1-5

"Engineered control system"

Detects engine speed and throttle opening, and by computer built in CDI unit, Sonoidval
It controls the opening and closing of the switch. This system controls the amount of air to the air jet
and supplies a proper mixture at all times even when the throttle is rapidly opened or closed.

Operating system of solenoid valve

Turn the throttle. ①

I listen to the throttle valve.

Throttle position sensor moves ↑, throttle opening degree and throttle speed are replaced with
signals and sent to the CDI unit. ②

In the CDI unit, the computer calculates the signal from the sensor (signal from the sensor) and the
signal for detecting the engine speed. ③

I will send a signal to the air jet control solenoid.

The solenoid valve snaps

We control the amount of air to the air. ④

1-6

Digital CDI ignition method for map control

The CDI ignition method for map control is the mechanism by which the computer controls the
ignition timing.
Unlike the conventional ignition timing control that detects only the engine speed, it is a computer
control mechanism that detects the engine speed and throttle degree (by CDI unit) and optimally
controls ignition advancement.
As a result, even when suddenly listening to the throttle from the low / medium speed range, the
ignition timing changed instantaneously to realize the ignition timing that gives the optimum timing.
As a result, even better combustion efficiency was obtained over the entire revolution range,
enabling a good response.
[It reacts faithfully to Ryder's will and demonstrates excellent controllability. ]

[BOX]Ignition timing determination system. Turn the throttle. ①

I listen to the throttle valve. Throttle position sensor works

Replace the throttle opening with the signal and send it to the CDI unit. ②

In the CDI unit, the computer calculates the throttle position (signal from the sensor) and the signal
to detect the engine speed. ③

Based on the signal calculated by the CDI unit, the optimum ignition demanded by the engine is
being performed.
1-11

YPVS interlocking auto lobe oil pump

By interlocking the throttle opening of the carburetor with the YPVS motor, the supply amount of oil
can be set as the throttle opening degree
(Operating condition) and engine speed to control oil consumption.

One operation
Operation of the servomotor replaces the engine speed with a signal by the CDI unit,
The opening timing of the engine is calculated, and the servomotor is driven to set the exhaust
timing according to engine rotation,
Link the oil pump and determine the amount of oil that matches the driving situation.

[Description BOX 1]
In the low revolution range, even if the throttle is opened, the YPVS will not operate, so the oil pump
will not be in the maximum stroke state. For that reason, we are trying to reduce the consumption of
oil by preventing excessive supply of oil.

[BOX 1] When suddenly heard throttle

To throttle
To oil pump
To servo motor

[Description BOX 2]
Even if the throttle is abruptly closed in the high engine speed range, the oil pump will not be in the
minimum stroke state because the YPVS is open. Therefore, it is possible to reduce the setting of the
minimum stroke, and it is possible to reduce the oil consumption in the low revolution range.

[BOX 2]
When the throttle is suddenly closed
To throttle
To oil pump
To servo motor

The oil pump adopted a small, high-performance newly designed oil pump.
2-12 Cable, wire, pipe thread drawing [Front/Top]

① Subcode
② Insulc hand
③ Wire harness
④Capretter hit 11 (throttle cable)
⑤ carburetor return tilt 11 (throttle cable)
⑥ High tension code
⑦ Rectifier Guide Regulator
⑧ Equination coil
⑨ Flasher relay
⑩ Y. PVS control cable
⑪ Pump cable
⑬ Throttle cable
[A] Make the area horn lead wire clamp of the stay and bend the clamp
[B] Direct Throttle Cable Passes Horn Stay Guide
[C] The solid speed meter cable is passed through the guide of Hornstein
[D] Times marker lamp
[E] To the country headlights.
[F] Tighten with the front flasher and tighten so that the cord comes out from the bottom side.
[G] To solid throttle grip.
[H] Cross the long side of the eye high tension cord with the right cylinder, in the front. Through the
throttle cable.
[I] Recovery hose: Pass through the silencer.
[J] To the carburetor joint.
[K] The trouble clutch cable passes the outer part of the wire guide.
[L] Toward an oil pump.
[M] To the Y. PVS pulley of the times cylinder.
[N] The breather pipe of the country oil tank passes through the silencer
2-13 Cable, wire, pipe thread drawing [Sideview Left]

① Throttle cable
② handle switch lead wire
③ Recovery tank
④ Side stand switch
⑤ Fuel hose
⑥ Shoji Hose
⑦ Starter cable
⑧ hot water hose
⑨ Speedometer cable
⑩ front brake caliper left
[A] To the radiator.
[B] To the oil tank.
[C] To wire harness.
[D]To Mini Akurina.
[E] To the oil link cylinder.
[F] Go to the carburetor pulling side.
[G] Go to the carburetor return.
[H] Clamp the compensator lead wire Fix to the air cleaner hose.
[I] Fuel tank drain pipe, oil tap Breather pipe, Recovery tank Riesa pipe, C. D. I magneto lead wire
Clamp to the stay.
[J] C. D. I Magnet lead wire is a frame engine Run through the outside of the suspension.
[K] Insuroc pan for subtank hose I clamp it to the side covered stay. Cut the remainder of the band. (2
mm or less).
[L] Fuel tank drain pipe, oil tap Breather pipe, Recovery tankRiesa pipe runs through the guide.
[M] Carburetor overflow pipe is siled Clamp of the sensor and battery box Pass through the lamp and
go outside the hole of the cow
[N] Air cleaner drain pipe is battery B Insert the projecting part.
[O] Carburetor overflow pipe and air Pass the Lina drain pipe through the clamp.
[P] Rake the radiator stay and suction pipe. Lamp and fix.
[Q] Speedometer cable is guide wire
[R] Tighten with radiator and tighten when turning Make it in close contact with the frame.
2-14 Cable, wire, pipe thread drawing [Sideview Right]

① Brake hose
② master stator
③ Reserve hose
④ C. D. I Unit
⑤ Reservoir tank
⑥ front brake brake caliper right
⑦ Pump cable
⑧ Oil pipe
⑨ Rear stop switch
⑩ Rear brake caliper
[A] Random with insulock band. Cut the remainder of the band. (Within 2 mm)
[B] Clamp at pipe collapsed part.
[C] Pass through the welding clamp. Bending the clamp after passing through the harness.
[D] The reserve hose is fixed to the side cover stays with the insulock band. The clamp part should
not be conspicuous downward. Cut the remainder of the punch. (Within 2 mm)
[E] Pass through the guide.
[F] To C. D. I unit.
[G] y.p.v.s To the motor.
[H] To oil tank cylinder
[I] To Thermo unit
[J] Brake hose must be rebuilt to inner tube with left and right insulation bands. Cut the remainder of
the band. (Within 2 mm)
[K] Head meter section To sublead..
[L] Define corrugated tube with clamp.
[M] Fit the right side of the brake hose forward into the clamp of the phone stay.
[N] Caliper to the left.
[O] Handle switch Clamp the right lead wire.
[P] Secure the suction pipe to the radiator hose with a clamp.
[Q] 60 mm or more
[R]Tighten the throttle position sensor lead wire and the oil pump cable to the stay with the clamp.
[S] Make the lead wire Iku deep.
[T] Clamp battery lead wire to frame.
[U] Close the side stand switch lead wire, battery lead wire, rear stop switch lead wire to the frame
cross pipe.
Side stand switch lead wire and pattery lead wire are passed through the rear side of the frame cross
pipe. The clamp should be cut before the engine mount bracket and the remainder of the band.
(Within 2 mm)
2-15 Cable, wire, pipe thread drawing [Exhaust/ Engine(Carb)]

① carburetor throttle position sensor lid wire

② Thermo unit lead wire
③ Starter cable
④ Compensator
⑤ hot water pipe
⑥ Rear Fuenta
[A] To C. D. I unit.
[B] Pass the muffler drain pipe through the outside of the fendaste.
[C] The muffler drain pipe is fixed to the rear footrest bracket with an insulc hand, and the end is
fixed to the rear footrest bracket
Insert into the hole of (Do not overdo one or more.)
Cut the remainder of the band. (Within 2 mm)
[D] Pass the muffler drain pipe through the clamp and bend the clamp.
2-16 Cable, wire, pipe thread drawing [Top View]

① Oil tank breather pipe

② Flasher relay
③ Battery lead wire
④ Side stand switch lead wire
⑤ Rear stop switch lead wire
⑥ Sublide
⑦ handle
⑧ inner tube
⑨ Handle switch Lead wire right
⑩ Front stop switch Lead wire
⑪ Brake hose left
⑬ Brake hose right
⑬ master stator
[A] Tail light harness and rear flasher harness are assembled on insulock. Cut the remainder of the
band. (Within 2 mm)
[B] Clamp the C. D. I magneto lead wire in the hole of panel 4 with insulock band. Cut the remainder
of the band. (Within 2 mm)
[C] C. D. I Magnet lead wire should pass through the back side of panel 4.
[D] Pass through the clamp.
[E] Pass harnesses through the throttle cable.
[F] To the compensator.
[G] To oil link.
[H] times Handle switch Lead wire Left: Inner tube inside
[I] Handle switch Left wire and clutch cable are clamped in place. (Small diameter on the clutch side.)
[J] Main switch lead wire and handle switch left lid wire are fastened together with a clamp
[K] Handle switch switch Lead wire passes right inside IJ of inner tube.
[L] Bending the welding clamp through the main harness.
[M] To the thermo unit. Pass through the silencer.
[N] To clutch.
[O] To throttle position sensor. Pass the clamp of the bridge plate with the main harness.
This branch point of the [P] harness puts the main harness and the throttle position sensor lead wire
into the bridge plate clamp behind this clamp.
[Q] Fix C. D. I Magnetized wire, side stand switch lead wire, rear stop switch lead wire to panel 4 with
shrock band. Cut the remainder of the band. (Within 2 mm)
Pass through [R] clamp.
[S] Through the frame and muddgard.
[T] Handle switch Lid wire right and front stop switch Lid wire is clamped at the joint mouthpiece on
the left side of the front brake hose.
3-6 engine

Picture 1

Check mission oil quantity

Always inspect the car vertically at a flat place

Doing it in an upright position.

1. Perform the following checks.

Mission oil volume
Stop the engine after idling for 2 to 3 minutes and check the car to be vertical within 2 to 3 minutes
and check if it is within the range mark ② of the inspection window ①.

Time for replacement

Doing according to the table below.
Mission oil quantity · Designated oil
Normal replacement 900 ccm
Yamaha gear oil

Picture 2

Extraction of mission oil

1. Remove the following parts.
· Front underbody, yes
· Drain bolt ①
After warm up operation, tilt the car slightly to the right side and pull out the mission oil.

3-7

Picture 1

2. Assemble the following parts.

· Drain bolt
· Kahosket
NEW gasket
Drain bolt
2.2 kgm
3. Remove the following parts 0
· Oil plug ①
· O ring ②
4. Inject a specified amount of mission oil.
5. Assemble the following parts.
· Ore league ①
· 0 ring ②
· Front anabo, de, y
3-7 Picture 2, 3, 4

Inspection of carburetor
Carburetor full open check
1. Remove the following parts.
· Front under body 2
2. We will hold a late night meeting.
· Full open inspection
When the throttle is fully opened, check that the center of the inspection window ① of the
carburetor matches the center of the · mark of the piston valve.
Mismatch → Adjust
3. Make the following adjustments.
Adjust all questions
Lo loosen Kunat ① and adjust with Ajyasuta ②.
4. Assemble the following parts.
· Front under hoist, dead, 2

Inspection of throttle cable pool play

1. Perform the following checks.
· Slip y Torque grip tip amount of play on the outer periphery ①

[Box] Throttle grip Tappa play amount on the outer periphery 4 to 6 mm

Other than regulated value → Adjust

2. Make the following adjustments.

· Throttle cable play amount
Loosen the locker y ① and adjust it with the adjuster ②.
3-8 Idling adjustment

1. Remove the following parts

Front under body

2. Set the following equipment.

Engine tachometer ①
[Box] Engine tachometer 90890-03113

Set the engine tachometer to high tension code.

3 Confirm the following.

Water temperature gauge pointer ①
Start the engine and warm up until the pointer of the water temperature gauge ② is in the position
shown in the figure.

4. Make the following adjustments.

· Standard idling speed Throttle Stop Screw ① to match the standard idling speed, throttle grip a
few times to set the idling speed to change without standing.

[Box] Standard idling speed 1250 rpm

Inspection of oil pump matching mark

[Picture 4]

1. Remove the following parts.

· Front underbody. A

2. Make the following checks.

Check the oil mark. Check the engagement mark When the main switch is set to [ON] and the valve is
made to perform one cycle (position of the whole valve of the valve) When checking the throttle all
the time, check whether the pulley end face ① and the scribe line ② are in agreement .
Mismatch → Adjust

3. Make the following adjustments.

· Adjustment of oil pump matching mark
Loosen the lock nut and adjust.
3-9 Oil pump worker pulled out
1. Remove the following parts.
· Front under body 2
· Bleeder bolt ①
2. Remove the oil from the bleeder hole until the oil containing bubbles does not come out.

[Box] · Go to the oil tank after you oyed.

· Cover the lower part of the oil pump with waste cloth etc.
· The oil attached to the engine is cleared.

3. Assemble the following parts 0

· Breed Dubbo, Rut
· Front underbody. ²

3-10 Recovery tank water quantity check

1. Perform the following checks.

Recovery tank water quantity
Check the water level in the middle of the FULL level ② and the LOW level ③ of the recovery tank
①.
LOW level or lower → FULL-LOW level Supply tap water to the middle.

[BOX] Do not use natural water with well water (hard water) or salt, use water from the tap water to
replenish.

[BOX] You can not enter more than the FULL level
3-11 Change of cooling water

· Immediately after the engine stops, coolant is hot, so replace the coolant after the engine has
cooled down.
· Do not remove the radiator cap when it seems that the cooling water is 1000 C or more. When
unavoidably removing it, cover it with a thick cloth like a towel and slowly remove it.
· When cooling water is applied to the car, wash it with water.

L. Remove the following parts.

· Front anabo, de, y

2. Remove the following parts.

· Recovery tank ①
· Breather pipe ②
Remove the recovery tank, remove the breather nozzle on the side of the recovery tank, and remove
the cooling water in the recovery tank.

3. Remove the following parts.

Drain bolt ①
Striptease 2
· Radiator cap 3
Slowly remove the radiator cap, cool down the water
.

[BOX]
· Remove the radiator cap after removing the drain bolt.
· The cooling water can not completely escape unless the car is made vertical at a flat place.

4. Inject the tap water from Rasaieta and wash the inside of the radiator.
3-12 Change of cooling water [continued]

5. Assemble the following parts.

· Drain bolt ①
· Gasket ②

Drain bolt
1. 6 kgm

[NEW] Gasket

6. {Fulfillment of decree p.
· Yamaha genuine long life coolant ①
· Tap water ②
Mix Yamaha genuine long life coolant and tap water at a 1: 1 ratio to make cooling water.

7. Inject coolant slowly into the radiator specified water surface ①.

8. Assemble the following parts.

· Radiator cap
· Rika / 'i' re-tank
· Breather, notebook

9. Start the engine.

10. Make the following checks.

· Stop the engine, the cooling water is stabilized at the specified water level
Check if it is.
Specified water surface or lower → Cooling water is replenished and the cooling water surface is
Perform until stable.
11 Inject the cooling water in the closed state during the FULL - LOW level of the recovery tank.

[Box]
Do not enter more than the FULL level.

12. Assemble the following parts.

· Front underbody
3-13 Inspection of the radiator tap cap
1. Remove the following parts.
· Air Scoop 1
.Stopper
· Radiator cap
2. Make the following checks.
· Radiator cap ①
· Packing ②
· Valve, valve seat ③
Crack, damage, presence or absence of packing crack, damage, deformation → exchange valve
Deformation of the valve seat, scratch mark, presence or absence of water scattering, dent mark →
exchange water burning → cleaning or interchange
3-15 Check and adjust the clutch

1. Perform the following checks.

. Amount of play at the clutch lever tip ①

[Box] Play amount of clutch lever distal end portion 10 to 15 mm

Other than regulated value → Adjust

2. Remove the following parts.

Front Underbody,
3. Make the following adjustments.
· Loosen the lock nut ① and adjust with the adjuster ②.
(Symbol adjustment is done on the lever side.)
4. Check the operation of the clutch after adjustment.
6-1 Carburetor

[Box] Component parts

① Thermo sensor assembly

② carburetor assembly 2
③ Filter 1
④ Carburetor Ass'yl
⑤ Choke lever Comp
⑥ Starter cap
⑦ Starter case
⑧ Cap top
⑨ Connector
⑩ Bracket
⑬ Pilot screw
⑫ Piston valve
⑬ float
⑭ Float Champa
⑬ float arm
⑩ Float pin
⑬ Pulp sheet assembly
⑬ Main Jet
⑩ Ni-dollar jet
⑫ Pilot jet
⑫ Jettnyi Dollar
⑫ Jet holder
⑫ Starter set
⑫ Throttle lever
⑫ Plate
6-3 Disassembly of carburetor

The throttle position sensor is absolute

Do not remove it.
1. Remove the following parts 0
· Each hose, pipes
2. Following sound 1; Remove item O
· Upper plate ①
· Low plate ②
· Shuttle 3
3. Remove the following parts.
· Mixing champagne ①
· Cable connecting screw ②
· Circlip③
· Shaft ④
· Spring ⑤
·bracket
4. Remove the following parts 0
. Cable connector ①
· Needle set screw ②
· Two-dollar set

6-4

5. Remove the following parts.

· Front Chamber Body
6. Remove the following parts.
· Cap ①
7. Remove the following parts.
Float ①
·Valve seat assembly②
8. Remove the following parts.
. Main Jet ①
· Main nozzle ②
· Pilot jet ③
· Power jet ④
9. Remove the following parts.
. Starter plunger ①
10. Remove the following parts.
. Plunger ①
· Spring ②
· Starter cable ③
- 0 ring ④
6-5 Inspection of carburetor
1. Perform the following checks.
· Mixing body
· Float chamber body
Check the presence or absence of each passage.
In other words → cleaning through air

[BOX] Do not sweep through etc.

2. Make the following checks.

Main jet ①
· Jettini dollar ②
· Pilot jet ③
Check the passage, that is, whether there is damage.
That is what it is → cleaning through the air.
Damaged one → exchange

[BOX] Do not clean through wires etc.

3. Make the following checks .
· Valve seat ①
· Needle valve ②
Check for damage, stepped wear.
Damaged, with stepped wear → Interchange
6-6 Inspection of carburetor [continued]

4. Make the following checks .

.float
Check for damage.
Damaged one → exchange
5. Make the following checks.
- Starter Jet
Check the presence or absence of it.
In other words → cleaning through air

[BOX]
· Since the starter jet is press fitted
Removal is not possible.
· Do not clean with wire or the like.

6. Make the following checks 0

. Piston valve ①
· Jettini dollar ②
Check for damage.
Damaged one → exchange

7. Make the following checks O

- Plungerr
Check for damage.
Damaged one → exchange
6-7 Assembling the carburetor

1. Assemble the following parts.

. Main nozzle ①
. Main Jet ②
· Pilotage ③
2. Assemble the following parts O
· Needle valve ①
· Float pin ②
· Arm ③
Install the needle valve on the valve seat.
3. Assemble the following parts 0
· Valve seat assembly 1
Float ②
4. Do the following checks.
- Simple oil surface dimension (H dimension)

[BOX] Inspect a float and check the position where the tip of the river, the needle valve and the arm
slightly touch. (Check both sides to the same value.)

[BOX] Simple oil surface dimension (H dimension) 18.9 - 20. 9 mm

Other than regulated value → Adjust

5. Make the following adjustments.

Simple Oil Surface Dimensions
Adjust by bending arm ①.
6-8 Assembling the carburetor continued

6. Assemble the following parts.

· Cap ①
7. Assemble the following parts.
. Float chamber
8. Assemble the following parts.
. Plunger ①
· Spring ②
· O Ring③
· Starter cable ④
9. Assemble the following parts.
. Piston valve ①
· Needle set ②
Nibble connector ③
9. Assemble the following parts.
. Piston valve ①
· Needle set ②
· Nibble connector ③
10. Assemble the following parts.
Piston bulb, 'Ass'y 1
11. Assemble the following parts.
Spring ①
· Shaft ②
· Cable connecting screw ③
Slide the spring into the mixing chamber and let the shaft say the car once, align the holes of the
shaft with the screws of the shaft and fit and tighten the cable connection.
6-9 Assembling the carburetor continued

12. Assemble the following parts.

· Nylon washer ①
· Circlip ②
13. Assemble the following parts.
· Mixing chamber top
· Bracket
14. Do consolidation.
· Slot shafts ①
·Throttle stop screw front and throttles
Align and fit the stopper portion of the torlev lever.
15. Temporarily tighten the following parts
Shaft ①
· Color ②
16. Assemble the following parts.
· Upper plate
· Lower plate
17. Tighten the shaft.
[NOTE] The Throttle slides react on missalignment of the two throttleshafts. Double check the full
closed and full open position of the throttle slides. If you have a missalignment of both slides ie. left
falls behind. Loosen the connecting screw on the top bracket and shift the carbs towards each other
and slightly tighten the screw. Find synchronity at Full closed position again [14] and check
synchronity at WOT again. If there is still a missalignemnt repeat until both slides are within [0,5mm]
18. Assemble each hose.

6-10/11 Assembling the carburetor

1. Assemble the following parts.

· Throttle cable
2. Assemble the following parts.
· Carburetor
3. Make the following connections.
·Throttle position sensor lead tightening coupler
4. Assemble the following parts.
·Fuel pipe①
· Hose ②
5. Assemble the following parts.
. Starter case ①
6. Keep below sound 1 item.
· Silencer ①
-hose
7. Assemble the following parts.
· Fuel hose
· Negative pressure pipe
· Radiator
· Front underbody
6-11 Inspection of fuel level

1. Remove the following parts.

Front underbody
2. Assemble the following parts.
- Fuel level gauge ①
Installing on the drain outlet.
3. Do the following checks.
· Fuel level ②
Loosen the reference plug and read the oil level according to the mating surface of the float chamber
body.
[BOX] Fuel level 5 to 7 mm
Adjustment other than specified value → Adjust (bend arm to adjust)
8-27-28 Oil level warning light system check

Inspection of oil level warning light

1. Remove the following connections.

· Oil level warning lamp coupler
2. Do the following checks.
· Check the continuity of terminal listening.
Oil Level Warning Light Coupler ①
Tester red lead wire ②
Tester black lead wire ③

Inspection of coupler, connector, wire harness

1. Perform the following checks .
· The play of the coupler, connector connection (gruel), dirty
Yes, the presence of rust
With play → correction
There are dirt, rust etc. → Cleaning
2. Do the following checks.
· Whether wire harness is disconnected
Those with disconnection → Correction or exchange

Inspection of oil level gauge

L. Remove the following parts.
· Front Underbody
2. Remove the following items.
Oil level gauge ①
3. Do the following connection
· Oil level gauge ①
.12 V power supply 2
· Pilot lamp (3.4 V) ③
4. Do the following checks.
· Check the oil level gauge upside down and lit with the pilot lamp, with a clear light.
A. When the float is at the lowest position (A)
· Pilot lamp lights up - - - - - Good
· Pilot lamp does not light - - Fault
Replace the oil level gauge for defective ones.
B. When the oil level gauge is reversed (when the float is at the top)
· Pilot lamp lights up - - - - Defective
· Pilot lamp does not light - - Good
8-31 YP.V.S system point check

Servomotor inspection
1. Perform the following checks.
· Operation, points, inspection
When the main switch is turned on, pulley 1
Check if 1 cycle operation.
It works → good.
Does not operate → Servomotor single unit inspection

2. Make the following checks.

· Single inspection (Do remove after removing the fuel tank.)
· Servomotor coupler ①
· Lead wire from battery [+] ②
· Lead wire from battery [-] ③

What does not work → Servo motor change

Inspection of coupler, connector, wire harness
1. Points below + eat.
· Coupler, connection playing sound 15 (play), dirty
Yes, the presence of rust
With play → correction
There are dirt, rust etc. → Cleaning
2. Make the following checks.
· Presence or absence of 1 fold line of wire harness
Those with disconnection → Correction or exchange