NOTICE anual was written by the Yamaha Motor Company primaril jalitied mechanics. It is not possible to put an entire mechanic’s education Into one manu: 9d that persons using this book to perform maintenance and repairs on Yamaha motorcycles have ic understanding of the mechanical concepts and procedures inherent in motorcycle repalr “technology. Without such knowledge, attempted repairs or service to this model may render it unfit to “use and/or unsafe. ESCORTSLTD.MSD | SERVICE DEPARTMENT | HOW TO USE THIS MANUAL WARNING indicates special procedures that must be followed to avoid injury to a motoreycle operator or ING: rson inspecting or repairing the motorcycle. Hof the Peoereuges im this manual are organized in a sequential, step-by-step format. The information ues cor Provide the mechanic with an easy to read, handy reference that contains Inti vavand eeortions of al lsassombly, repair, assembly, and inspection operations. 8 i, a faulty componer “Of gotion required wil follow the symbol, e.g bts og cme Secor earings, ee Pitting/Damage > Replace. ich chapter provides expl lod lisassombly and assembly cog ae PetOr® each disassembly section for ease in identifying correctILLUSTRATED SYMBOLS (Refer to the illustration) Mlustrated symbols(@to(7)are designed as thumb: tabs to indicate the Chapters number and content (1) General information (2) Periodic inspection and adjustment (3) Engine @) Carburetion @) Chassis (6) Electrical @ Appendices Illustrated symbols @)tof3are used to identify the specifications appearing in the text. 8) Filling fluid Lubricant (0) Tightening G) Wear limit, clearance Engine speed LMA lilustrated. symbols @@ to €9 in the exploded diagram indicate grade of lubricant and location of lubrication point. Apply locking agent (LOCTITE; or equivalent) {8 Apply engine oil Apply gear oil 7) Apply molybdenum disulfide oil 8 Apply whee! bearing grease ‘Apply lightweight lithium soap base grease Apply molybdenum disulfide greaseGENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS =) ENGINE OVERHAUL on KI = CARBURETION |_# or 4 | CHASSIS oS ICHAS| APPENDICESCHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION. FRAME SERIAL NUMBER. ENGINE SERIAL NUMBER IMPORTANT INFORMATION ALL REPLACEMENT PARTS. GASKETS, OIL SEALS, AND O-RINGS. LOCK WASHERS/PLATES AND COTTER PINS. BEARINGS AND OIL SEALS. GIRGLIPS SPECIAL TOOLS. FOR ENGINE SERVICE. FOR CHASSIS SERVICE. FOR TUNE-UP. FOR ELECTRICAL COMPONENTS.GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number(1is stamped into the right side of the steering head pipe. ENGINE SERIAL NUMBER. The engine serial number(s stamped into the left side of the engine NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. Starting Serial Number: RXx100 1L1-000101 NOTE: ee eee Designs and specifications are subject to change without notice.IMPORTANT INFORMATION IMPORTANT INFORMATION ‘ALL REPLACEMENT PARTS 1, We recommend to use Yamaha genuine parts for all replacements. Use oll and/or grease recommended by Escorts for assembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 4. All gaskets, seals, and O-rings should be replaced when an engine is overhauled, All gasket surfaces, oil seal lips, and O-rings must bbe cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips, LOCK WASHERS/PLATES AND COTTER PINS 1, All lock washers/plates()and cotter pins must be replaced when they are removed. Lack tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened BEARINGS AND OIL SEALS 1, Install the bearings(s)Dand oil seal{s)(@with their manufacturer's marks or numbers facing ‘outward. (In other words, the stamped letters Must be on the side exposed to view.) When Installing oil seal(s), apply a light coating of light-weight lithium base grease (eg. Servo Grease M.P,) to the seal lip(s). Oil the bearings liberally when installing CAUTION: Do not use compressed air to spin the bearings dry. This causes damage to the bearing surlaces.eS SPECIAL TOOLS CIRCLIPS 1. All circlips should be inspected carefully before Teassembly. Always replace piston pin clips after one use. Replace distorted circlips. When Installing a circlip@) make sure that the sharp- edged comer (2)is positioned opposite to the thrust @) it receives. See the sectional view, @ Shaft SPECIAL TOOLS ‘The proper special tools are nacessary for complete 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 ENGINE SERVICE 1. Flywheel Holding Too! SM-100000201 2. Flywheel Puller &SM-10000202 3. Crankcase Separating Tool ESM-100000265i | i SPECIAL TOOLS 4. Clutch Holding Toot ESM-100000233 Q 5. Crank Installing Tool ESM-100000266 re Ao: 8 Adapter 6. Driving Sprocket Holder ESM-100000205, a= 7. Piston Pin Replacer ESM-100000207 a8, Piston Ring Compressor ESM-100000210 Oo 9. Punch ESM-100000222 For Crank-Shaft Seal c- 10Punch ESM-100000233 For Gear Shaft Seal a FOR CHASSIS SERVICE 1. Steering Nut Wrench ESM-100000221 2. Front Fork Top Plug Spanner ESM-1000002143. T Handle ESM-100000213 4, Front Fork Inner Tube Adjuster ESM-100000264 oaen | 5. Speedometer Gear Nut Spanner | ESM-100000237 A FOR ELECTRICAL COMPONENTS. 1. Pocket Tester ESM-100000270CHAPTER 2 . PERIODIC INSPECTIONS AND ADJUSTMENTS NOTES ON MAINTENANCE . PERIODIC MAINTENANCE/LUBRICATION .. ENGINE ..... SPARK PLUG | AIR CLEANER ELEM TRANSMISSION OIL, AUTOLUBE PUMP CARBURETTOR CLUTCH , ‘CHASSIS BRAKE . TYRE ... DRIVE CHAIN . STEERING HEAD ELECTRICAL | BATTERY .NOTES ON MAINTENANCE NOTES ON MAINTENANCE 1, Thoroughly clean the frame and engine of dirt and dust in order to prevent them from enter ing the inside of the engine 2, Keep off fire. 8. When the special tools are required, be sure to use them so that damage to the motorcycle parts can be avoided. Always use the right tools and instruments for = the right purposes. (Avoid using an open-end wrench a much as possible, in place of a box ‘or socket wrench.) 4, Always use @ new gasket (packing), O-ring, — ‘cotter pin, circlip, lock washer, etc. for repairs. ‘Also use genuine Yamaha parts, oil and grease, or those recommended by Escorts.Avold using other brands. During service, take special care so that you don't get injured or burt from the engine, ‘exhaust pipe or muffler.CLUTCH/BRAKE 4, Loosen: Locknut 6. Screw in adjuster @) until tight and back it out 1/4 turn: 6, Tighten: @ Locknut CHASSIS BRAKE Front 1. Loosen: ® * Locknut 2. Adjust: + Free play by adjuster (2) 8 Tighten: Locknut @), 5~3 mm * Free play @ = by turning the adjuster (2) (Ref. Page 2-11)@® Adjuster TYRE 1. Inspect: * Tyre wear 1) Wear indicator @) Replacement limit 1 mm 2. Check: © Air pressure MAXIMUM 162 Ko. LOAD* Front Rear Single Rider | 1.5 kg 2.0 kg Jem’, (22 psi) | /om?, (28 psi) Double Rider| 1.5 kg 2.3 ko /om*, (22 psi) | /em?, (32 psi) * Load is the total weight of cargo, rider, passenger, and accessories. Too high — Risky — Poor Road holding Good — Good & sate riding Too low — Causes higher tyre wear fuel economy low. DRIVE CHAIN Slack Check 1. Remove: © Rubber cap 2. Check: ive chain slack@| 835 Az Emer Ts | Eee I DRIVE CHAIN/STEERING HEAD Slack Adjustment 4, Remove: * Cotter pin @) 2, Loosen: * Axle nut '* Sprocket shaft nut @) 3, Adjust: * Slack @ Adjusting bolt NOTE:. Be sure that both right and left chain pullers are in the corresponding positions. STEERING HEAD Checking 1. Raise front wheel off the ground. 2. Check: © Steering head bearing for looseness Gently rock fork assembly backward and forward, Looseness — Adjust. Adjustment: 1, Loosen: ® * Steering fitting bolt '* Front fork pinch bolts (2) 2, Adjusts * Steering head ring nut @) Tighten nut until steering head is tight without binding, Heavy binding > Replace bearings. 3. Tighten: ® Steering fitting bolt @). * Front fork pinch bolt @) Steering Fitting Bolt (1): 3.1 mikg, (22 fall) Front Fork Pinch Bolt (2): 2.0 mkg, (14 ft-lb)BATTERY ELECTRICAL BATTERY Fluid Level 1, Check: * Fluid level @) Fluid level should be between upper(2) and lower level tins @) Use only distilled water for refilling. Battery Charging 1, Check: * Battery fluid gravity SPEGIFIC GRAVITY CLIMATE —_ INITIAL AT 20° cFULLY CHARGED] TROPICAL 1.240 1.240-1.250 | (ABOVE 30°C) COLD/ TEMPERATE 1.260 1.260-1.270 (BELOW 30°C) 2. If gravity is below specified, recharge battery. Charging Curr Charging HoutNOTES ON MAINTENANCE 6. Battery Take care so that the battery fluid does not spill (on your clothes body or the motorcycle. T. Notes on disassembly and reassembly 4. Place all removed'parts neatly and separately in groups so that they will not ba confused or lost, 'b. Wash the engine and transmission parts in a detergent oil and blow them out dry with compressed air, c. While checking the smooth movement of parts, install them, d. Oil the contact surfaces of the moving parts. 8. Tightening torque. Tighten the parts to specification by using the torque wrench.Unit : Km, BEMAAKS BREAK-IN | THEREAFTER EVERY 7/000, 3.000 6,000 12000 or3 monthslor § months| or 12months Check/Giaan or replace [6 ai Airtiter (Clean, Replace if necessary oO o Carburettor iCheck/Adjust/idle speed, starter operation| 0 ei Sean Fuel tine, [Cheek fuel hose for cracks or aamage 0 0 Tranamission oll” {Replace (Warm engine before draining) | REPLACE | GHEOK | REPLAGE Auiolube pump | Check/Adjust’/Air bleeding? 0 0 : Brake" Check/operation 0 0. Le Clutch? Cheek operation 0 0 a arm pivot” |Chack tear arm assembly for looseness 0 0 feplace Silent block bushes 24,000 or 24 months. Wheels’ Check balance/damage/runouvepoke ° 0 tightness, Wheel bearings" Check bearings assembly for loosenese/ 0 | REPACK™ | | damage. Replace if damaged Grease | | Steering b ‘Check bearings assembly for looseness, 0 REPACK™ GREASE FrontFork™ (Check operation/all leakage TF CHECK CHECK | REPLACE iL Rear Shock Chock operation/ell leakage 0 x absorber Drive Chain Clean/iube/align® 0 Check tension every 1000 kms align’ Fittings/Fasteners’| Check all chassis/engine/Gyi/Gyl. Head a Ou | anata Battery” = Gheck specific gravity tT — Check breather pipe for proper operation, o ° — Gheck electrolyte level/aca distilled water every 15 days. Decarbonising® | Remove carbon trom (Gyi/Gyl. Heads 0 Piston Assy/Mutfier) oe Ignition Timing* | Check Fuel Strainer Clean is om 5 Fuel Tank/Fue! | Glean Cock” Tyres Check eo 1 lt is recommended that these Items be serviced by Yamaha dealer. © Medium weight wheel bearing grease. , ‘4H.Use 175 + dco ‘Servo Toleshocab’ all of M/s Indian Qil ‘Battery Spacitic gravity — 1240/20°C2 CST AE SN A FN YG PERIODIC MAINTENANCE/LUBRICATION | | INSP | Qe‘UPPER f OWERL. ZN rim neENGINE SPARK PLUG 4, Clean; * Spark plug 2, Adjust: Plug gap@) AIR CLEANER ELEMENT 1, Remove: © Right side cover * Air cleaner case cover(7) * Air cleaner element (2) 2. Clean: * Air cleaner element Wash the element in solvent. Squeeze excess solvent out of the element and dry. CAUTION: DO NOT SQUEEZE BY TWISTING 3. Apply: * A small quantity of 2-stroke engine oil Squeeze excess oil. 4. Install: © Air cleaner element TRANSMISSION OIL Checking 1. Check: * Gil level Maintain transmission oil level always bet- ween MAX and MIN lines Recommended Oil: Servo Super 30 or Equivalent2 ANSNISS ON OH] RS? TRANSMISSION OIL/AUTOLUBE PUMP SLL Al Replacement 1. Start the engine and tet it warm up 2. Remove; © Drain bolt G) Drain oil after warming up engine. 3. Install: a * Drain bolt @ ee 3. Fill * Transmission oil yy 0.65 L 4, Check : * Oil level AUTOLUBE PUMP Cable Adjustment 1. Check to see if pump guide pin is aligned ” with mark on adjusting pulley 2. If not aligned, align by tuning adjuster Min or out. -Minimum pump stroke adjustment 1. Rotate engine so that adjust plate moves out to limit 2. Measure, * Minimum pump stroke | X<] Minimum Pump Stroke: | 25 mm | I clearance is not correct, adjust by the shim © Adding of shim will increase the stroke and vice versa. Air Bleeding 1. Remove: * Pump bleed screw (1) Keep oil running out until air bubbles disappear 2. Install * Bleed screw (1) 8. Start the engine and pull the pump wire@) all the way for some minutes, CARBURETTOR Throttle Grip Free Play 4. Loosen: © Locknut @ . Adjust: * Cable free play @) 1~2 mm Turn cable adjuster @) in or dut. Tighten: * Locknut @)CARBURETTOR/CLUTCH |. 2 Throttle Gable Free Play Loosen: * Loosen () . Adjust * Cable free play @) 5~8 mm Turn cable adjuster (8) in or out. Tighten: * Locknut (@), Idle Speed 1. Turn pilot air screw (7) in until lightly seated. 2. Back out by specified numbers of turns, Xa] Pilot Air Screw Turn Out: t1/as1/2 @rvasve 3. Start the engine and let it warm up. 4, Turn the throttle stop screw (@) in or out un til idle speed is at specified rpm eS Engine Idle Speed: 1,200 + 50 rpm CLUTCH Cable Adjustment Looser * Locknut @) Adjust: * Cable free play (2) 2~3 mm Turn cable adjuster (3) in or out. Tighten; * Locknut @) Mechanism Adjustment . Remove; ® Left crankcase cover Position the push lever (2) by the cable adjuster 3. Install: "Lett crankcase cover @ @ 75mmCHAPTER 3 ENGINE OVERHAUL ENGINE DISASSEMBLY .. CYLINDER HEAD AND CYLINDER PISTON ... . 1 FLYWHEEL MAGNETO .. 1 CLUTCH .. - &2 KICK STARTER «2 SHIFT SHAFT 33 CRANKCASE ae 233 TRANSMISSION AND SHIFTER. 33 GRANKSHAFT . Bice 34 INSPECTION AND REPAIR 35 CYLINDER HEAD 35 CYLINDER . 35 PISTON ...... 36 PISTON RING . 37 37 PISTON PIN AND SMALL END BEARING CLUTCH! =...2-° KICK STARTER 38 (CRANKSHAFT ... 39 _ TRANSMISSION . BEARINGS AND OIL SEALS 3-12 ENGINE ASSEMBLY AND ADJUSTMENT 3-13 GRANKSHAFT o..sseerecrre see 3-13 TRANSMISSION AND SHIFTER. 3-14 CRANKCASE ASSEMBLY . 315 SHIFT SHAFT 316 KICK STARTER, 347 CLUTCH 4 3-18 PRIMARY GEAR 319 FLYWHEEL MAGNETO 3-19 PISTON 3-20 CYLINDER 221 CYLINDER HEAD aa ENGINE MOUNTING .ENGINE DISASS CYLINDER HEAD | 1, Remove: , © Cylinder head nuts © Cylinder head #0) fer nuts © Cylinder PISTON 4, Remove: ® # Piston pin clip © Piston pin) + Piston * Piston rings NOTE: Before removing the piston pin lip, cover the crankease with a clean rag FLYWHEEL MAGNETO. 11. Remove: * Crankcase cover (Left) 2. Attach: * Flywheel Holding Tool ESM-100000201(1) 3. Remove: * Flywheel holding nut @) * Lock washer © Washer 4. Attach © Flywheel Puller ESM-100000202 (0) (Left-Hand-Threads) 5. Remove oriywhee! @) © Woodruff key 6. Remove: Stator holding screws () Neutral switch lead wir * Stator assembly @)ir: ankshaft Ising coppar hammer (7) Measure: © Big end side clearance Use feeler gauge (1 Out of specification + Repair or replace. Big End Side Clearance: 0.20.7 mm Measure: © Small end free play Out of specification > Replace. ~] ‘Small End Free Play: 1.5~2.0 mm 1. Inspec TRANSMISSION it © Shift shaft @. * Springs: Wear/Bend — Replace.= a ll 1 INSPECTION AND REPAIR Shitt Fork 1. Inspect: © Shift forks (1) (on the gear and shift. cam contact surface) © Shift fork guide bars (2) Wear/Ghafing/Bends/amage — Replace, 2, Check: © Shift fork movement (on shift cam) Unsmooth operation > Replace fork and/or guide bar. Shift Gam 1. Inspect * Shift cam grooves @) Wear/Damage/Scratches - Replace. * Shift cam pins Wear/Damage + Replace. Main Axle and Drive Axle 1. Measure: © Axle runout Use centering device and Dial Gauge @) ‘Out of specification > Replace. Runout Limi 0.1mm Gears 1. Inspect: * Gears Damage/Wear — Replace. 2. Check: © Gear movement Unsmooth operation — Replace. 3. Inspect: * Matching dogs Gracks/Wear/Damage — Replace.INSPECTION AND REPAIR BEARING AND OIL SEALS | 4, Chack: | * All bearings (with finger) Rough spot/Play + Replace. 2. Inspect: © All oll seal lips Damage/Wear —» Replace. NOTE: ‘Always replace crankshaft oil seals.ENG ENGINE ASSEMBLY AND ADJUSTMENT ENGINE ASSEMBLY AND ADJUSTMENT NOTE: Before assembling the engine, thoroughly wash the parts in mild solvent, CRANKSHAFT CRANK PIN WOODRUFF KEY OJL SEAL 4, Attach: * Crankshaft Installing Toot —sm-100000266 (1 (to the left side crankcase) 2. Tighten + Nut of the installing too! Hold the connecting rod at top dead center,GUIDE BAR oO GUIDE BAR FORK 2 314 1.4 mekg (10 ft-tb) 5 DRIVE ! Ge : SPROCKET He on 1ST WHEEL GEAR ' TRANSMISSION AND SHIFTER RIVE AXLE BEARING QIL SEAL COLLAR aTH ec es ily, 3RD WHEEL cean FORK 3 @, DOG aurer (Q OD 0, 2ND WHEEL- QO eel con 0%, L B ig [5.5 m-kg.(40 ft-Ib) FORK 1 3RD PINION GEAR—— ) 20 mckg (14 fei) "8") GEAR 2 2ND PINION GEAR 1. Install = Transmission assembly 2, Check: ‘© Transmission operation Incorrect operation -» Reassambly.SZ Teme] — hy & + Yamaha Bond No.4 (to both crankcase mating surfaces.) install ‘© Dowel knock pins @) . Install: © Right crankcase half (Tap with plastic hammer) Tighten: Crankcase tightening screws Tighten the screws in showing sequence and in two steps.SHIFT LEVER, TENSION SPRING SHIFT SHAFT ASSY RETURN SPRING 1. Install: * Stopper lever assembly @) 3. ST cxmen | © Shift shaft assembly 2) * Washer @ © Girclip @ 2, Adjust; © Shift lever position (by adjuster screw () and locknut @)) Gap-@) To be equal on both sides,ENGINE ASSEMBLY AND ADJ. USTMENT KICK STARTER - RETURN SPRING KICK GEAR ME et 28 “Gio” ILE GEAR ss ee BALC it ce “Gh. = - ft oe, Oil SEAL WASHER “i Install * Kick starter assembly Position the kick clip @) in groove @) of the crankcase as shown. s Hook; © Hoturn spring @ 4, Install: © Circlip * Washer * Kick idle. gear @ «Washer (2 + Circlip @ a a aENGINE ASSEMBLY AND ADJUSTMENT CLUTCH GLUTCH SPRING [cea oR, PRESSURE PLATE = LUT ESAT WARP LIMIT: 0.05 FRICTI TE WEAR LIMIT: 2.7 mm PusH ROD PS 43 mek (94 feIB) BAI h cturen aost a PUSH ROD & ae? _OIL SEAL ADJUSTER ps Nea . Install: © Thrust washer (1) * Spacer Clutch housing © Thrust washer (4) Install: +:Clutch boss *.Washer ©) o Nut G) Clutch Boss: 4.3 m-kg, (31 ft-lb)ENG 3. Install: * Friction plates . Sutsh plates * BallG * Push rod (2) CAUTION: The clutch thelr cutaws (A) : 1st and [CG] :3rd. | [B) : 4th 4. Install: * Pressure plate @) * Springs: * Bolts (3) S Cluteh Spring Nut: 0.6 mikg. (4.3 ftulb) PRIMARY DRIVE GEAR 4. Install: * Spacer (@) © Primary drive gear(@) * Straight key @ * Washer (4) * Nut @ * Primary Drive Gear: 5.5 m.kg (40 fib) FLYWHEEL MAGNETO 1. Install: ® Stater assembly @) Stator; 0.7 im.kg, (5.1 ttlb) 2, Connest: ® Neutral switch led wire @) 3. Install: ‘© Woodruff key ©) © Flywheel 2) Flywheel Magneto: T.0m-kg. (50 ftb)ENGINE DISASSEMBLY 2 CLUTCH 7 Remove: * Grankcase cover (Right) * Clutch spring bolts * Clutch springs © Pressure plate 1 * Friction plates © Clutch plate) Remove: ® ® Primary drive gear nut Use folded rag (@) + Washer # Primary drive gear@) © Straight key * Spacer 3. Attach: ® Clutch Holding Tool ESM-100000233 (1) Remove: © Clutch assembly © Oil seal retainer @) KICK STARTER 1 Unhook: © Kick return spring@) Remove: © Kick starter assembly @) Remove: * Circlip © Washer! ® Kick idle gear @) © Washer © CirclipENGINE ASSEMBLY AND ADJUSTMENT PISTON 2.5 mekg.(18 ftlby END GAP; 0.18-0.35 mm ALWAYS USE A NEW ONE| 1, Install: * Piston rings @) ¢ Smail end bearing @) * Piston pin * Piston pin clips (New)(@) * Piston 6) NOTE: ‘© Make sure ring ends (1) are properly fitted around ring locating pins in piston grooves. s The arrow @) on piston deme must face ex. haust side.ce ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER 1. install * Gasket (New) ylinder Cyl 3. (25 ft.lb) CYLINDER HEAD 41, Install * Head gasket @) * Cylinder head(2) * Nuts) Cylinder Head: 2.5 m.kg, a ENGINE MOUNTING Engine Mount Bolts: 3.0 m.kg, (22 ftlb) 6.0 m.kg, (43 ftlb)‘SHIFT SHAFT 1. Remove: * Girclip (on left side) 2. Remove: © Shift shaft assembly @) + Stopper lever assembly) ‘CRANKCASE 1. Remove: * Grankease tightening screws 2. Attach: © Crankcase separating too ESM-100000265@ (to the right side crankcase) NOTE:. i Make sure the tool body is parallel with the case. ‘Make sure the too Se ee 3. Tighten: © Securing bolt (2) TRANSMISSION AND SHIFTER 4. Remove: Shift cam blind plug @). * Gasket (@)ENGINE DISASSEMBLY 2, Remove: * Transmission assembly CRANKSHAFT 4. Attach: © Grankcase separating tool ESM-100000265 (1) NOTE: Make sure the tool body is parallel with the case. 2. Tighten: + Securing bolt) | 3. Remove: | * Crankshaft Assy. |INSPECTION AND REPAIR CYLINDER HEAD 1. Remove: * Carbon deposit Use rounded scraper. NOTE:, $$$ Do not use a sharp instrument and avoid damag- ing or scratching. 2, Measure: * Cylinder head warpage Out of specification + Resurface or replace. @ Straight edge @) Thickness gauge CYLINDER 1, Remove: © Garbon deposit Use rounded scraper. NOTE Do not use a sharp instrument and avoid damage or scratching 2. Inspect * Cylinder wall Wear/Scratches -» Rebore or replace. 3, Measure * Cylinder bore “C” Use Cylinder Bore Gauge ‘Out of specification - Rebore, @w ‘Standard 50,00 50.02 mm 50.1 mm Cylinder Bore C: | 0.05 mm Cylinder Taper T: © = Cylinder bore T = (Maximum ©)-(Minimum C)INSPECTION AND REPAIR PISTON 4, Inspect # Piston wall Wear/Scratches/Damages ~» Repair or re- place. 2. Remove: | * Carbon deposit | Use rounded scraper. NOTE:. © Do not use a sharp instrument and avoid damag- ing or scratching. * After correcting, clean the piston with a clean cloth, 3. Measure: ® Piston outside diameter “P” Out of specification + Replace. Size A [Standard 49.966 — 49.986 mm 49.90 mm Oversize 4 50.25 mm Oversize 2 50.50 mm Oversize 3 50.75 mm Oversize 4 51,00 mm NOTE ————— ‘© Measurement should be made at a point 10mm above the bottom edge of the piston ski 10 mm Piston pin 90° +. 4, @ Piston clearance ~ Out of speci replace piston. Piston Clearance = Minimum Cylinder Bore ‘C’ — Piston dia ‘P’ 0.030~0.038 mm ation —» Rebore cylinder or2, Measure, Maximum cylinder bore P = Piston outside diameter PISTON RING 1. Measure: * Side clearance (1) Use a feeler gauge @) Out of specification > Replace piston and/or rings. Side Clearance: 0.02 — 0.06 mm * End gap: (®) Use feeler gauge @) ‘Out of specification + Replace rings as a set. Standard Limit End Gap: |} — (installed) | 0.15~0.35 mm | 0.6 mm | as a ed PISTON PIN AND SMALL END BEARING 2. Install 3. Check 4. Install: 5, Check: Lubricate: '* Piston pin (1) and bearing + Piston pin and bearing {into small end of connecting rod@) ) '* Free play Free play > Inspect connecting rod for wear. Wear 9 Inspect connecting rad and piston pin. ‘* Piston pin @) (into piston) © Free play Free play + Replace piston pin and/ar piston.ISPECTION AND REPAIR CLUTCH Cluteh Hou 4, Inspect: * Dogs on housing (1 Cracks/Wear/Damage — Deburr or replace. 2, Check: * Circumferential play Play — Replace. NOTE: DO NOT CLEAN WITH PETROL Clutch Boss 1, Inspect: * Glutch boss splines(2) Scoring/Wear/Damage > Deburr or replace. NOTE: Scoring on clutch plate splines will cause erratic operation. Friction Plate 1. Inspect: * Friction plates(1) Damage/Wear = Replace as a set 2, Measure: © Friction plate thickness Measure all at four points. Gut of specification > Replace as a set. X<]_ Wear Limit: 2.7 mm Clutch Plate 4. Measure: © Clutch plate @ warpage Use surface plate (@) and feeler gauge. Out of specification -» Replace, Warp Limit: 0.05 mm.INSPECTION AND REPAIR Clutch Spring 1. Measure: © Free length Out of specification + Replace asa set Minimum Length: i 33 mm KICK STARTER 1. Inspect © Kick gear teeth * Kick idle gear teeth Wear/Damage + Replace. 2. Check: * Kick gear movement 3. Measure: © Kick clip friction force Out of specification - Replace kick elip. Kick Clip Friction Force: 0.8~1.2 kg CRANKSHAFT 1. Measure: * Runout@) Use Dial Gauge (1) Out of specification —> Repair or replace. @ 75mm Runout Limit: 0.03 mm 2. Measure: © Crank width Gut of specification —» Repair or replace. ‘Crank Width: 55.90~55.95 mmCARBURETTOR ... SECTION VIEW . WORKING RANGE REMOVAL AND DISASSEMBLY . INSPECTION REED VALVE ,. INSPECTION , CHAPTER 4 CARBURETION 44 EACH COMPONENTVALVE STOPPER REED VALVE ! a e CARB F CARBURETTOR CARBURETTOR HROTTLE VALVE: (CUTAWAY) 2: p muor ver. minor am scReW ONG ye ‘VALVE SEAT FLOAT VALVE NEEDLE JET Ne THROTTLE STOP SCREW FLOAT HEIGHT: 211mm Throne valve Main jet SECTION VIEW ere 2 Mixwe: fan Ove v4 v2 a 6 4) Main jet @) Needle jet & Jet necille Throtia valve cutanay Pilot sic screw & jet 6) Closed Fut open Nardle valve Pit jot Jat needle cdl jotCARBURETTOR REMOVAL AND. DISASSEMBLY 4. Remove: | © Right side cover Air cleaner case sorews (1) Loosen * Carburattor joint screw |. Disconnect: * Fuel hose: * Oil delivery hose @) oon 4, Remove: * Carburetor * Carburetor top(@) . Disconnect: * Throttle cable 2) 6. Remove: # Starter plunger) * Float Ss * Needle valve @) = Main jet # Pilot jet INSPECTION 1. Using high pressure air, blow out all passages and jets. 2. Inspect: Needle valve Damaged or worn -+Replace as a set.CARBURETOR ae SEU 3. Inspect * Throttle valve) * Jet needle (2) Scraich/Bent + Replace. Measure: * Float height (1) Without Gasket incorrect > Adjust X&] Fioat Height: *F 214.0 =1.0 mm Dye EE The float should be just resting on, but not depressing, the spring loaded inlet needle. 5, Adjust ‘© Float height ‘ by bending the tang (1) REED VALVE INSPECTION Measure! Valve stopper height 1) Out of specification — Adjust. + Reed valve bending @) Out of specification —» Replace. Valve Stopper Height: mm. Reed Valve Bending Limit: 0.3mm Nove, Note the cut In the lower corner of the reed and stopper plate.CHAPTER 5 CHASSIS WHEELS, BRAKES, SPROCKETS AND CHAIN FRONT WHEEL REMOVAL .. REAR WHEEL REMOVAL INSPECTION . INSTALLATION . FRONT FORK REMOVAL ..... DISASSEMBLY INSPECTION . REASSEMBLY INSTALLATION ‘STEERING HEAD REMOVAL. INSPECTION . INSTALLATION . REAR SHOCK ABSORBERS AND SWINGARM 544 REMOVAL . 5-11 INSPECTION . 5-12 INSTALLATION 12PR mt WHEELS, BRAKES, SPROCKETS AND CHAIN WHEELS, BRAKES, SPROCKETS AND CHAIN DUST COVER oi seat me (508) aan & Lp. | = spacer’ TWA J] seaninc Ae on SEAL 43 ekg (31 ft FRONT WHEEL REMOVAL 1. Place a suitable stand under the engine. 2. Disconnect: * Brake cable @) 3. Disconnect: 2 Speedometer cable @) 4, Remove © Cotter, pin * Axle nut © Axle shatt + Front whee!7 STEERING HEAD 4. Install: * Front forks ‘* Handle crown @ Steering fitting bolt Fitting Bolt: 4.0 m-kg(29 ft-lb) 5. Tighten: * Inner tube pinch bolts Inner Tube Pinch Bolt: Upper (1) : 1.5 mkg, (11 fib) Lower (2) : 9.0 m.kg, (22 {t1b)a a a 6.0 m-kg.(43 (+15) ~ REAR SHOCK ABSORBER AND SWINGARM [a i REAR SHOCK ABSORBER AND SWINGARM 40 mokg 128 feb) PIVOT SHAFT REMOVAL +. Remove: * Rear wheel © Chain case © Driven Sprocket ‘© Drive chain 2. Remove: # Shock absorber mount bolts @) Shock absorbers 3. Remove: * Pivot shaft nut @) + Pivot shalt @2) * Swingarmd& INSPECTION 1. Inspect: Shock absorber Oil leaks/Damage — Replace. 2. Inspect © Swingarm With the swingarm installed grasp the swingarm end to check for free play. Free play Replace bushes. ‘Swingarm Free Play Limit: 2.0 mm A 3. Inspect *» Bush @) '* Pivot Shatt (2) Rust/Dirty > Clean or Replace. Bent + Replace INSTALLATION Reverse removal steps. 1. Grease the bushes and pivot shaft 2. Install: © Swingarm * Pivot shaft Q aaee | CHAS [I REAR SHOCK ABSORBER AND SWINGARM |3.8 mekg (13 ftetb) : ve Ieseteniere| 0.9 sk (6.5 (tI) IL SEAL BEARING SPACER REAR WHEEL REMOVAL 1. Place the motorcycle on its centerstand 2. Remove: ‘© Brake tension bar @) * Brake rod) 3. Remove: + Cotter pin © © Axionut © Axle shaft © Rear wheel4. Remove: * Chain case © Sprocket shaft nut * Sprocket assembly * Drive chain INSPECTION 4. Inspect: © Axle shaft Roll the axle shaft on a Flat Surface. Bends + Replace. 2. Inspect: © Wheel Cracks/Heavily Bends —> Replace. 3. Measure: ‘* Wheel runout Out of specification -> Retighten or Replace. Rim Runout Limits: Radial @) — 2.0 mm Lateral (2) — 2.0 mm 4. Inspect: + Wheel bearings Bearings allow play in the wheel hub or wheel turns roughly -> Replace. 5. Measure: * Brake shoe thickness Out of specification > Replace. X4]_ Brake Shoe Wear Limit: 2mm6. Measure: ® Brake drum Inside diameter Out of specification > Replace. Brake Drum Wear Limit: 131 mm 7. Inspect: ® Drive sprocket © Driven sprocket Wear ~ Replace with the chain as a set. Good No Good 8. Measure: © Drive chain length (10 Links) @) Out of specifiction -> Replace. Drive Chain Length (10 Links) Limit: 421mm. INSTALLATION 4. Install: + Wheels Reverse removal steps. Note the following installation points: > Lightly grease the wheel oil seal lips and gear teeth of the speedometer drive and driven gears. (Use lightweight, lithium base grease.) }> Be sure that the torque stopper is positioned correctly. j= Install the chain clip wi the direction of travel. rounded:end facing @® Drive directionFRONT FORK FRONT FORK ‘CLIP OL SEAL. lL SEAL, LO — sere. 23 miko ftelb) Gap BOLT. GasKeT—_& Ss — 7 a a CYLINDER FORK OL. SERVO TELESHOGAS' OIL 47523ce per side REMOVAL 1 ~ > © Remove: © Front wheel ‘* Front fender Loosen: ‘« Front fork pinch bolt @) * Gap bolt (2) Use Top Plug Spanner (ESM-100000214) (@) Loosen: * Front fork pinch bolt (Lower) (1) Remove: © Front forkFRONT FORK DISASSEMBLY 1, Remove: * Cap bolt @) * Spacer @) * Spring ra © Spring @ 2. Drain: 8 * Fork oil 3. Remove: * Bolt Hex Sockethead rod securing bolt (1) Use T-Handle (2).(ESM-100000213) Inner tube) Spindle @) 4, Remove: pple * Glip Oilseal * Oil seal (2) INSPECTION 1. Inspect: © Inner tube (1) # Outer tube Cylinder Complete (4) Soratches/Bends/Damage > Replace. 2. Measure: * Fork spring (2) ‘Out of specification —s Repalce. Fork Spring Free Length: 206.5 mm. Limit 291.5 mmFRONT FORK ASSEMBLY 1. Install: * Cylinder Complete @) * Spindle (2) © Inner tube @ * Bolt Hex Socket Hd @ Cylinder Comp. 2.3 m.kg. (17 ftalb) LOCTITE OR EQUIVALENT. x Install: * Oil seal @) © Clip oilseal * Dust cover @ Inner tube @ Outer tube 3. Fill * Front fork Each Fork: 175 + 3ce SERVO TELESHOCAB' OIL install: '* Fork spring Perce) * Spacer @) Cap bolt Rubber cap 6) 5. After installing the front fork, tighten the capSTEERING HEAD STEERING HEAD TIGHTEN UNTIL BALL RACE IS FIXED. CERTAINLY AND STEERING SHAFT REVOLVES SMOOTHLY. BO mwa (22 (1b) 1.9 mekg (93 ft-lb) BALL (3/18" x22 pa} BALL (1/4719 pes) ait UNDER BRACKET ACUTE REMOVAL ve Remove: © Front wheel © Front forks Disconnect: © Brake cable © Throttle cable © Cluth cable Disconnect * Electrical lead wires (in the headlight case) Remove: © Headlight Remove: * Steering fitting bolt * Handle crown assembly © Headlight stays (together with headlight case)bola] STEERING HEAD 6, Remove: * Forkstem nut * Bearing cover (2) NOTE: Support the under bracket not to lose any bearings. # Under bracket * Bearings INSPECTION 1. Wash the bearings in solvent. 2. Inspect * Bearings Pitting/Damage — Replace. © Bearing races (@) Pitting/Damage — Replace. NOTE: Always replace bearing and race as a set. 3, When replacing the bearing, use a long rod @and cold chisel @) to remove the race. INSTALLATION 1, Grease the bearings and races, 2, Install: # Under bracket * Bearing cover * Ring nut 3. Tighten: # Ring nut (so all free play is taken up, but so the bracket can still pivot freely.)GIRGUIT DIAGRAM ... IGNITION SYSTEM CHARGING SYSTEM LIGHTING SYSTEM SIGNAL SYSTEM .. SWITGH INSPECTION (CHAPTER 6 ELECTRICAL_ CIRCUIT DIAGRAM Additional electrical accessories may overload the o xisting electrical system. Severe overloads may. damage the wiring harness or create a dangerous si ituation due to the loss of electrical power during ‘the operation of the motorcycle.Brake light Front brake switch Rear brake switch Light switch Dimmer switch Headlight Park light ‘HIGH BEAM" indicator Meter light Tail light Main switch Ignition coll Spark plug CDI unit Pulsar coil Source coil 47 18 19 20 2 22 23 24 25 26 27 28 29 30 31 92 Charge/lighting coil C.D.I. magneto Body earth Battery Fus Rectifier/Regulator Main switch Flasher lights (left) Flasher pilot light Flasher lights (right) Flasher relay Flasher switch Horn switch Horn Neutral switch Neutral light CIRCUIT DIAGRAM Black Brown - Chocolate - Dark green Green - Blue Pink + Red - Sky blue White Orange Yellow Black/Red Black/White Brown/White - White/Red + Yellow/Red Yellow/White ++. Blue/White + Blue/Red | +. Green/YellowIGNITION COIL PRIMARY Ignition Cail ag Source Coil FUNCTION Function No. 1 ‘As the rotor tums, current is produced in the source coil and then stored in the ignition ‘condensor. Function No.2 ‘At the same time, the pickup coll sends a pulse (signal) to activate the thyristor. Function No.3 Then, the ignition conder discharges the ‘stored current rapidly. This induces a high voltage in the ignition coil, and a strong spark is producedIGNITION SYSTEM TROUBLESHOOTING CHART Allwires connection must be checked in advance. Spark Plug Pickup Coi Bors 105 (W/R=B), Ground the spark plug to the eylinder head and Check the pickup coil resistance. kick the starter. No spark lo spar Si a Joc or weak spark Replace the pickup colt 2 | Spark Gop Test 5 [Source Coll Check 5mm Hold the ignition lead mm from the cylinder head Check the source coil resistance. eae ieae wosont Qs ox Br © | lantion Coll Test Z| Main Switch Tost mai a) DDiseonnact the main switch caupter and kick the PRIMARY, ONDARY. esi eauie2 Check the resistance of tha primary and secon: dary eoil windings. arte. No spork J] spark OK NGCHARGING SYSTEM CHARGING SYSTEM ELEC RECTIFIER REGULATOR Fuse BATTERY. 1, Charging Voltage Test Connect the tester leads wit! ‘as shown, Start the engi h battery terminals and check voltage. 2. Charging Coil Resistance Disconneet the generator leads and check chara ing eoil windings resistance. Charging Voltage! Lf out of specifications, check charging coll wine dings resistance. And if more than $V, replace the Rectifire/ Regulator. If aut of specification, replace charging colLIGHTING SYSTEM LIGHTING SYSTEM HIGH BEAM INDICATOR LIGHT auxin ice oy oh METER LIGHT rain ¢ voltage. 4. Lighting Voltage Test Remove the headlightleads and connect the tesor leads as shown. Start the engine and check the RECTIFIER/ REGULATOR Le, BATTERY. 2. Lighting Coil R BS ney ‘8.0/8 000 rpm] ‘BODY ELLE 8.0V/2,500 rpm EARTH| Vortage 500 +/ in If out of specifications, check lighting coil re- sistance and rectfier/regulator,@y 0 gy FLASHER J} p © elias HORN swiTcH(?P); i H rvasuen(1e FLASHER ‘ Sree UGHT IRR FLASHER INDICATOR UGHT IAP BRAKE LIGHT FLASHER, UGHTIL ES ‘SWITCH INSPECTION Main switch [EXAMPLES FOR LEADS CONTINUITY TEST: FLASHER GO Uschi Bal aael ae aS) FLASHER, a8 on ©. BATTERY INDIGATOR hE UGHT IL) BRAKE SWircH (CONTINUED) (DISCONTINUED)af el SS i) al ae SIGNAL SYSTEM Dimmer switeh Brake switch | [OF to de ‘Hime io eeSPECIFICATIONS ....... CABLE ROUTINE DIAGRA! WIRING DIAGRAM .... ENGINE TAOUBLESHO:! ELECTRICAL SYSTEM .. COMPRESSION SYSTEM INTAKE AND EXHAUST S' CHAPTER 7 APPENDICESina SPECIFICATION A. GENERAL SPECIFICATIONS ‘SPECIFI CATION ori Model Model Code Numbar Frame Starting Number 1k 4L1-000001 Engine Starting Number 4111-00001 ing System Lubrication System: Dimensions: ‘Overall Length 2040 mm ‘Overall Width 740 mm ‘Overall Height 14050 mm ‘Seat Hoight 785 mm Wheelbase 4,240 mm Minimum Ground Clearance 4145 mm Basic Weight With Oil and Full Fuel Tank 103 kg Minimum Turaing Radius 2,100 mm, Engine: Engine Type Air e00l6d, 2-atroke, gasoline 7 port torque induction Cylinder Arrangement Single cylinder, Forward-inelined Displacement 98 em? Bore * Stroke. 50 * 50 mm Compression Ratio erst Max. Power 11.0 PS @ 7,500 RPM Kick Starter ‘Separate Iubrication (Yamaha Autolube Patent) ll Type or Grade: Engine Olt Transmission Oil Servo 2T Supreme or equivalent | Sore sp saree Oil Capacity: Oil Tank (Engine Oi) 13L Transmission Gil Poriodié Oil Change 0.85 1 Total Amount 0701 ‘Ait Filter ‘Wet foam (Weshable) Ful: Type Regolar gasoline (87 Octane) Tank Capacity 708i Carburetior: Type/Manutacturer VM2O/MIKUNI ‘Spark Plug: ‘ pee tinea BPTHS/NGK of Equivalent Gap 07—08mm Cluteh Type Wat, multiple-Dise— —_ [apex ei CIFICATIO C. ELECTRICAL Veltage ev | Prenton sys | Jonition Timing (8.1. 20° 1.6% 5,000 r/min Advancer Type Electrical O12 34s 6 7 6 9 Engina Stee (310? rin) Ee oi Pickup Coll Reslatence (Colour) 20.1. + 10% at 205 (68°F) (WR—B) ‘Source Coil Resistance (Colour) 220.7. + 10% at 20°C (68tF) (B/R—B) Tgnition Colt External Sealed type Minimum Spark Gap 49 KV or more at $00 r/min 42kV or more at 8,000 r/min 6—7mm Primary Winding Resis 1:61 * 10% at 20°C (68°F) Secondary Winding Rasis 66k C1 4 20% at 20% (6a%r) ~--—-+} Charging System/Type Flywheel magneteEW. Magneto: Charging Current-Day -Night Charging Goll Resistance (Colour) Lighting Voltage Lighting Goil Resistance (Colour) ) Changing Voltage 1] = 3 i Zo = SPECIFICATIONS APPX AX 100 0.7A or mora at 2,500 r/min 8.04 or leas at 8,000 r/min t 2,500 #/min ‘at 8,000 r/min 0.4.1. 10% at 2050 (6atF) (W—B) 6.0¥ or moro at 2,500 r/min, 8.0V or less at 8,000 r/min. 0.3.01 4 10% at 20:0 (88°F) (VRB) BD. With no regulator igh > With regula (Day) (Night! 5 8 Engine speed (x 10 v/minkRectilir/Regulator iis SPECIFICATIONS Waximum Amperage No Load Regulator Voltege (Gharging) | 7.6 —B0V. (Lighting) Less than 8.6 Capacity (charging) | 408 (Cightingy 8.04, Battory: Capacity ev 4H ‘Specitic Gravity 1.240/20°6, Horn ‘TyperQuentity Plain type = 1 4.08 Spare Flasher Relay: Type Condenser type Flasher Frequency 60 — 120 cycle/min Wattage tow «2+ 3W Circuit Breaker: Type. Fuse Amperage for Individual Circuit/Quantity Main 0A «1 WA x1‘Motor bracket Band Brake switch lead, Handlebar svetch tna 2 Pilot tight tea Poe Hh at Main swith Jead—————SS Speedornete igh las touch 19 hain Flasher light lead Fork cover Fork cover oo Horn lead Clamp Cluteh cable Oil pump cable il tank breather hose a [aa asCCrankease ventilation hose Oil dotivery hose ‘Wire eylinder Oil tank breather hose Baitory naga! Brake cable High tension lead eerie, Soe Neutral swatch featB. a. cn. Og. Rociifier/Reguiator a. Flasher reley ue flasher tight (right) ae Sb w Y ° @@) Neuteal light switeh QSE55Eg33 Binck Brown Chocolate Dark green Green - Blue Pink. Rod + Sky blue + White Yellow Orange + Black/Red Black/White Brown/wnite White/Red : Yollow/Red ellow/wnite : Bluenmnite Bluemed Green/YellowENGINE TROUBLESHOOTING 1, ELECTRICAL SYSTEM *GHEGK ALL WIRES CONNECTIONS, IGNITION COIL ee “Primary or Seeondary Windinge | ‘Main Switch is Shorted are Broken oF Faulty. *High Tension Lead ie Faulty Plug Cap is Fouly a SPARK PLUG *Many Carbon Deposits “Electrodes are Wet, slmproper Gap. Broken, PICKUP COL “*Windings ore broken.aa a WEAR/SCRATCH INSUFFICIENT TIGHTENING [ToRQUE [CARBON DEPOSITS, I = SERIE INSUFFICIENT TIGHTENING TORQUE| appx 3. INTAKE AND EXHAUST SYSTEM: A CLEANER LENT] [RECTAN] hy or topped] [reese aR COE co melee = a “Caged, Cracked i 2 Kinked (GS ZI | CARBURETOR JOINT =A Las — SILENCER CARBURETOR EXHAUST: FIFE. =Clessed ‘carton Greets eh ‘Mos Spee an Sone ‘improperly Adjusted (idling Anal Starting) STARTER PLUNGER ‘simproporly Adjusted (Starting! PILOT JET. 'sClogged (Low Speed MAIN JET ‘Incorrect Size Clogged (High Speed inpronerty Adjusted ‘incorrect Fuel Level Adjustment ating And Starting) “=Puneture (Overflow) FLOAT CHAMBER ‘Accumulated Dust And/or WaterSPECIFICATIONS Mod AX 100 Transmissio! Size (A) ‘Tyre Pressure (Cold tyra}: Singer rider: (Front) i) (Front) Double Rider (Roar) Maximum Load + Primary Reduetlon System Holcal gear Primary Reduction Ratio T4/19 (3.895) Secondary Reduction Systom Chain Drive Secondary Reduction Ratio 39/15 (2600) Tranamission Type Constant meth, 4-speed Operation Loft feat operation Gear Ratio ist 35/11 (8.182) and 0/1 (2000) ara 260/19 (1.368) at 22/28 (1.000) Chassis: Frame Type: Double cradle Caster Angle aie Teal comm With tube 2,50-18-4PR 2.75-18-6PR 41.8 kg/emt (22 pal) 2.0 kg/am? (28 pl) 1.5 kg/om? (22 pal) 2.3 kg/em? (32 pai) “162k9 Max Load Is the total woight of cargo, fider, passenger,and accessories lear Suspension Brak Front Brake Type Brum brake (130 ) peration Right hand operation ear Brake Type Drum brake (190 @) Operation Right foot operation Suspension: Front Suspension ‘Telescopic fork (Japanese Kayaba) ‘Swing arm (Adjustable 5 Positions) "Front Wheel Travel Rear Wheol Travel Electrical: Ignition System ‘Generator System Battery Capacity ‘Shock Absorber, Front shock Absorber Coll sprir ing, Oil dampar lear Shock Absorbs Gail spring, Oll damper whee! Trav 110mm, 75mm GD. Magneto Flywheel magneto 0V 4AHSPECIFICATIONS Model AX 100, ght Ty led beam Bulb Wattage/Q vanity Headlight ey. 250/250" Tall/Brako light BV. 8/18 Wet Flasher light 8V. 10/4 Park light ev. aWs41 Indicator Light Wattage/Quantity NEUTRAL" ey. awe HIGH BEAM ev. Wat “TURN" ey. aW:2 Meter light ev. Ws B, MAINTENANCE SPECIFICATIONS ENGINE Model AX 100 Cylinder Head: ‘Warp Limi <003 mm Lines indicate straightedge measurement Cylinder: Bore Sire Taper Limit ‘Out of Round Limit 50.0 «i mm <005 mm <0.01mm Piston Piston ae ey Fg oi : ae Piston Clearance Te Oversize 198 2nd a 4th Piston Pin Offset Piston Ring’ Sectional Sketch Top Ring 2nd Ring 500-8 mm 10 nm 0.080 — 0-088 rm 60.25 mm 50.50 mm 50.75 mm 51,00 mm mm (0 in) Keystone Bri2mm omm Koystone Brizmm 720mmAK 100 Connecting Rod Big End Side tito ‘Crank Width "A™ Z 55.9 48mm 02 07mm Cloarance “D’ Small En Free Play Limit "F 20mm, Giutch Friclion Plate Thieknass/Quantity 310 mm ~5) ‘Wear Limit <27 mm ‘Clutch Piate Thickness/Quantity 12mm+4 ‘warp Limit <005 mm) Gluten Spring Free Length/Quantity 345mm x4 Cluten Spring Minimum Length, <33.0mm) Giuich Release Method Inner push, Seraw push Push Rad Bending Limit '<0.15 mm Transmission’ Main Axle Deltection Limit (Runout) 041 mm [freA Detection Limit (uncun 0.1mm Shiller ‘Shifting Type ‘Guide bar Guide Bar Bending Limit ‘<0.05 mm Kick Staner Type: Kick and mesh type Kiek Clip Friction Force P=10k9 490. mm <131mm, Lining Thickness Limits. 5.0mm <20mm Brake Lever & Brake Pedal Brake Lover Free Play/position Grake Pedal Free Play/position Clutch Lover Free Play/position 5 — Bmmiat lover pivot, 20—30 mm/i5 mm. (Vertical height below footrest top) ‘2— 3 mmlAt lever pivotam SPE Tightening Torque Front axle shaft Grown handie-Stearing shal ‘Thread Size Mio=25) M 8x4.25 M0025 Handle crown-Handie holder M8125, Under bracket:Inner tuba 10% .25 Shock absorber. 1 4 2 Pivot shaft 12.25 1 Tension bar M 8x3.25 2 Sprocket (Rear) M 8x4.25 4 ‘Gamshatt lever M 6x10 2 Rear axie sh Mie 5 1 7 M20"1.0 Front engine mounting bolt ine lmounting M 6x1.25 Rear upper engine mounting bal MI0*1.25, Rear lower engine mounting bolt M10«1.25 Footrest-Frame M 621.25 Gap Bott-Front fork Ma5~1.0