim Material Steel
Rim Runout Limit
Vertical 2.0 mm (0.08 in)
Lateral 2.0 mm (0.08 in)
Drive Chain:
Type! Manufacturer 420M/ DAIDO
Number of Links 99 Links +joint
Chain Free Play 25-30 mm (1.0- 1.2 in)
Front Disc Brake:
TYpe Single
Disc Outside Diameter 203 mm (8.00 in)
Disc Thickness 4.0 mm (0.16 in)
Pad Thickness 6.0 mm (0.24 in)
<Wear Limit > < 0.5 mm (0.02 in) >
Master Cylinder lnside Diameter 11.O mm (0.433 in)
Caliper Cylinder lnside Diameter 34.9 mm (1.37 in)
Brake Fluid Type DOT No. 3
Rear Drum Brake:
TYpe Leading, Trailing
Brake Drum lnside Diameter 110 mm (4.33 in)
< Limit > < 111 mm (4.37 in) >
Shoe Spring Free Length 50.5 mm (1.99 in)
Lining Thickness 4 mm (0.16 in)
< Limit > <2 mm (0.08 in)>
Brake Lever and Brake Pedal:
Brake Lever Free Play 2-5 mm (0.08-0.20 in)
Brake Pedal Free Play 20-30 mm (0.8-1.2 in)
Below top of footrest
TIGHTENING TORQUE
Tightening torque
Part to be tightened BoltlNut size
ft-lb
Chassis:
Engine mounting;
Engine stay
Frame and engine
Pivot shaft and nut
Rear shock absorber and frame
Front fork cap bolt (Handlebar)
Under bracket and inner tube
Steering ring nut
Refer to NOTE
Steering stem bolt
Wheel hub and wheel rim
Front brake disc and wheel hub
Brake caliper and outer tube
Front wheel axle and nut
Brake cam lever and camshaft
Rear wheel sprocket and wheel hub
Tension bar and platelframe
Rear wheel axle and nut
Rear view mirror and stay
Brake hose union bolt
Footrest and frame
Cowling stay and frame
Windscreen and cowling
CDI unit and frame
Rectifier1Regulator
Down tube and frame
Engine bracket (Front) and frame
Engine bracket (Rear) and frame
NOTE:
1. First, tighten the ring nut approximately 30 Nm (3.0 m-kg, 22 ft-lb) by using the torque wrench,
then loosen the ring nut one turn.
2. Retighten the ring nut to specification.
MAINTENANCE SPECIFICATIONS 1-
ELECTRICAL
Model
- - - -
Voltage:
Ignition System:
Ignition Timing (B.T. D.C.) 22O at 5,000 r l m i n
Advancer Type Electrical type
0 1 2 3 4
Engine
C.D.I.:
Magneto ModelIManufacturer 2RRlYAMAHA
C. D.I. Unit Model/ Manufacturer 2GXlYAMAHA
Pickup Coil Resistance (Color) 16-240 at 20°C (68OF)
(WhiteIRed- Black)
Source Coil Resistance (Color) 264- 396fl at 20°C (68OF)
(Black/ Red - Black)
Ignition Coil:
ModelIManufacturer 2JNlYAMAHA
Minimum Spark Gap 6 mm (0.24 in)
Primary Coil Resistance 0.7- 1.1Q at 20°C (68OF)
Secondary Coil Resistance 5.7-8.5kQ at 20°C (68OF)
Spark Plug Cap:
TYpe Resin Type
Plug Cap Resistance 4-6kQ at 20°C (68OF)
MAINTENANCE SPECIFICATIONS 1-
Model Y S R50T
-
I Voltage Regulator:
ModelIManufacturer
Rectifier:
ModelIManufacturer
Capacity
Withstand Voltage
Battery:
Specific Gravity
Horn:
TYpe Plane Type
Quantity 1 PC.
Model1Manufacturer GF-12lNIKKO
Maximum Amperage 1.5A
MAINTENANCE SPECIFICATIONS I SPEC I p? I
Model
Flasher Relay:
Type Condenser Type
ModelIManufacturer FZ636SDlNIPPON DENS0
Self Cancelling Device No
Flasher Frequency -
75 95 cycles1min
Wattage +
17W x 2 3W (6V)
Oil Level Switch:
ModelIManufacturer
Curcuit Breaker:
Type Fuse
Curcuit (Fuse):
"MAIN"
GENERAL TORQUE SPECIFICATIONS1
DEFINITION OF UNITS
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for standard fasteners General torque
with standard I.S.O. pitch threads. Torque specifi- A B specifications
cations for special components or assemblies are
included in the applicable sections of this book.
(Nut) (Bolt)
Nm 1 m-kg / ft-lb ,
To avoid warpage, tighten multi-fastener assem-
blies in a crisscross fashion, in progressive stages,
until full torque is reached. Unless otherwise
specified, torque specifications call for clean, dry
threads. Components should be at room tem-
perature.
I
A: Distance across flats
B: Outside thread diameter
DEFINITION OF UNITS
I Piston
Cylinder inner surface
Piston pin
I Kick axle
Primary drivenldrive gear -+a
I
Push rod
Push lever
A=
PinionIWheel gears -4
Collar (Drive axle) -la
I Guide bar (Shift fork)
Shift shaft -la
Shift cam -a
CHASSIS
@ Flasher relay
@ CDI unit
lNTRODUCTlONlPERlODlC MAINTENANCE1
LUBRICATION INTERVALS 1 lNSP
I
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary t o perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information ap-
plies to vehicles already in service as well as new vehicles that are being prepared for sale. All service
technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCEILUBRICATION INTERVALS Unit: km (mi)
I ITEM
1
REMARKS
BREAK-IN
1,000 (600)
7 EVERY
(2,000) or
6,000
(4,000) or
1 6 months 1 12 months
I Spark plug(s)
Check condition. Clean or replace if
necessarv.
I Air filter" Clean. Replace if necessary.
Check idle speedlstarter operation.
Carburetor*
Adjust if necessary.
Check fuel hose for cracks or damage.
Fuel line*
Replace if necessary.
Check oil levelloil leakage.
Correct if necessary.
Replace every 12,000 (8,000) or 24 months
REPLACE 0 0
(Warm engine before draining.
Check operation. Correct if necessary.
Air bleeding.
Check operation/fluid IeakageISee NOTE.
Brake* Correct if necessary (front).
Check operation. Adjust if necessary (rear).
Check operation. Adiust if necessarv.
Check balanceldamagelrunout.
Wheels*
Repair if necessary.
I Wheel bearings*
Check bearings assembly for looseness/
damage. Replace if damaged.
Check bearings assembly for looseness.
Correct if necessary.
Steering bearing*
Moderately repack every 24,000 (16,000)
or 24 months.**
Check operationloil leakage.
Front forks*
Repair if necessary.
Check operationloil leakage.
absorber* Repair if necessary.
Check chain slacklalignment.
Drive chain EVERY 500 (300)
Adjust if necessary. Clean and lube.
Check all chassis fittings and fasteners.
Fittings1Fasteners*
Correct if necessary.
Check operation. Repair if necessary.
I Sidestand switch*
Check operation.
Clean or replace if necessary.
Check specific gravity.
Battery* Check breather pipe for proper operation.
Correct if necessary.
*: It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
**: Medium weight wheel bearing grease. (bearing type) 3-1
INTRODUCTION/PERIODIC MAINTENANCE1
LUBRICATION INTERVALS
NOTE:
Brake system:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add the fluid as required.
2. W e recommend that, on the inner parts of the master cylinder and caliper cylinder, replace the
oil seals every t w o years.
3. W e recommend that, replace the brake hoses every four years, or if cracked or damaged.
"Front seat @
@Sidecover @
@Engineidle speed
ut of specification* Adjust.
@Engineidle speed
1. Check:
@Throttlecable free play @
2. Adjust:
1. Remove:
Lower cowling
e pump cover a
Check:
~Aiignmenimark
5. Measure:
ut of speci3icatioi~-~Adjus-t~
Measure ?he gap with the Thickness gauge
between the raised boss @ on the pump
-
adjusting pulley an the adjusting plate a.
stroke is increase
@Installthe adjustin
locknut.
7. Install:
. Air bleed:
appear.
@ W h e nair bubbles are expelled completely,
tighten the bleed screw.
: - -- 4
maximum.
5. Install:
Q Lower cowlin
PA
'1. Remove:
4. Inspect:
@Electrode
@Insulator a
Abnormal coIor-9
orrnal color is a medium-$0-light tan color.
5. Clean the spark
er or wire brus
. Measure:
7. Tighten:
N TBMINNG CHECK
Adjustment free.
il Tank Capacity:
"OIL" warning indicator light
A
1. Place the motorcycle on a level surface and
warm up the engine for several minutes.
2. Stop the engine and remove the oil filler cap.
false readings.
4. Inspect:
il level should b
A
he engine for several minutes an
stop the engine.
2. Place an oil pan under the engine.
. Fill:
7. Install:
5- 14
ten the locknuts.
~Clutcchpush lever free play
5. Install:
@Flywheelmagneto cover
"Lower cowling
6. Adjust:
@Clutchcable free play
efer to "Free play adjustment" section.
@ Front seat
2. Turn the fuel cock to "
"Fenel tank @
4. Remove:
ir filter cover @
Clean:
@Airfilter element
4 '1. Install:
@Fueltank
Front seat
cSide cover
2. Inspect:
@Carburetorjoint @
"Lower cowl
"Lower cowl
@bowercowling
. Install:
@ l o w e rcowling
1. Check:
rake lever free play @
ut of specification+lnspect the brake
section.
REA ENT
1 . Check:
edal free play @
Out of specification-AcdjuS
Adjustment st8 I
@Turnthe adjuste in or out until the spsci-
fied free play is obtained.
i
BRAKE FLUID !
1. Make sure the r top is horimontaal
by turning the handlebars.
2. 1nspecr:
oBrake fluid level
Fluid lwei is under "L WER" level line
a+~eplenisk.
- - - -
INSPECTIOPJ
1. Activate the brake lever,
2. Inspect:
2. Inspect:
ar indicator @
cator at wear limit line
brake shoes.
1. Inspect:
I . Check:
rive chain slack @
ut of specification-tAdjcest.
slack is obtained
alignment.)
eTighten the nut ( ear wheel axle)
center rollers.
2. To clean the chain, remove 'he
machine, dip it in solvent, an
9. Remove:
bower cowling
r Avoid over-tightening.
--
- - - - , -- , , .,
5. Install:
Lower cowling
TlRE INSPECTION ml INSP I
TlRE INSPECTION
I wheel I Tire I
I Tube type 1 Tube type only I
I Tubeless ( Tube type or tubeless I
Be sure t o install the correct tube when us-
ing tube type tires.
1. Measure:
*Tire pressure
Out of specification-+Adjust.
Basic weight:
With oil and full
fuel tank
I Maximum load* / 68 k g (150 Ib) I
I Cold tire Dressure I Front / Rear I
Zero - Maximum
load*
1 130 kPa 150 kPa
(1.3 kg/cm2, (1.5 kg/cm2,
18 psi1 21 psi)
*Load is the total w e i g h t o f cargo, rider, and
I
accessories.
2. Inspect:
*Tire surfaces
Wear/ Damage-+Replace.
@ Tread depth
a Side wall
@ Wear indicator
WHEEL INSPECTIONICABLE INSPECTION AND lNSP
LUBRICATION
ADJ
WHEEL INSPECTION
1. Inspect:
Wheels
Damage/ Bends* Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
2. Tighten:
*Valve stem locknut
1. Inspect:
*Cable sheath
Damaged Replace.
CABLE INSPECTION AND LUBRICATIONILEVER AND
PEDAL LUBRICATIONISIDESTAND LUBRICATION
2. Check:
@Cableoperation
Unsmooth operation* Lubricate.
Recommended Lubricant:
Yamaha Chain and Cable Lube
or SAE 10W30 Motor Oil
NOTE:
Hold cable end high and apply several drops of
lubricant to cable.
Recommended Lubricant:
Yamaha Chain and Cable Lube
or SAE 10W30 Motor Oil
SIDESTAND LUBRICATION
Lubricate the sidestand at pivot points.
Recommended Lubricant:
Yamaha Chain and Cable Lube
or SAE 10W30 Motor Oil
1. Remove:
@Frontseat
@Sidecover
Refer t o "'SIDE COVER" section
2. Inspect:
Fluid level should be between upper aand
lower @ level marks.
Incorrect-. Refill.
3. Inspect:
@Batteryterminal
Dirty terminal-Clean with wire brush,
Poor connection+Correct.
--:
After cleaning the terminals, apply grease lightly
t o the terminals.
--------
4. Connect:
@Breatherhose
Be sure the hose is properly attached and
routed.
@ Pass the breather hose into the clamp.
5. Inspect:
@Breatherhose
Obstruction-+ Remove.
Damage-+Replace.
6. Check:
@Specificgravity
Less than 11.280-.Recharge battery.
Replace the battery if:
Battery voltage will not rise to a specific value
or bubbles fail to rise even after many hours
of charging.
*Sulfation of one or more cells occurs, as in-
dicated by the plates turning white, or an ac-
cumulation of material exists in the bottom
of the cell.
*Specific gravity readings after a long, slow
charge indicate one cell to be lower than the
rest.
*Warpage or buckling of plates or insulators
is evident.
4. Replace:
@Blownfuse
3-28
'I. Adjust:
@Headlightbeam (Vertical)
2. Adjust
@Headlightbeam (Horizontal)
@Lowercowling
*Flasher lights (Left and right)
sflasher light stay
Refer t o "COWLINGS" section.
2. Remove:
@Headlight@
3
Install:
@Headlight(New)
Install:
@Flasherlight stay
@Flasherlights (Left and right)
@Lowercowling
Adjust:
@Headlightbeam
Refer to "HEADLIGHT BEAM ADJUST-
MENT" section.
@Autolubepump
@Transmissionoil
section.
@Frontseat
section.
'1. Turn the fuel cock to " FF" position and dis-
connect the fuel hose @.
2. Remove:
@Fueltank
VAL
@Autolubepump cover @
@Autolubepump cable
@Oilhose a
Plug the oil hose end with a suitable screw.
eNecatral switch leads
RBVE cwim
Loosen:
adjuster @
2. Push forward t e rear wheel to loosen the
drive chain.
. Place a suitable stand under the engine.
QLower cowlin
0Muffler
2. Remove:
~ G a s k e ?(Cylinder head) @
cylinder @ J
gasket (Cylinder)
~ I n t a k ernanifoid @
--
pin circlip, cover crank-
CLUTCH AND P R I M A R Y
TE: - --
Bower cowl
2 , IYsi-xve:
-
8 Boles (Pressure plate) .
:,
^Springs (Pressure plats)
4. Remove:
@Kickaxle assembly a
NOTE: -..-- - -.
With the engine mounted, the CDB ma
be mainlained by removing the fcallo
Lower covviiiyj
- ---
1. Remove:
2. Measure:
.Cylinder tiead warpage
Out of specification-+Resurface.
Warpage Limit:
0.02 m m (0.001 in)
CYLINDER A N D PISTON
1. Eliminate:
.Carbon deposits
From the piston crown and ring grooves.
2. Eliminate:
.Score marks and lacquer deposits
From the sides of piston.
Use a 600-800 grit wet sandpaper.
NOTE:
Sand in a crisscross pattern. Do not sand exces-
sively.
3. Inspect:
.Piston wall
INSPECTION AND REPAIR
4. Remove:
1-
.Carbon deposits
Use a rounded scraper.
5. Measure:
*Piston-to-cylinder clearance
"C"
TaperJ1T" 1 - / 0.05 mm
10.0019 in)
)ut of Round
"R" 1 - 1 0.01 mm
10.0004 in1
C = Maximum D
T = (Maximum Dl, or D2)-
(Maximum Ds or D6)
R = (Maximum Dl, D3 or D5)-
(Minimum Dz D4 or D6)
fz "
Standard
Piston size P
39.96-39.98 mm
-
(1.573 1.574 in)
Oversize 1 40.25 mm (1.58 in)
Oversize 2 40.50 mm (1.59 in)
*If out of specification, replace piston and
piston rings as a set.
Third Step:
*Calculate the piston-to-cylinder clearance with
following formula:
- - -
Piston-to-cylinder Clearance =
Cylinder Bore "C" -
Piston Skirt Diameter "P"
Piston-to-cylinder Clearance:
-
(0.0012 0.0014 in)
Limit: 0.1 m m (0.004 in)
PISTON RINGS
1. Measure:
*Side clearance
Out of specification+Replace piston and/or
rings.
Use a Feeler Gauge @.
0.03-0.05 mm
Clearance 0.03-0.05 mm
-
(0.001 0.002 in)
INSPECTION AND REPAIR I ENG 1 a-1
2. Install:
*Piston ring
lnto the cylinder.
Push the ring with the piston crown.
3. Measure:
*End gap
Out of specification-+Replace rings as a set.
1 :l 1 I
Use a Feeler Gauge.
1
4 End Gap
0.15-0.35 mm
(0.006-0.014 in1
0.15-0.35 mrn
(0.006-0.014 in)
3. Check:
*Free play
There should be no noticeable free play.
Free play exists+lnspect the connecting rod
for wear1Replace the pin and/or connect-
ing rod as required.
4. Install:
@Pistonpin
lnto the piston pin hole.
INSPECTION AND REPAIR ( ENG 1 \ j l
5. Check:
.Free play (when the piston pin is in place in
the piston)
There should be no noticeable free play.
Free play exists-+ Replace piston pin and/or
piston.
6. Inspect:
.Piston pin and bearing
Signs of heat discoloration-+Replace.
CLUTCH
1. Inspect:
.Friction plate
Damage/Wear-+Replace friction plate as a
set.
2. Measure:
.Friction plate thickness
Out of specification-+Replace friction plate
as a set.
Measure at all four points.
3. Inspect:
.Clutch plate
Damage+Replace clutch plate as a set.
4. Measure:
.Clutch plate warpage
Out of specification+Replace clutch plate
as a set.
Use a surface plate and Feeler Gauge a.
Warp Limit: 0.05 mm (0.002 in)
5. Inspect:
.Clutch damper
Wear/ Damage-+Replace.
INSPECTION AND REPAIR [ ENG 1
6. Measure:
*Clutch spring free length @
Out of specification+Replace spring as a
set.
7. Inspect:
*Dogs on the clutch housing
Cracks/Wear/Damage+Deburr or replace.
*Clutch housing bearing
ScoringlWear/Damage+Replace clutch
housing.
NOTE:
Scoring on the clutch housing dogs will cause
erratic operation.
8. Inspect:
*Clutch boss splines
Scoring1Wear/ Damage+Replace clutch
boss.
NOTE:
Scoring on the clutch boss splines will cause er-
ratic operation.
9. Check:
*Circumferential play
Free play exists+Replace.
10. Measure:
@Pushrod runout
Ou i: of specification+ Replace.
primary drive gear teeth
~ P r i r n s r ydriven gear teeth
KICK STARTER
1. Inspect:
Measure:
ick clip Pension
u l of specification+
Use a spring balance a.
SHBFT SHAFT
4 . Inspect:
rk cam foliower
2. Inspect:
fork movement
Unsrnooth speratiois+Repface shiftfork
andlor guide bar.
. Measure:
se centering device
UT of specification-+
INSPECTION AND REPAIR
6. Inspect:
1-
.Gear teeth
Blue discoloration/ Pitting/ Wear+ Replace.
.Mated dogs
Rounded edges/Cracks/Missing portions-+
Replace.
7. Check:
.Proper gear engagement (Each gear)
( t o its counterpart)
Incorrect+ Reassemble.
.Gear movement
Roughness+ Replace.
8. Inspect:
.Circlips
Damage/ Looseness/ Bends+Replace.
CRANKSHAFT
1. Measure:
.Runout
Use a centering device and Dial Gauge.
Out o f specification-+ Replace or repair.
Runout Limit:
0.03 mm (0.0012 in)
2. Measure:
.Small end free play a
Use a Dial Gauge.
Out of specification-+Replace the defective
parts.
1
Small End Free Play:
0.8- 1.0 mm (0.032-0.039 in)
I1
<Limit > :
< 1.5 mm (0.060 in) >
3. Measure:
.Big end side clearance @
Use a Feeler Gauge.
Out of specification-+ Replace the defective
parts.
I
- -
NOTE:
Lubricate the bearings immediately after examin-
ing them to prevent rust.
5. Inspect:
-Oil seals
Wear/ Damage* Replace.
CRANKCASE
1. Thoroughly wash the case halves in mild
solvent.
2. Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3. Inspect:
-Crankcase
Cracks/Damage+Replace.
-Oil delivery passages
Clog+Blow out with compressed air.
AUTOLUBE PUMP
Wear or an internal malfunction may cause pump
output to vary from the factory setting. This sit-
uation is, however, extremely rare. If improper
output is suspected, inspect the following:
1. Inspect:
-Delivery line
Obstructions+Blow out.
-Pump body seallcrankcase cover seal
Wear/ Damage+Replace.
-Check ball/Spring
Miss/ lmproper+Repair.
2. Inspect:
-Allowing air
Air exists+Air bleed.
edt of specification -,A
4. Inspect:
rankshaft Installing Tool @
@Adapter a
Installing Tool:
2 Install:
3. Install:
heck:
@ $ l i f t e r operation
@Transmissionoperation
eration- Repair.
90 the mating surfaces of both crank-
~i.ase
halves.
4. Tighten:
NOTE: . - . ,
hole.
7 . Check:
. Install:
@ Bearing
@Neutralswitch lead
2. Install:
3. Tighten:
KlCK AXLE
I . Install:
@Kickaxle assembly
: 1
3, Install:
@Kickidle gear a
@Washers@
@ Circlip @ Kick crank
@ Shift lever @ Return spring
@ Rotor 0 Collar
@ Return spring @ Kick axle
@ Pin Kick idle gear
0 Oil seal
IMAWY DRIVE GEAR
I . Install:
~Gonicalspring washer
NOTE: ------- - - ,
2. Tighten:
o N u k (Primary drive gear)
NOTE: - -
etween the teeth of the
3. Install:
@Thrustwasher a
@Clutchboss Q
4. Tighten:
nut (Clutch boss) a
niversal Clutch older @ to hold
clutch boss.
5. Install:
lutch damper Q
. Install:
@Gasket(Crankcase cover-New) @
the crankcase.
7. Install:
Vkl A
a Cylinder head
@ Gasket (Cylinder head)
@ Spark plug
@ Cylinder
@ Gasket (Cylinder)
Note the following points.
1. Install:
Q Engine assembly
ENT" section.
9. Adjust:
@Throttlecable free play @
Spring (Throttle valve)
Jet needle assembly @ Main jet
Throttle valve @ Valve seat assembly
@ Throttle stop screw 0 Float
@ Pilot screw @ Pin (Float)
@ Starter plunger @ Float chamber
a Pilot jet @ Drain screw
Float height
REb?QOAk
MOTE : - -- , .
"Pilot screw
0 Lower cowling
Refer so "'CHA
sectioja.
2 , Turn the fuel cock to "OFF" piaskion and dis-
connect the fuel hose a.
3, Loosen:
Screws (Carburetor joint)
4" Eernove:
srburetor assembly a
DiSASSEMBL?!
4 . Remove:
~ T h r o t t i evalve assembly
oSpring (Throttle valve) @
2. Remove:
tarter plunger g]
throttle stop screw @
pilot screw
I . Inspect:
@Carburetorbody
@Fuelpassage
Contamination-~Cleanas indicated.
based solvent.
(Do not use any caustic carburetor cleaning
solution).
low out all passages and jets with com-
pressed air.
P -.
2. Inspect
@Float
amage+ Replace.
Inspect:
o Needle va!ve
@Valveseat @
@Gasket@
amage/Wear/Contamination+ Replace.
-: -
Always replace the needle valve and valve seat
as a set.
- -
4. Inspect:
@Throttlevalve
5. Check:
Free movement
Inspect:
@Clipposition
7 . Inspect:
@Starterplunger @
@Throttlestop screw @
1. Measure:
ut of specification+Adjust.
5-5
__-p_-____n_l__- -
Float height measurement an
the carburetor in an up
sition.
measure the distance between the w
-__-_ -
---_Y__YV___L_ _ -&-- ---iT_ --
BfqSTALLATIOM
Reverse the removal procedures.
ole the foilowin
1. ins tali^
~ThrottEevalve assern
MOTE: - - - .-
ADJUSTLdEMT
Fuel Levee A d j u s t m e n t
OTE: -- ->- " - - - - - - -
Adjust:
a Fuel level
Adjustment steps:
e m w e the carbbirelor.
@Inspectthe valve seat and needle vaive.
0 1 % either is worn, i. place them both.
@Ifboth are fine, a jusd the float height by
ending the float tang a
on the float.
echeck the fuel level.
I . Measure:
@Valvestopper hei
u t o f specification-~Replace.
2. Measure:
eed valve bending @
efer t o "CHA
"Collar
ofront wheel axle
n y corrosion f r o m parts
2. Inspect:
@Frontaxle
oll the axle o n a flat surface.
. Inspect:
4. Measure:
@Wheelrunout
heck the wheel and
e esnservatiwely
tor injury.
@Aftera tire repair or re
hten the valve stem locknut @
t o specification.
val procedure. Roae the follow-
2. Install:
Install:
@ Joint
Brake cam shaft @ Rear wheel axle
lacing a suitable
a Wear wheel
I Ti 8
1 . Inspect:
@Wearwheel axle
EEL-INSPECTI
section.
2. Inspect:
-6
section.
-_Je"
a
I
11
3. Measure:
section.
section.
7. Measure:
__=----
-----
Inspect:
rum inner surface
9. Measure:
Brake drum inside diameter
ut of specification-Replacs
BNSTALLATUO
everse the removal procedure. Note the follow-
ing points.
-
--.
-
2. Install:
rake cam lever @
- , -
. Apply:
ium soap base
nto the brake cam lever aand pivot shaft
0.
ipe off the s x c s
e n installing t h e spying and brake shoe,
take care rest to damage t h e spring and not
to apply grease to the brake sb:oes.
-----_ -__ rr_Z___----------- _--_Xg____
5.Apply:
Lithiurn b a s e grease
rease to uhe oil seal lips.
. Adjust:
rive chain slack
Refer to "CHAPTER 3--DRIVE CHAIN A
JUST:\hRfi T'" section.
. Install:
@Colterpin
I@. Adjust:
rear brake pedal pree piay
--REAR BRAKE A
TM ENT" section.
@ Brake hose
@ Union bolt
0 Copper washer
@ Brake pads aster cylinder kit
@ Bust seal
@ Piston seal
@ Brake disc
1 is not necessa to disassemble the brake caliper
8
and brake hose t o replace the brake pads.
. -----
a suitable hose
eed screw. Then,
this hose into an open container.
4. Loosen the cali
istons into the calipe
NOTE: -
- -
7, Install:
@Calipercoves
lever operation
A softy or spongy fillin
-- P
section.
emre disassemblying the front master cylinders,
drain the brake syste of the brake flui
-
@Mastercylinder boot @
eCirclip
@Mastercylinder kit @
P
2. Measure:
rake pad thickness
u t of specification
et if either is found t o be
---
4. Inspect:
@Mastercylinder body @
@Mastercylinder kit
eat of specification-+
NOTE: ----- . -- -
ly the lithium soap
piston seal, caliper
3. Install:
@Padsprings @
E
section.
4. Install:
5. Install:
Air
From brake system.
" section
'8%. Install:
-. -
. Remove:
ofron-l: fender
4- Loosen:
inch bolt (bower) a
@Frontfork @
seat a (Left si
ring @ (Left si
1. Inspect:
@Innerfork rube a
- - -=- - - - -=
~s- - - - - -?
m
pT- -=
2. Inspect:
oDusl seal
Reverse t h e disassern
Note the following poin'.s.
NOTE: --..-..-----. - . - - - 7 . A - - -.2-n
i-:
@Clip@
To inner tube.
. Install:
~ l n n e tube
r @
To outer tube.
4 Press the oil seal into the inner tube with Fork
5. Install:
oPlain washer
a6irclip a
. Fill:
Front fork
Rig ha:
164 cm3 E5.77 lamp qt,
5.54US st)
Grade:
Yamaha Fork OBI "MWT oa
7 . Measure:
2. Install:
0TE: . , , -
Apply the lithium soap base rease onto the
-ring.
-- - -
A
a Bearing race (Lower- Bottom)
all (114 i n 4 9 pcs.)
@
@
Handle crown
Steering stembolt
earing race (Lower-Bop)
earing race (Upper- @ Handlebar (Left)
all (3116 in-22 pcs.) Q Cap
earing race (Upper-Top) @ Throttle housing
earing race cover @ Throttle grip
ing nut
otorcyele ss there is
"Lower cowling
QUpper cowling
ofront wheel
section.
@Frontforks
section.
'j F'emove:
~ S l e e r i ~stern
g bolt
washer 2
handle crown
. .-
all bearings and bearing races with
a solvent.
Inspect:
bower balls @
To bearing race (bower-Bottom).
rrange the bearings around race, and ap-
3. Install:
- - ----- ~---
~Loosenthe rin
Avoid over-tightening.
handle crown
NOTE: , -- a
6. Install:
front forks
section.
7. Tighten:
. Install:
. Install:
@Frontbrake master cylin
-:
~ I n s t a lthe
l master cylinder bracket w i t h the '"
11. Install:
section.
ear shock absorber
@ Cotter pin
@ Swingarm
@ Push
@ Spacer
Chain support
Chain cover
SecuueEy support the motorcycle so there is
sr of it falling over.
, , , , &
section.
3. Remove:
* ~@
Q C O ~pin
oPBain washer
QPin (Rear shock absorber- Lower) a
section.
Remove:
DISASSEMBLY
oChain guide
tension bar
A
1. Install:
2. Install:
ear shock absorber- Lower)
@Cotterpin
3. Install:
section.
1. Install:
ear shock absorber
2. Install
3. install:
NOTE: .- -- ., --
During reassern ly, the master link clip must be
installed with the rounded en facing the direc-
tion sf travel.
-
a Turning direction
4. Lubricate:
o5rive chain
Chain Lube:
Yemaha Chain Lube or
la-=
-
YSRSOT CIRCUIT DIAGRAM
@ Spark plug @ Flasher relay
a Ignition coil
@) CDI magneto
0 "TURN"
@
switch
"TURN" indicator light
@ CDI unit @ Flasher light (Left)
@ RectifierIRegulator @ Flasher light (Right)
@ "ENGINE STOP" switch @ Horn
a Main switch
@ Fuse
@
@
"HORN" switch
"OIL" warning indicator light
@ Battery @ Oil level switch
@! "LIGHTS" (Dimmer) switch @ "NEUTRAL" indicator light
@ "HIGH BEAM" indicator light @ Neutral switch
@ Headlight a Front brake switch
@ Rear brake switch
@ Meter light
@ Sidestand switch @ TailIBrake light
@ lgnition control unit
COLOR CODE
B Black P Pink
R Red Sb Sky blue
Br Brown BIR Black1Red
0 Orange BIW BlackIWhite
W White WIR WhiteIRed
L Blue BrIW BrownIWhite
G Green GIY GreenIYellow
Y Yellow YIR YellowIRed
D!3 Dark green
- LIY BlueIYellow
Ch Chocolate -
ELECTRICAL COMPONENTS I ELEC 1 El 1
ELECTRICAL COMPONENTS BATTERY:
@ Wireharness @ Sidestand switch I CAPACITY 6V 4AH
@ Main switch @ Neutral switch
@ Ignition control unit @ lgnition coil
1 SPECIFIC GRAVITY 1.280
@ Oil level switch @ CDl unit I IGNITION COIL:
@ Rectifier/Regulator @ Flasher relay PRIMARY COlL
@ Horn @ Battery 0.7- 1.1Q at 20°C (68OF)
@ Rear brake switch @ Fuse
SECONDARY COlL
IGNITION AND STARTING SYSTEM I ELEC 1 IS I
For the color codes, see page 7-2.
Spark plug
Ignition coil
CDI magneto
CDI unit
"ENGINE STOP" switch
Main switch
Sidestand switch
Ignition control unit
Neutral switch
IGNITION AND STARTING SYSTEM
-
I ELEC 1 'B1
IGNITION CONTROL CIRCUIT OPERATION
The ignition control circuit on this model consists
of the ignition control unit, neutral switch, neu-
I I Transmission I Sidestand Isparkt
(Neutral switch) (Sidestand switch) plug
tral indicator light, and the sidestand switch. If
Neutral
the engine stop switch and the main switch are (close)
both on, the ignition spark can produce only if:
Neutral Down
1. The transmission is in neutral (the neutral
(open)
switch is on).
I N gear
2. The sidestand is up (the sidestand switch is (close) Spark
on).
I N gear
(open) (open) spark
7-6
IGNITION AND STARTING SYSTEM I ELEC 1 El I
I I I
TROUBLESHOOTING
Procedure (1)
Check;
1. Spark plug Ignition coil resistance
2. lgnition spark gap Pick-up coil resistance
3. Ignition circuit Source coil resistance
4. Main switch Wiring connection
5. Spark plug cap resistance (Entire ignition system)
6. "ENGINE STOP" switch
NOTE:
*Remove the following parts before troubleshooting.
1) Lower cowling
2) Upper cowling
3) Seat
4) Side cover
5) Fuel tank
*Use the following special tool(s) in this troubleshooting.
Pocket Tester:
Y U-03112
1. Spark plug
*Check the spark plug condition.
*Check the spark plug type.
*Check the spark plug gap.
Refer to the "SPARK PLUG INSPECTION"
section in the CHAPTER 3.
U CORRECT
IGNITION AND STARTING SYSTEM I ELEC 1 a
V
MEETS SPECIFICATION
OUT OF SPECIFICATION
OR NO SPARK
I
3. Ignition circuit I
*Disconnect the ignition control unit lead
(Brown).
*Start the engine.
- P
Starting circuit is faulty, go to "Procedure (2)".
NOT START
IGNITION AND STARTING SYSTEM I ELEC I I
4. Main switch
*Disconnect the main switch coupler (Red,
Brown and Black) and lead (BlackIWhite)
from the wireharness.
Connect the Pocket Tester (flx 1) to the main
switch.
+
Tester ( 1 Lead-+Black/White @ Lead
Tester ( - 1 Lead-+Black @ Lead.
BAD CONDITION
*Turn the main switch to "ON" and "OFF".
*Check the main switch for continuity.
-
Switch
position
OFF
1 condition
Oood
0
1 x
Bad condition
x 0
Main switch is faulty, replace it.
ON x 0 x 0
0:Continuity x: Nocontinuity
- --
1I
5. Spark plug cap resistance
GOOD CONDITION
Spark Plug Cap Resistance: Spark plug cap is faulty, replace it.
4-6kQ at 20°C 168OF)
1 1
MEETS
SPECIFICATION
+
Tester ( 1 Lead+Black/Whie @ Lead
Tester ( - 1 Lead+Black @) Lead
Bad condition
condition
J
OUT OF SPECIFICATION
.Check the secondary coil for specificated
resistance.
I1 MEETS SPECIFICATION
OUT OF SPECIFICATION
*Check the source coil for specificated
resistance.
(BlackIRed- Black)
it MEETS SPECIFICATION
.3c 7-12
IGNITION AND STARTING SYSTEM I ELEC 1 I9 I
10. Wiring connection
- POOR CONNECTION
Check the entire ignition system for connec-
tions. Refer to the "WIRING DIAGRAM" b I
section.
I Correct.
CORRECT
Procedure (2)
Check;
1. Sidestand switch
2. Neutral switch
3. Wiring connection
(Entire starting system)
I 1. Sidestand switch
*Disconnect the sidestand switch coupler
(Blue/Yellow and Black) from the wire-
harness.
*Connect the Pocket Tester ( Q x 1) to the side-
stand switch.
II GOOD CONDITION
2. Neutral switch
.Disconnect the CDI magneto coupler (Sky
blue, White, Black and Yellow/Red) from the
wireharness.
Connect the Pocket Tester (52 x 1) to the neu-
tral switch leads.
U GOOD CONDITION
IGNITION AND STARTING SYSTEM
-x
POOR CONNECTION
3. Wiring connection
Check the entire starting system for connec-
tions. Refer to the "WIRING DIAGRAM"
section. Correct.
II
U CORRECT
- -- ---
@ CDl magneto
@ RectifierIRegulator
@ Fuse
@ Battery
CHARGING SYSTEM I ELEC I I
TROUBLESHOOTING
Procedure
Check;
1. Fuse 4. Charging coil resistance
2. Battery 5. Wiring connection
3. Charging voltage (Charging system)
NOTE:
Remove the following parts before troubleshooting.
1) Side cover
.Use the following special tool(s) in this troubleshooting.
1. Fuse NOCONTINUITY
CONTINUTY
INCORRECT
2. Battery
-
.Check the battery condition. Refer to "CHAP-
TER 3. BATTERY INSPECTION".
CORRECT
3. Charging voltage
@Connectthe Engine Tachometer to the s
plug lead.
battery.
attery ( + ) Ter
attery B - 1 Ter
-.
@Check the charging coil for speci%icated
resistance.
CDI magneto
tifierl Regulator
n switch
Fuse
Headlight
TailIBrake light
ove the following arrs before trou
Switch
position
HI
I condition
Oood
0
I x
Bad condition
GOOD CONDITION
MEETS SPECIFICATION
Do not run the engine in neutral above d
a Standard Output:
62-7.2" at 3,000 rlmin or more
OUT OF
Lighting system is good.
SPECIFICATION
MEETS SPECIFICATION
Lighting coil is faulty, replace it. I
5. Wiring connection
Check the entire lighting system for connec- POOR CONNECTION
tions. Refer to the "WIRING DIAGRAM"
section.
( I CORRECT I Correct. I
I Rectifier/Regulator is faulty, replace it.
TROUBLESHOOTING (2)
Procedure
1. Fuse
2. Battery
3. TailJBrake light bulb
4. Main switch
5. Wiring connection
NOTE:
*Remove the following parts before troubleshooting.
1) Seat
2) Side cover
*Use the following special tool(s) in this troubleshooting.
1. Fuse
NOCONTINUITY
, *Remove the fuse.
Connect the Pocket Tester (Q x 1) to the fuse.
*Check the fuse for continuity.
Fuse if faulty, replace it.
CONTINUITY
LIGHTING SYSTEM I ELEC 1 IS 1
2. Battery
*Check the battery condition. Refer to the INCORRECT
"BATTERY INSPECTION" section in the
CHAPTER 3.
Specific Gravity:
*Refill battery fluid.
1.280 a t 20°C W 0 F )
*Clean battery terminals.
*Recharge or replace battery.
U
3. TailIBrake light bulb
CORRECT
Tester ( + Lead-Terminal @
Tester ( - ) Lead-Terminal @
Tester ( + 1 ~ e a d - ~ e r m i n a@
l
Tester ( - ) Lead-Terminal @
I
-
C h e c k the taillbrake light bulb for continuity.
TailIBrake light bulb is faulty, replace it.
I I
CONTINUITY EXISTS
ON BOTH CIRCUITS.
4. Main switch
*Disconnect the main switch coupler (Red,
Brown and Black) from the wireharness.
*Connect the Pocket Tester (fl x 1) to the main
switch leads.
LIGHTING SYSTEM I ELEC 1 I
Tester ( + ) Lead-Red @ Lead
Tester ( - Lead+Brown @ Lead
position
Switch I condition
=Ood I Bad condition
I
Check the entire lighting system for connec-
INCORRECT
tions. Refer to the "WIRING DIAGRAM"
section.
I I CORRECT I
Correct.
a Main switch
@ Fuse
@ Flasher light (Right)
@C Horn
@ Battery @ "HORN" switch
@ Flasher relay Front brake switch
0 "TURN" switch @ Rear brake switch
@ Flasher light (Left) @ TailIBrake light
SIGNAL SYSTEM 1-
TROUBLESHOOTING
Procedure
Check;
1) Fuse
2) Battery
3) Main switch
4) Wiring connection
NOTE:
*Remove the following parts before troubleshooting.
1) Seat
2) Side cover
*Use the following special tool(s) in this troubleshooting.
Pocket Tester:
Y U-03112
1. Fuse I
*Remove the fuse. NOCONTINUITY
*Connect the Pocket Tester (Q x 1) to the fuse.
*Check the fuse for continuity.
2. Battery
*Check the battery condition. Refer to the
"BATTERY INSPECTION" section in the
CHAPTER 3. INCORRECT
--
Specific Gravity:
1.280 a t 20°C (68OF)
*Refill battery fluid.
*Clean battery terminals.
CORRECT Recharge or replace battery
-
3. Main switch
.Disconnect the main switch coupler (Red,
Brown and Black) from the wireharness. I
Connect the Pocket Tester (Q x 1) to the main
switch leads.
SIGNAL SYSTEM ( ELEC 1
Tester ( + 1 L e a d j R e d @ Lead
Tester ( - ) Lead+ Brown @ Lead
position
Switch I condition
Good I Bad condition
GOOD CONDITION
INCORRECT
4. Wiring connection I
Check the entire signal system for connections.
Refer to the "WIRING DIAGRAM" section.
I I
Correct.
CORRECT
+
Tester ( 1 Lead+Pink @ Lead
Tester ( - ) Lead* Black @ Lead
- -
: Nocontinuity
"HORN" switch is faulty, replace handlebar
switch.
I( GOOD
CONDITION
2. Voltage check
.Connect the Pocket Tester (DC20V) to the
1 horn at the brown terminal.
I
r Tester ( + 1 Lead+Brown @ Lead
Tester ( - ) Lead* Frame Ground
SIGNAL SYSTEM I ELEC 1 s 1
-
3(Dz -@
* OUT OF SPECIFICATION
3. Horn check
disconnect the "Pink" lead at the horn
terminal.
connect a jumper lead @ to the horn termi-
nal and ground the jumper lead.
HORN IS SOUNDED
V Horn is good.
HORN IS NOT
SOUNDED
4. Voltage check
+
Tester ( ) Lead+Pink @ Lead
Tester ( - 1 Lead+Frame Ground
SIGNAL SYSTEM I ELEC 1 I
.Check for voltage (6V) on the "Pink" lead at OUT OF SPECIFICATION
the horn terminal.
MEETS SPECIFICATION
(6V)
Horn is faulty, replace it.
Adjust or replace horn.
2. Brake light does not come on when applying rear or front brake.
Tester ( + ) Lead-tTerminal @
Tester ( - ) Lead-tTerminal @
+
Tester ( ) LeadjTerminal @
Tester ( - LeadjTerminal @
CONTINUITY EXISTS
BOTH CIRCUITS
Front brake
is applied.
Front brake
is not applied 1 Front brake switch is faulty, replace it.
0: Continuity x : Nocontinuity
GOOD
CONDITION
3. Voltage check
@Connectthe Pocket Tester (DC20V) to the
front brake switch.
- - - -
OUT OF SPECIFICATION
3C
SIGNAL SYSTEM I ELEC 1 Is 1
4. Rear brake switch check
Switch
position
1 c ~ ~ I ~Bad~condition
o n
BAD CONDITION
Rear brake
is applied.
Rear brake
X O X 0 Rear brake switch is faulty, replace it.
is not applied
0:Continuity x : Nocontinuity
5. Voltage check
*Connect the Pocket Tester (DC2OV) to the
rear brake switch.
+
Tester ( ) Lead-Brown @ Lead
Tester ( - ) Lead+ Frame Ground
SIGNAL SYSTEM I ELK 1 a 1
*Check for voltage (6V) on the "Brown" lead OUT OF SPECIFICATION
at the brake switch connecter.
MEETS
Wiring circuit from main switch to brake switch
SPECIFICATION (6V)
connector is faulty, repair.
1. Bulb check
+
Tester ( ) LeadjTerminal @
Tester ( - ) Lead-+Terminal @
7-39
SIGNAL SYSTEM I ELEC I I
NOCONTINUITY
4 ICONTINUITY
I I
0: Continuity
-- - -
x: Nocontinuity
U GOOD
I "TURN" switch is faulty, replace handlebar
switch.
* CONDITION
SIGNAL SYSTEM I ELEC 1 1
4. Voltage check
0
f /DCZOV(
OUT OF SPECIFICATION
u -
-
II
Wiring circuit from main switch t o flasher re-
lay connector is faulty, repair.
I
SPECIFICATION (6V)
METER LIGHT AND/OR "HIGH BEAM" INDICATOR LIGHT DO NOT COME ON.
Procedure
Check;
1) Meter light and "HIGH BEAM" indicator light
2) "LIGHTS" (Dimmer) switch
3) Lighting circuit output
4) Lighting coil resistance
5)Wiring connection
NOTE:
.Remove the following parts before troubleshooting.
1) Seat
2) Side cover
*Use the following special tool(s) in this troubleshooting.
+
Tester ( ) Lead-tTerminal @
Tester ( - 1 Lead-tTerminal @
CONTINUITY
*
DISPLAY SYSTEM I ELEC 1
2. "LIGHTS" (Dimmer) switch
Switch
~osition
I condition
I Bad condition
I 1 I I
"LIGHTS" (Dimmer) switch is faulty, replace
0:Continuity x : Nocontinuity handlebar switch.
GOOD CONDITION
I
n
a Lighting Coil Resistance:
0.16-0.24, at 20°C (68OF)
(YellowIRed- Black)
I
OUT OF SPECIFICATION
I
Lighting coil is faulty, replace it.
MEETS
SPECIFICATION
1 5. Wiring connection
Correct.
CORRECT
Procedure
Check;
1) Fuse
2) Battery
3) Main switch
4) Wiring connection
NOTE:
.Remove the following parts before troubleshooting.
1) Seat
2) Side cover
*Use the following special tool(s) in this troubleshooting.
I 1. Fuse I NOCONTINUITY
CONTINUITY
1 2. Battery I
.Check the battery condition.
Refer to the "BATTERY INSPECTION" sec- INCORRECT
tion in the CHAPTER 3.
- -- -
Specific Gravity:
1.280 at 20°C (68OF) .Refill battery fluid.
.Clean battery terminals.
1 3. Main switch
x 0
OFF x 0 x 0 F s s w i t c h i s a u ~
replace
t y , it.
0:Continuity x : Nocontinuity
(I GOOD CONDITION
4. Wiring connection
INCORRECT
Check the entire display system for connec-
tions. Refer to the "WIRING DIAGRAM"
section.
I Correct.
I
CORRECT
1. Bulb check
+
Tester ( ) Lead-+Terminal @
Tester ( - 1 Lead-+Terminal @
GOOD CONDITION
3. Voltage check
-
.Connect the Pocket Tester (DC20V) to the
"NEUTRAL" indicator light lead.
-
Tester ( + 1 LeadhBrown @ Lead
Tester ( - ) Lead-+Frame Ground
-
Q 1 EVT2 S b Y
D Ch
B
L
B Y Sb
L Ch Dg
OUT OF SPECIFICATION
I
-
3 Wireharness
.Check for voltage (6V) on the "Brown" lead Wiring circuit from main switch to "NEUTRAL"
at the connector. indicator light connector is faulty, repair.
-
MEETS
II SPECIFICATION (6V)
I1
II
INDICATOR LIGHT
COMES ON.
CONTINUITY
3C
DISPLAY SYSTEM 1 ELEC
fiV
+
Tester ( ) L e a d 4 Brown @ Lead
@@y,RLE&Tl
Tester ( - 1 Lead+Frame Ground
S b Y B B Y Sb
D Ch L L Ch Dg
@ Wireharness
DISPLAY SYSTEM I ELEC 1 a 1
I *Check for voltage (6V) on the "Brownr' lead I OUT OF SPECIFICATION
at connector.
MEETS i
@PECIFICATION (6V) Wiring circuit from main switch to "OIL" warn-
ing indicator light connecter is faulty, repair.
Wiring connection is faulty, correct.
1. Bulb Check
*Remove the bulb.
*Connect the Pocket Tester (Q x 1k) to the
bulb.
Tester ( + 1 Lead-Terminal @
Tester ( - 1 Lead-tTerminal @
II GOOD
db CONDITION
3. Voltage check
+
Tester ( ) Lead+Brown @ Lead
Tester ( - ) Lead-Frame Ground
OUT OF SPECIFICATION
u -
.Check for voltage (6V) on the "Brown" lead Wiring circuit from main switch to flasher re-
at the flasher relay terminal. lay connector is faulty, repair.
MEET
SPECIFICATION (6V)
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide t o troubleshooting. Refer to the relative procedure in this manual for inspection,
adjustment and replacement of parts.
rt
FUEL S'rE T E M PROBABLE CAUSE
Empty
.Clogged fuel filter
Clogged air passage (Fuel tank cap)
.Deteriorated fuel or fuel containing water or
foreign material
lanky
Fuel cock .Clogged fuel hose
COMPRESSION SYSTEM
IDLE SPEED PERFORMANCE
PROBABLE CAUSE
rTRBL 3
l
Cylinder and cylinder head .Loose spark plug
.Loose cylinder head or cylinder
.Broken cylinder head gasket
*Broken cylinder gasket
.Worn, damaged or seized cylinder
Reed valve
.Improperly seated crankcase
.Improperly sealed crankcase (Damaged oil seal)
.Seized crankshaft
I"'t
.Clogged fuel filter
Deteriorated fuel or fuel containing water
or foreign material
Clogged air passage (Fuel tank cap)
' kna t
Fuel cock .Clogged fuel hose
Transmission
.Groove jammed with impurities
.Seized shift fork
.Bent shift fork guide bar
t Shift cam
Transmission
L
*Improper thrust play
*Worn shift cam groove
CLUTCH SLIPPINGIDRAGGING
CLUTCH SLIPPING PROBABLE CAUSE
.Improperly adjusted clutch cable
Noose clutch spring
Watigued clutch spring
.Worn friction plate
.Worn clutch plate
t
Kick axle assembly .High tension of kick clip
*Seized kick gear
.Seized kick idle gear
t Transmission oil
T
.Damaged or seized piston
.Damaged or seized piston ring
7 @Improperlyseated crankshaft
.Damaged or seized crankshaft
.Damaged or seized crankshaft bearing
FAULTY BRAKE
POOR BRAKING EFFECT PROBABLE CAUSE
.Worn brake pad
.Worn brake disc
.Air in brake fluid
.Leaking brake fluid
.Faulty cylinder kit cup
*Faulty caliper kit seal
.Loosen union bolt
.Broken brake hose
*Oily or greasy brake disc
.Oily or greasy brake pad
.Improper brake fluid level
1
INSTABLE HANDLING
Handlebars
PROBABLE CAUSE
4mproperly installed or bent
Irt
Front forks .Uneven oil levels on both sides
.Uneven spring tension
(Uneven damping adjuster position)
.Broken spring
.Twisted front forks
.Twisted
.Damaged head pipe
.Improperly installed bearing race
Drive chain
-Fatigued spring
-Improperly adjusted spring preload
.Oil leakage
mDamaged or broken
.Incorrectly installed
FAULTY SIGNAL A N D LIGHTING SYSTEM 1- SHTG
FAULTY SIGNAL AND LIGHTING SYSTEM
HEADLIGHT DARK PROBABLE CAUSE
*Improper bulb
*Too many electric accessories
*Hard charging (Broken charging coil and/or
faulty rectifierlregulator)
.Incorrect connection
*Improperly grounded
,
FLASHER WINKS QUICKER PROBABLE CAUSE
.Improper bulb
.Faulty flasher relay
7 Faulty battery
.Faulty main and/or horn switch
.Improperly adjusted horn
.Faulty horn
.Broken wireharnes
3
OVERHEATING
TRBL
IsmGI I
OVERHEATING
OVERHEATING PROBABLE CAUSE
t
Ignition system
Fuel system
.Improper spdrk plug gap
.Improper spark plug heat range
.Faulty C.D.I. unit
t
t
Transmission oil
Brake
.Incorrect oil level
Improper oil viscosity
.Inferior oil quality
Dragging brake