Manual Servicio FZ-16 PDF

SERVICE MANUAL
FZ-16
21C-F8197-E0
FZ-16
SERVICE MANUAL
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
INDIA YAMAHA MOTOR PVT. LTD.
is expressly prohibited.
NOTICE
This manual was produced by IYM. primarily for use by IYM dealers and their qualified mechanics. It is
not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this
book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of
mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted
by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
India Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized IYM dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death to the
vehicle operator, a bystander or a person checking or repairing the vehicle.
CAUTION : A CAUTION indicates special precautions that must be taken to avoid damage to the
vehicle.
NOTE : A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out
with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a
disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described
sequentially.
3 Clutch Hub Holder

YSST-733 7
4
5
6
2
SYMBOLS 1. Serviceable with engine mounted
The following symbols are used in this manual for 2. Filling fluid
easier understanding. 3. Lubricant
4. Special tool
NOTE:
5. Tightening torque
The following symbols are not relevant to every
6. Wear limit, clearance
vehicle.
7. Engine speed
8. Electrical data
9. Engine oil
1 2 3
10. Gear oil
11. Molybdenum disulfide oil
12. Brake fluid
13. Wheel bearing grease
14. Lithium-soap-based grease
4 5 6 15 Molybdenum disulfide grease
16. Silicone grease
17 Apply locking agent (LOCTITE®).
18 Replace the part with a new one.
T.
R.
7 8
9 10
E G
11 12
M BF
13 14
B LS
15 16
M S
17 18
LT New
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
CARBURETOR 6
ELECTRICAL SYSTEM 7
TROUBLESHOOTING 8
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER.......................................................1-1
ENGINE SERIAL NUMBER .......................................................................1-1
FEATURES .................................................................................................1-2
LCD METER.................................................................................1-2
IMPORTANT INFORMATION ..........................................................................1-3

PREPARATION FOR REMOVALAND DISASSEMBLY...............................1-3
REPLACEMENT PARTS............................................................................1-3
GASKETS, OIL SEALS AND O-RINGS ......................................................1-3
LOCK WASHERS/PLATES AND COTTER PINS........................................1-3
BEARINGS AND OIL SEALS......................................................................1-4
CIRCLIPS...................................................................................................1-4
CHECKING THE CONNECTIONS ..................................................................1-5
SPECIAL TOOLS ............................................................................................1-6

IDENTIFICATION
IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER (FRAME

NO.)
The vehicle identification number “1” is stamped
into the frame.
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
crankcase.
NOTE:
Designs and specifications are subject to change
without notice.
1-1
FEATURES
LCD METER
1 2
SELECT
1. LCD Meter
2. “SELECT” button
The LCD Meter is equipped

with the following:
l a speedometer (which shows the riding spe-
ed)
l an odometer (which shows the total distance
traveled)
l one tripmeter (which show the distance
traveled since they were last set to zero)
l a fuel meter (shows the fuel level available in
the fuel tank)
NOTE
Be sure to turn the key to “ON” before using
the “SELECT” button.
ODOMETER & TRIP METER MODE

A brief push (less than one second) on the
“SELECT” button switches the display between
the odometer & Trip meter mode.
Fuel meter
1
1. Fuel meter
The fuel meter indicates the amount of fuel in the

fuel tank. The display segments of the fuel meter
disappear towards “E” (Empty) as the fuel level
decreases. When the last fuel meter segment
starts flashing, refuel as soon as possible.
1-2
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
2. Use only the proper tools and cleaning parts and bearings and lubricate the oil
equipment. seallips with grease.
Refer to “SPECIAL TOOLS” on page 1-8.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mated”
through normal wear. Mated parts must always
be reused or replaced as an assembly.
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates “1”
and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassembly.
This will speed up assembly and allow for the
correct installation of all parts.
5. Keep all parts away from any source of fire.
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended
by Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-3
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals “1”, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
CAUTION :
Do not spin the bearing with compressed air
because this will damage the bearing
surfaces.
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip “1”, make sure the sharp-
edged corner “2” is positioned opposite the thrust
“3” that the circlip receives.
1-4
CHECKING THE CONNECTIONS
CHECKING THE CONNECTIONS NOTE:
Check the leads, couplers, and connectors for • If there is no continuity, clean the terminals.
stains, rust, moisture, etc. • When checking the wire harness, perform
steps (1) to (3).
1. Disconnect: • As a quick remedy, use a contact revitalizer
• Lead available at most part stores.
• Coupler
• Connector
2. Check:
• Lead
• Coupler
• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several
times.
3. Check:
• All connections
Loose connection → Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend it up.
4. Connect:
• Lead
• Coupler
• Connector
NOTE:
Make sure all connections are tight.
5. Check:
• Continuity
(with the multimeter)
1-5
SPECIAL TOOLS
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the
appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or
improvised techniques.
Tool name/Tool No. Illustration
Tappet screw holder

YSST-706
This tool is used to adjust the valve clearance by tappet

adjusting screw
Tappet adjusting socket

YSST-806A
This tool is used to loosen and tighten tappet adjusting nut.
Feeler gauge
YSST-815
This tool is used to adjust the valve clearance

in an engine
Rear shock absorber adjuster

YSST-821
This tool is used to measure the preload of rear shock

absorber
Magneto holder
YSST-601B
This tool is used to hold the magneto when removing

or installing the magneto securing Nut and Primary
Drive Gear Nut
Magneto puller
YSST-628
This tool is used to remove the magneto with the help of

magneto holder.
1-6
SPECIAL TOOLS
Crank Shaft Installing Tool with Spacer

(a) (b)
(a) YSST-266
(b) YSST-267
These tools are used for installation of Crank Shaft.
Crankshaft removing tool

YSST-265
This tool is used to remove the Crank Shaft from

the Crank Case.
Clutch hub holder

YSST-733
This tool is used to hold the Clutch Hub while

removing or installing Clutch Main Shaft Nut.
Timing light
This instrument is used to check the ignition timing.
Compression gauge
This instrument is used to measure the engine

compression.
Scraper
YSST-612
This tool is used for scraping the sealent from

Crankcase joining surface.
Valve spring compressor

YSST-603
This tool is used to remove and install Valve & Spring

Assemblies.
1-7
SPECIAL TOOLS
Valve spring compressor attachment

YSST-803A
This tool is used to remove and install Valve & Spring

using YSST 603.
Vacuum/pressure pump gauge set
This instrument is used to offer the vacuum to air

induction system for checking.
Steering nut socket

YSST-721
This tool is used to loosen and tighten the steering

nut.
T-handle
YSST-813
This tool is used to hold the TFF plunger for loosening

and tightening of Hex Socket Head Bolt
TFF Oil Seal Installation Tool

YSST-875
This tool assists to install the TFF Oil Seal.
Ignition checker
This instrument is used to check the effficiency of

ignition at spark plug.
1-8
SPECIAL TOOLS
Multimeter
This instrument is used to check the electrical circuits

or components.
Yamaha bond No. 1215
This adhesive is used on mating surfaces while assem-

bling Crankcase#1 and #2.
LOCTITE
Three Bond 1322
This adhesive is used to offer extra strength to torx screw

on tightening.
Piston base
YSST-604
This tool is needed to support the piston while installing

Cylinder.
Center plug spanner

YSST-625
This tool is used to remove/install the Center plug from

Crank case Cover#1 (L.H.)
1-9
SPECIFICATIONS
GENERAL SPECIFICATIONS ..........................................................................2-1
ENGINE SPECIFICATIONS .............................................................................2-2
CHASSIS SPECIFICATIONS............................................................................2-9
ELECTRICAL SPECIFICATIONS ..................................................................2-12
TIGHTENING TORQUES ...............................................................................2-14

GENERAL TIGHTENING TORQUE SPECIFICATIONS..........................2-14
ENGINE TIGHTENING TORQUES..........................................................2-16
CHASSIS TIGHTENING TORQUES........................................................2-19
LUBRICATION POINTS AND LUBRICANT TYPES .......................................2-21

ENGINE...................................................................................................2-21
CHASSIS.................................................................................................2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS.......................................2-24

ENGINE OIL LUBRICATION CHART ......................................................2-24
LUBRICATION DIAGRAMS ....................................................................2-25
CABLE ROUTING ..........................................................................................2-27

GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model 21C1
Dimensions
Overall length 1973 mm
Overall width 770 mm
Overall height 1045 mm
Seat height 790 mm
Wheelbase 1334 mm
Ground clearance 160 mm
Minimum turning radius 2340 mm
Weight
With oil and fuel 135.0 kg
Maximum load 195.0 kg
2-1
ENGINE SPECIFICATIONS
Engine
Engine type Air cooled 4-stroke, SOHC
3
Displacement 153.0 cm
Cylinder arrangement Forward-inclined single cylinder
Bore x stroke 58.0 x 57.9 mm
Compression ratio 9.50 :1
Compression pressure (at sea level) 1200 kPa
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 12.0 L
Reserve capacity 1.4 L
Engine oil
Lubrication system Wet sump
Type SAE20W40
Recommended engine oil grade YAMALUBE (Grade-SG)
Engine oil quantity
Periodic oil change 1.00 L
Total Amount 1.20 L
Oil filter
Oil filter type Paper
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.15 mm
Limit 0.20 mm
Outer-rotor-to-oil-pump-housing clearance 0.13–0.19 mm
Limit 0.15 mm
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm
Limit 0.15 mm
2-2
Spark plug (s)

Manufacturer/model NGK / CPR8EA-9
Spark plug gap 0.8–0.9 mm
Cylinder head
Volume 13.40–14.00 cm³
Warpage limit 0.03 mm
Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
Intake A 31.342 - 31.442 mm
Limit 31.342 mm
Intake B 25.166 - 25.266 mm
Limit 25.136 mm
Exhaust A 31.110 - 31.210 mm
Limit 31.080 mm
Exhaust B 25.096 - 25.196 mm
Limit 25.066 mm
Camshaft runout limit 0.03 mm
2-3
Timing chain
Model SILENT CHAIN
Tensioning system Automatic
Rocker arm/rocker arm shaft

Rocker arm inside diameter 9.985–10.000 mm
Limit 10.030 mm
Rocker arm shaft outside diameter 9.966–9.976 mm
Limit 9.950 mm
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.08–0.12 mm
Exhaust 0.12–0.16 mm
Valve dimensions
Valve head diameter A (intake) 27.90–28.10 mm
Valve head diameter A (exhaust) 23.40–23.60 mm
A
Valve face width B (intake) 1.538–2.138 mm
Valve face width B (exhaust) 1.538–2.138 mm
Valve seat width C (intake) 0.90–1.10 mm

Valve seat width C (exhaust) 0.90–1.10 mm
Valve margin thickness D (intake) 0.50–0.90 mm

Valve margin thickness D (exhaust) 0.50–0.90 mm
Valve stem diameter (intake) 4.975–4.990 mm

Limit 4.950 mm
Valve stem diameter (exhaust) 4.960–4.975 mm
Limit 4.935 mm
Valve guide inside diameter (intake) 5.000–5.012 mm
Limit 5.042 mm
Valve guide inside diameter (exhaust) 5.000–5.012 mm
Limit 5.042 mm
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm
2-4
Limit 0.080 mm
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm
Limit 0.100 mm
Valve stem runout 0.010 mm
Valve spring
Free length (intake) 39.40 mm
Limit 37.40 mm
Free length (exhaust) 39.40 mm
Limit 37.40 mm
Installed length (intake) 34.50 mm
Installed length (exhaust) 34.50 mm
Spring rate K1 (intake) 35.08 N/mm
Spring rate K2 (intake) 44.40 N/mm
Spring rate K1 (exhaust) 35.08 N/mm
Spring rate K2 (exhaust) 44.40 N/mm
Installed compression spring force (intake) 160–184 N
Installed compression spring force (exhaust) 160–184 N
Spring tilt (intake) 2.5°/1.7 mm
Spring tilt (exhaust) 2.5°/1.7 mm
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Cylinder
Bore 58.000–58.010 mm
Taper limit 0.05 mm
Out of round limit 0.05 mm
Piston
Piston-to-cylinder clearance 0.020–0.035 mm
Limit 0.15 mm
Diameter D 53.970–53.985 mm
2-5
H
D
Offset 0.25 mm
Offset direction Intake side
Piston pin bore inside diameter 15.002–15.013 mm
Limit 15.043 mm
Piston pin outside diameter 14.995–15.000 mm
Limit 14.975 mm
Piston ring
Top ring
Ring type Barrel
Dimensions(B x T) 0.80 x 2.30 mm
B
T
End gap (installed) 0.10–0.25 mm

Limit 0.40 mm
Ring side clearance 0.030–0.065 mm
Limit 0.100 mm
2nd ring
Ring type Taper
Dimensions (B x T) 0.80 x 2.40 mm
B
T

Limit 0.40 mm
Ring side clearance 0.020–0.055 mm
Limit 0.100 mm
Oil ring
Dimensions (B x T) 1.50 x 2.25 mm
B
T
2-6
Connecting rod
Small end inside diameter 14.090–15.028 mm
Big end inside diameter 36.000-36.009 mm
Crankshaft
Width A 47.95–48.00 mm
Runout limit C 0.030 mm
Big end side clearance D 0.110–0.410 mm
Balancer
Balancer drive method Gear
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 10.0–15.0 mm
Friction plate thickness 2.90–3.10 mm
Wear limit 2.80 mm
Plate quantity 4 pc
Clutch plate thickness 1.85–2.15 mm
Plate quantity 3 pcs
Warpage limit 0.20 mm
Clutch spring free length 41.60 mm
Minimum length 40.60 mm
Spring quantity 4 pcs
Push rod bending limit 0.500 mm
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system spur gear
Primary reduction ratio 75/22 (3.409)
Secondary reduction system Chain drive
Secondary reduction ratio 40/14 (2.857)
Operation Left foot operation
Gear ratio
1st 38/14 (2.714)
2nd 34/19 (1.789)
3rd 29/22 (1.318)
4th 23/22 (1.045)
5th 21/24 (0.875)
2-7
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork thickness 4.76–4.89 mm
Decompression device
Device type Auto Decompression
Air filter
Air filter element Dry element
Carburetor
Type x Quantity BS26x1
ID Mark 21C110
Main jet #112.5
Main air jet 0.9
Jet needle 4D1Z11
Needle jet P-1M
Pilot outlet 0.8
Pilot jet # 15
Pilot screw turns out 3-1/4
Valve seat size 1.5
Starter jet 1 # 35
Starter jet 2 0.7
Throttle valve size 1.25
Idling condition
Engine idling speed 1300–1500 r/min
0
Oil temperature 75.0–85.0 C
CO% 2.0– 6.0
Intake vacuum 27.9-33.3 kPa
0
Plug seat temperature 110.0-130.0 C
Oil filter type Paper
Throttle cable free play 3.0–5.0 mm
2-8
CHASSIS SPECIFICATIONS
Chassis
Frame type Diamond
Caster angle 25.00 0
Trail 101.2 mm
Front wheel
Wheel type Cast wheel
Rim size 17 M/CXMT2.50
Rim material Aluminum
Wheel travel 130.0 mm
Radial wheel runout limit 1.0 mm
Lateral wheel runout limit 0.5 mm
Rear wheel
Wheel type Cast wheel
Rim size 17 M/C x MT 3.50
Rim material Aluminum
Wheel travel 120.0 mm
Radial wheel runout limit 1.0 mm
Lateral wheel runout limit 0.5 mm
Front tyre
Type Tubeless
Size 100/80-17M/C 52P
Manufacturer/model MRF / ZAPPER-X
Rear tyre
Type Tubeless
Size 140/60–R-17 M/C 63P
Manufacturer/model MRF / ZAPPER revz
Tyre air pressure (measured on cold tyres)
Front 200 kPa, 28psi
Rear 225 kPa, 33psi
Front brake
Type Single disc brake
Operation Right hand operation
2-9
Front disc brake

Disc outside diameter & thickness 267.0 x 4.0 mm
Brake disc thickness limit 3.5 mm
Brake disc deflection limit 0.10 mm
Brake pad lining thickness (inner) 4.5 mm
Limit 0.8 mm
Brake pad lining thickness (outer) 4.5 mm
Limit 0.8 mm
Master cylinder inside diameter 12.00 mm
Caliper cylinder inside diameter 28.0 mm x 2
Recommended fluid DOT 3 or DOT 4
Rear brake
Type Drum brake
Operation Right foot operation
Brake pedal free play 15-20mm
Rear drum
Drum brake type leading, trailing
Brake drum inside diameter 130.0 mm
Limit 131.0mm
Brake shoe lining thickness (inner) 4.0 mm
Limit 2.0 mm
Shoe spring free length 52.0 mm
Shoe spring free length 2 48.0mm
Steering
Steering bearing type Ball bearing
Center to lock angle (left) 39.0°
Center to lock angle (right) 39.0°
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 130.0 mm
Fork spring free length 254.4 mm
Collar length 221.0 mm
Installed length 246.4 mm
Spring rate K1 9.0 N/mm
Spring stroke K1 0–75.0 mm
Spring stroke K2 75.0–130.0 mm
Inner tube outer diameter 41.0 mm
Recommended oil Fork oil 10W or equivalent
Quantity 459.0 cm³
Level 87.0 mm
Rear suspension
Type Swingarm (monocross)
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 44.0 mm
2-10
Spring free length 187.0 mm

Installed length 178.0 mm
Spring stroke K1 0.0–20.0 mm
Swingarm
Swingarm end free play limit (axial) 2.4 mm
Drive chain
Type/manufacturer R428HBSX/LGB
Link quantity 128
Drive chain slack 30.0-40.0 mm
15-link length limit 191.5 mm
2-11
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system DC, CDI
Advancer type Digital
0
Ignition timing (B.T.D.C.) 7.0 /1400 r/min
0
Pickup coil resistance 192-288Ω at 20 C
Ignition coil
0
Primary coil resistance 0.32–0.48 Ω at 20 C
0
Secondary coil resistance 5.68–8.52 kΩ at 20 C
Spark plug cap

Material Resin
0
Resistance 5 kΩ at 20 C
AC magneto
Standard output 14.0 V 125 W @ 5000 rpm
0
Stator coil resistance 0.464-0.696 Ω at 20 C
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 13.7–14.7 V
Rectifier capacity 20.0 A
Battery
Model AB5L-B
Voltage, capacity 12 V, 5.0 Ah
Ten hour rate amperage 5.0 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage & qty.

Headlight 12 V, 35.0W/35.0X1
Tail/brake light 12 V, 5.0 W/21.0 W x 1
Front turn signal light 12 V, 10.0 W x 2
Rear turn signal light 12 V, 10.0 W x 2
Meter lighting L.E.D.
Auxiliary light 12V, 5.0Wx1
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
High beam indicator light LED
Engine trouble warning light LED
2-12
Electric starting system

System type Constant mesh
Starter motor
Power output 0.25 kW
Starter relay
Amperage 100 A
Coil resistance 3.51–4.29 Ω
Horn
Horn type Plane
Quantity 1 pc
Maximum amperage 1.5 A
Turn signal relay

Relay type Full Transistor
Built-in, self-canceling device No
Turn signal blinking frequency 70-100 cycles/min
Fuel sender
Sender unit resistance (full) 19.0–21.0 Ω at 20 °C
Sender unit resistance (empty) 137.0–143.0 Ω at 20 °C
Starting circuit cut-off relay

Coil resistance 90.0–110.0 Ω
Fuse
Fuse 15.0 A
2-13
TIGHTENING TORQUES
TIGHTENING TORQUES
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
This chart specifies tightening torques for
standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special
components or assemblies are provided for each
chapter of this manual. To avoid warpage, tighten
multi-fastener assemblies in a crisscross pattern
and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications require
clean, dry threads. Components should be at
room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening
A (nut) B (bolt) torques
Nm m·kg ft·lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-14
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES

Thread
Item Qty Tightening torque Remarks
size
Cylinder head bolt (inside) M8 4 22 Nm (2.2 m.kg, 16ft.Ib) E
Cylinder head bolt (chain side) M6 2 10 Nm (1.0 m.kg, 7ft.Ib) E
Spark plug M10 1 13 Nm (1.3 m.kg, 9ft.Ib)

Cylinder head cover bolt (duct) M6 10 10 Nm (1.0 m.kg, 7ft.Ib)
Cylinder head bolt (exhaust pipe) M8 2 15 Nm (1.5 m.kg, 11ft.Ib)
Balancer weight gear nut M10 1 45 Nm (4.5 m.kg, 33ft.Ib)
Adjusting screw nut M6 2 13 Nm (1.3 m.kg, 9ft.Ib)
Decompressor assembly bolt M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
Stopper guide 2 bolt M6 1 8 Nm (0.8 m.kg, 6ft.Ib)
Tensioner assembly bolt M6 2 9 Nm (0.9 m.kg, 7ft.Ib)
Stopper bolt M6 2 9 Nm (0.9 m.kg, 7ft.Ib)
Rocker shaft 2 bolt M5 2 8 Nm (0.8 m.kg, 6ft.Ib)
Oil pump assembly M5 2 4 Nm (0.4 m.kg, 3ft.Ib)
Oil drain plug M12 1 20 Nm (2.0 m.kg, 14ft.Ib)
Element cover bolt M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Element cover bolt M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
Gear cover bolt M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Mainfold bolt M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Air Filter Assembly bolt (frame) M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Pipe 2 Bolt M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Al system assembly bolt M6 1 7 Nm (0.7 m.kg, 5ft.Ib)
Muffler comp. nut (cyl. head side) M8 2 15 Nm (1.5 m.kg, 11ft.Ib)
Muffler comp. bolt M8 1 12 Nm (1.2 m.kg, 9ft.Ib)
(right side bottom)
Muffler comp. bolt M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
(left side bottom)
Muffler Assembly bolt M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
(Rr. upper side)
Crankcase bolt 1 & 2 M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Crankcase bolt 1 & 2 M6 4 10 Nm (1.0 m.kg, 7ft.Ib)
Crankcase bolt 2 M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Crankcase 1 Cover bolt M6 6 10 Nm (1.0 m.kg, 7ft.Ib)
Crankcase 1 Cover plug M14 1 3 Nm (0.3 m.kg, 2ft.Ib)
(Timing mark cap)
Crankcase 1 cover plug M32 1 3 Nm (0.3 m.kg, 2ft.Ib)
(crank center cap)
Chain case 1 cover screw M6 7 2 Nm (0.2 m.kg, 1ft.Ib)
Crankcase 2 cover bolt M6 11 10 Nm (1.0 m.kg, 7ft.Ib)
2-15
TIGHTENING TORQUES
Thread
size
Crankcase 1 & 2 Bolt M6 1 10 Nm (1.0 m.kg, 7ft.Ib) E
Kick crank assembly nut M12 1 50 Nm (5.0 m.kg, 36ft.Ib) E
Ratchet wheel guide bolt M6 2 12 Nm (1.2 m.kg, 9ft.Ib)

Starter clutch outer assembly bolt M6 3 14 (Nm 1.4 m.kg, 10ft.Ib)
Primary drive gear nut M12 1 60 (Nm 6.0 m.kg, 43ft.Ib)
Pressure plate 1 screw M6 4 8 Nm (0.8 m.kg, 6ft.Ib)
Push rod 1 nut M6 1 8 Nm (0.8 m.kg, 6ft.Ib)
Clutch boss nut M14 1 70 Nm (7.0 m.kg, 51ft.Ib)
Drive sprocket bolt M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
Plate cover screw M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Stopper lever assembly bolt M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
Shift cam assembly screw M6 1 12 Nm (1.2 m.kg, 9ft.Ib)
Stator assembly bolt M6 3 10 Nm (1.0 m.kg, 7ft.Ib)
Pick up (stator assembly) bolt M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Rotor assembly nut M12 1 70 Nm (7.0 m.kg, 51ft.Ib)
Neutral switch assembly M10 1 20 Nm (2.0 m.kg, 14ft.Ib)
Starting Motor assembly bolt M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
2-16
TIGHTENING TORQUES
Cylinder head tightening sequence:
Magneto cover tightening sequence:

7 8
1,6
5
9
4
3
2,10
Clutch cover tightening sequence:
1,9
8 10
11
7 12
13
5
4 3,15 2,14
2-17
TIGHTENING TORQUES
Crankcase tightening sequence:
A B
14
1,6 7
8 15
5 9
2,12
4
10
3,13 11
A. Left crankcase
B. Right crankcase
2-18
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES

Thread
size
Crown handle bolt M8 2 16 Nm (1.6 m.kg, 12ft.Ib) E
Crown handle nut M22 1 110 Nm (11.0 m.kg, 80ft.Ib) E
Steering shaft and ring nut (Initial) M25 1 33 Nm (3.3 m.kg, 24ft.Ib)
Steering shaft and ring nut (final) M25 1 22 Nm (2.2 m.kg, 16ft.Ib)
FR. Fender comp. M6 1 6 Nm (0.6 m.kg, 4ft.Ib)
Steering lock/Main switch M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Head light stay M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Lever holder assy. M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Handle switch screw M5 2 10 Nm (1.0 m.kg, 7ft.Ib)
Meter and head light stay screw M5 3 1 Nm (0.1 m.kg, 1ft.Ib)
No. plate stay bolt M5 2 4 Nm (0.4 m.kg, 3ft.Ib)
Head light bolt M6 3 7 Nm (0.7 m.kg, 5ft.Ib)
Head light side cover M4 4 2 Nm (0.2 m.kg, 1ft.Ib)
Front Engine mounting M10 2 55 Nm (5.5 m.kg, 40ft.Ib)
Engine mounting front bracket bolt M8 2 55 Nm (5.5 m.kg, 40ft.Ib)
Engine mounting nut stay bolt M8 3 30 Nm (3.0 m.kg, 22ft.Ib)
Pivot shaft nut M12 1 46 Nm (4.6 m.kg, 33ft.Ib)
Rear cushion lower nut M12 1 60 Nm (6.0 m.kg, 43ft.Ib)
Rear cushion upper nut M12 1 40 Nm (4.0 m.kg, 29ft.Ib)
Bar tension and rear arm M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
Fuel cock screw M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Ignition coil bolt M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Side cover bolt M6 1 2 Nm (0.2 m.kg, 1ft.Ib)
Battery Box Bolt M6 3 7 Nm (0.7 m.kg, 5ft.Ib)
Fuel sender unit bolt M5 4 4 Nm (0.4 m.kg, 3ft.Ib)
Rectifier, regulator nut M6 1 7 Nm (0.7 m.kg, 5ft.Ib)
Seat lock assy. M6 1 4 Nm (0.4 m.kg, 3ft.Ib)
Side Cover Bolt M6 4 2 Nm (0.2 m.kg, 1ft.Ib)
Seat Handle bolt M8 4 25 Nm (2.5 m.kg, 18ft.Ib)
Tail light assy. M5 2 2 Nm (0.2 m.kg, 1ft.Ib)
Rear reflector nut M5 1 2 Nm (0.2 m.kg, 1ft.Ib)
Fuel tank top cover screw M5 10 2 Nm (0.2 m.kg, 1ft.Ib)
Fuel tank side cover screw M5 2 2 Nm (0.2 m.kg, 1ft.Ib)
Guide air ½ and air shroud bolt M5 2 2 Nm (0.2 m.kg, 1ft.Ib)
Air shroud bolt M6 2 2 Nm (0.2 m.kg, 1ft.Ib)
Horn nut M6 1 7 Nm (0.7 m.kg, 5ft.Ib)
2-19
TIGHTENING TORQUES
Thread
size
Front wheel axle nut M14 1 60 Nm (6.0 m.kg, 43ft.Ib) E
Rear wheel axle nut M14 1 90 Nm (9.0 m.kg, 65ft.Ib) E
Sprocket wheel and clutch hub bolt M8 6 43 Nm (4.3 m.kg, 31ft.Ib)

Tension bar and brake shoe plate M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
Camshaft and lever cam shaft M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
Calliper bolt M10 2 35 Nm (3.5 m.kg, 25ft.Ib)
Disk brake bolt M8 6 30 Nm (3.0 m.kg, 22ft.Ib)
Master cylinder bolt M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Brake pedal and footrest assy. M10 1 30 Nm (3.0 m.kg, 22ft.Ib)
Footrest assy and frame bolt M8 2 35 Nm (3.5 m.kg, 25ft.Ib)
Sidestand nut M10 1 44 Nm (4.4 m.kg, 32ft.Ib)
Main stand nut M10 2 46 Nm (4.6 m.kg, 33ft.Ib)
Shift pedal nut M8 1 2 Nm (3.0 m.kg, 22ft.Ib)
Bracket side stand and frame nut M10 1 44 Nm (4.4 m.kg, 32ft.Ib)
Footrest bracket plate nut M6 2 8 Nm (0.8 m.kg, 6ft.Ib)
Shift arm installation nut M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
Rear brake switch nut M6 1 7 Nm (0.7 m.kg, 5ft.Ib)
2-20
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Lubricant
Oil seal lips LS
Bearings E
O-rings LS
Cylinder head bolts and washers E
Connecting rod big end thrust surface E
Piston, Piston rings, and cylinder inner surface E
Balancer driven gear inner surface E
Camshaft lobes M
Decompression cam E
Valve stem seal M
Valve stem (intake and exhaust) M
Valve stem ends (intake and exhaust) M
Rocker arm shaft E
Rocker arm inner surfaces M
Decompression lever pin M
Oil seal (clutch cover) E
Oil pump driven gear E
Oil pump rotors (inner and outer) E
Starter clutch idle gear thrust surface E
Starter clutch idle gear shaft E
Starter clutch gear inner surface and thrust surface E
Starter clutch rollers E
Clutch push lever E
Primary driven gear inner surface E
Clutch push rod (short and long) and ball E
Clutch boss nut and lock washer contact surface E
Transmission gears (wheel and pinion) and collar M
Shift forks and shift fork guide bar E
Shift drum E
Shift shaft E
2-21

Yamaha bond No.
Crankshaft position sensor/stator assembly lead grommet 1215 (Three Bond
No.1215®)
Yamaha bond No.
Crankcase mating surface 1215 (Three Bond
No.1215®)
Yamaha bond No.
Timing chain tensioner bolts 1215 (Three Bond
No.1215®)
2-22
CHASSIS
Front wheel oil seal lip LS
Front wheel axle outer surface LS
Speed sensor unit LS
Rear wheel drive hub oil seal lip LS
Rear wheel drive hub mating surface LS
Rear wheel axle outer surface LS
Rear wheel axle and nut threads LS
Brake pedal pivoting point S
Brake caliper bracket boots inner surface S
Throttle grip tube guide inner surface and throttle cable end LS
Clutch cable end at the clutch lever LS
Brake lever pivot bolt outer surface S
Steering head bearings and upper bearing cover lip LS
Steering head dust seal LS
Bolt and nut threads (relay arm and flame) LS
Bolt and nut threads (connecting rod and relay arm) LS
Bolt and nut threads (rear shock absorber and relay arm) LS
Bolt and nut threads (connecting rod and swingarm) LS
Bearing inner surface (relay arm and swingarm) LS
Oil seal lips (relay arm and swingarm) LS
Collars (relay arm and swingarm) LS
Pivot shaft and nut threads LS
Pivot shaft outer surface LS
Swingarm bushing outer surface LS
Swingarm dust cover lips LS
Sidestand pivoting point and metal-to-metal moving point LS
Footrest pivoting point LS
Passenger footrest pivoting point LS
Shift pedal pivoting point LS
Engine mounting bolts and nuts E
2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS
ENGINE OIL LUBRICATION CHART
6
1
1. Oil strainer
2. Oil pump
3. Oil filter element
4. Crankshaft
5. Camshaft
6. Main axle
7. Drive axle
2-24
LUBRICATION DIAGRAMS
2
A
7
1. Clutch push lever
2. Main axle
3. Drive axle
4. Crankshaft
5. Oil filter
6. Oil pump assembly
7. Oil strainer
A. To cylinder head
2-25
LUBRICATION DIAGRAMS
1. Camshaft
2. Crankshaft
3. Main axle
4. Drive axle
2-26
CABLE ROUTING
3 1 A 10
4
9 6 5
3 7
C
8 6
F G
11
2 12 5
2
R R C 8
1
A 4 7
5
4 13 D
6
2 14 11
3 9
1 B 9 D
R-R
12
B
H
1
I
2-27
CABLE ROUTING
1. Front brake hose

2. Throttle Cable
3. Front brake light switch lead
4. Right handlebar switch lead
5. Left handlebar switch lead
6. Clutch switch lead
7. Clutch cable
8. Starter cable
9. Main switch lead
10. Meter lead
11. LH Front turn signal lead
12. RH Front turn signal lead
13. Headlight lead
14. Pilot light lead
A. Pass through the guide in headlight stay RHS
B. Pass through the guide in headlight stay RHS
C. Pass through the guide in headlight stay LHS
D. Pass through the guide in headlight stay LHS
E. Hold with the clamp to headlight stay
F. Pass the RH Fr. turn signal lead through the guide
G. Pass the LH Fr. turn signal lead through the guide
H. Pass the wire harness, handle switches lead, sensor unit lead
through the guide in headlight stay
I. Sensor unit lead through guide in headlight stay
2-28
CABLE ROUTING
17
3 17 17
13 2
5
4 13
E-E B-B D-D C-C
1 A
3 2 4 B
C
5
F
E DC
B
14 S
15
S
J E
D C B
16
L
N
I M
D
6
G H M 7
11 8
F 2
E
10
9
13 14 11 2 12
13
14
16
15 16
12 6
L 2 15 S-S N 6
J M-M
2-29
CABLE ROUTING
1. Clutch cable
2. Overflow pipe
3. Throttle cable
4. Starter cable
5. Carburetor air bend
6. AC magneto generator lead
7. Wire minus lead
8. Battery breather hose
9. Carburetor drain hose
10. Fuel pipe
11. Horn lead
12. Connector cover
13. Wire harness
14. Sensor unit lead
15. Switch handle (LH) lead wire
16. Switch handle (RH) lead wire
17. AIS hose pipe
A. Clutch cable and Starter cable through the guide
B. Overflow pipe through flange in left of fuel tank
C. Throttle cable and Starter cable through the guide
D. Hold the AC Magneto generator assembly lead with the clamp to frame
E. Pass battery breather hose and carburetor drain hose through to hole in
joint hose
F. Pass the overflow pipe through the guide
G. Pass wire harness, sensor unit lead, handle switches lead through the
guide
H. Pass horn lead after overflow pipe is passed through the guide
I. Pass wire harness, sensor unit lead, handle switches lead through the
guide
J. Insert projection in connector cover to hole in frame
K. After wiring is connected, all the leads are encompassed by cover,
connecter. Naked leads not protrude from cover, connecter.
2-30
CABLE ROUTING
6 9
10
8
5 11
2 3
4
1
10
3
20
19 13
18
17
16
15
22
21
12
A A
14
15 A-A
2-31
CABLE ROUTING
1. LH Handle switch
2. Clutch switch lead
3. Clutch cable
4. LH Handle switch lead
5. Starter cable
6. Main switch lead
7. RH Handle switch lead
8. Brake hose
9. Front stop switch assembly lead
10. Throttle cable
11. RH Handle switch
12. Rear turn signal lead (LH)
13. Turn signal relay assembly
14. Tail light unit assembly lead
15. Rear turn signal lead (RH)
16. Seat lock cover
17. Seat lock cable
18. Starting circuit cut off relay
19. CDI unit assembly
21. Rear fender
22. Rear fender cover
A. Insert carburetor air bend in the hole of air filter assembly
B. Hold clutch and handle switch leads with clamp to handle bar
C. Hold front stop and handle switch leads with clamp to handle bar
D. Pass tail light assembly, both rear turn signal leads through to hole of rear
fender
E. Fix high tension cord and bend hose 1 by clamp
F. Fix clutch cable and vacuum sensing hose 1 by clamp
2-32
CABLE ROUTING
25 31
16
17 28
29
16 5
30
10
H-H K-K U-U T-T
30
25 1 31
24 27
A 18 19 B 10 C 23
21 26 22 E
U 5
T
U
T
K
16 6
P O
K
8
N 7
M
15 H
F
9
G
I
29 H
14 10
J
L 11
13 K 12
2-33
CABLE ROUTING
1. Throttle cable lead through to clamp in battery box.

2. Sensor unit lead G. Pass battery breather hose and carburetor
drain hose through to outside of engine.
3. Brake hose H. Pass battery breather hose and carburetor
4. Horn lead drain hose through to inside from here.
I. Hold plus lead and fuse holder assembly
5. HT lead lead to battery band.
6. Spark plug cap J. Pass wire harness through to hook in battery
7. Starting motor lead box.
K. Hold rectifier regulator assembly lead, wire
8. Starter relay lead harness and stop switch assembly lead with
9. Fuse holder assembly clamp to frame .
L. Pass wire harness through to backside of
10. Wire minus lead battery box.
11. Carburetor drain hose M. Pass wire harness through to slit of air filter
12. Battery breather hose cover.
N. Fit white marking of wire harness to right end
13. Starter relay assembly in battery box clamp.
14. Stop switch assembly O. Hold minus & fuse assy. plus lead with
battery band.
15. Battery
16. Wire harness lead
17. Regulator, Rectifier assembly lead
18. Air filter cover
19. Regulator, Rectifier assembly
21. Wire plus lead
22. AC Magneto generator assembly lead
23. Ignition coil
24. Ignition coil lead
25. Clutch cable
26. Throttle position sensor lead
27. Sender assembly lead
28. Battery box
29. Stop switch assy. lead wire
30. Vacuum sensing hose
31. Bend hose, AIS unit
A. Pass wire harness through to guide of air
filter assembly.
B. Pass wire harness, minus lead through to
backside hook in battery box.
C. Fit white marking of wire harness to clamp.
D. Fit clamp to rear end of engine bracket 1 of
frame .
E. Match clamp to white paint of vacuum
sensing hose 1.
F. Pass starting motor lead and starter relay
2-34
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................3-1
INTRODUCTION..................................................................................3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ............3-1
ENGINE ...........................................................................................................3-3
ADJUSTING THE VALVE CLEARANCE ..............................................3-3
ADJUSTING THE ENGINE IDLING SPEED.......................................3-4
CO MEASUREMENT & ADJUSTMENT ...............................................3-5
ADJUSTING THE THROTTLE CABLE FREE PLAY ............................3-6
CHECKING THE SPARK PLUG ...........................................................3-7
CHECKING THE IGNITION TIMING.....................................................3-7
MEASURING THE COMPRESSION PRESSURE................................3-8
CHECKING THE ENGINE OIL LEVEL..................................................3-9
CHANGING THE ENGINE OIL ...........................................................3-9
ADJUSTING THE CLUTCH CABLE FREE PLAY...............................3-10
CLEANING THE AIR FILTER ELEMENT.............................................3-11
CHECKING THE CARBURETOR JOINT
AND AIR FILTER CASE JOINT ...........................................................3-12
CHECKING THE CYLINDER HEAD BREATHER HOSE ....................3-12
CHECKING THE EXHAUST SYSTEM................................................3-12
CHECKING THE FUEL COCK FILTER...............................................3-13
CHASSIS .......................................................................................................3-14
ADJUSTING THE REAR DRUM BRAKE............................................3-14
CHECKING THE BRAKE FLUID LEVEL.............................................3-14
CHECKING THE FRONT BRAKE PADS.............................................3-15
CHECKING THE FRONT BRAKE HOSE............................................3-15
CHECKING THE REAR BRAKE SHOES............................................3-15
ADJUSTING THE REAR BRAKE LIGHT SWITCH..............................3-15
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...............................3-15
ADJUSTING THE DRIVE CHAIN SLACK ...........................................3-16
LUBRICATING THE DRIVE CHAIN ....................................................3-17
CHECKING AND ADJUSTING THE STEERING HEAD ......................3-18
CHECKING THE FRONT FORK.........................................................3-19
CHECKING THE TYRES....................................................................3-19
CHECKING THE WHEELS ................................................................3-20
CHECKING AND LUBRICATING THE CABLES .................................3-20
LUBRICATING THE CLUTCH LEVER................................................3-20
LUBRICATING THE BRAKE LEVER ..................................................3-21
LUBRICATING THE PEDALS............................................................3-21
LUBRICATING THE SIDESTAND.......................................................3-21
LUBRICATING THE REAR SUSPENSION.........................................3-21
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ..............3-21
TROUBLESHOOTING
ELECTRICAL SYSTEM.................................................................................3-22
CHECKING AND CHARGING THE BATTERY...................................3-22
CHECKING THE FUSE......................................................................3-22
REPLACING THE HEADLIGHT BULB................................................3-22
ADJUSTING THE HEADLIGHT BEAM ...............................................3-23
REPLACING THE AUXILIARY BULB...............................................3-23
REPLACING TAIL/BRAKE LIGHT BULB............................................3-23
REPLACING SIGNAL INDICATOR LIGHT BULB...........................3-24
PERIODIC MAINTENANCE
Periodic maintenance and lubrication chart

NOTE:
l All the checks must be performed as per periodic maintenance schedule (mentioned below) to retain
better performance of vehicle.
l Items marked with an asterisk should be performed by a IYM dealer as they require special tools, data and
technical skills.
ODOMETER READING (x 1000 km)

NO. ITEM CHECK OR MAINTENANCE JOB
1 3 6 9 12 15
1 * Fuel line • Check fuel hose for cracks or damage. √ √ √ √ √
• Check condition.
2 Spark plug • Clean and reset the gap
• Replace. Every 12000 km
3 * Valves • Check valve clearance.

√ √ √ √ √
• Adjust.
• Clean. √ √ √ √ √
4 * Air filter
element • Replace. √
Every 12000 km √
5 * Battery • Check Battery output voltage
• Check electrolyte / specific gravity √ √ √ √ √
• Check operation.
6 Clutch
• Adjust. √ √ √ √ √ √
• Lubricate Lever
• Check operation, fluid level and for fluid √ √ √ √ √ √

leakage.
7 * Front brake
• Replace brake pads. Whenever worn to the limit
• Check operation and Brake shoe wear
√ √ √ √ √ √
8 Rear brake
• Replace brake shoes. Whenever worn to the limit
9 * Brake lines • Check for cracks or damage. √ √ √ √ √
• Replace. Every 4 years
10 * Wheels • Check runout and for damage. √ √ √ √ √

• Check tread depth and for damage.
• Replace if necessary.
11 * Tyres • Check air pressure. √ √ √ √ √
• Correct if necessary.
12 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √ √
• Check operation and for excessive play. √ √ √ √ √ √

13 * Swingarm
• Lubricate with lithium-soap-based
Every 12000 km
grease.
14 Drive chain • Check chain slack, alignment and

condition.
Every 500 km and after washing the motorcycle or riding in the rain
• Adjust and thoroughly lubricate chain.
3-1
ODOMETER READING (x 1000 km)

NO. ITEM CHECK OR MAINTENANCE JOB
1 3 6 9 12 15
• Check bearing play and steering for √ √ √ √ √ √

roughness.
15 * Steering • Lubricate with lithium-soap-based
bearings grease. Every 12000 km
• Make sure that all nuts, bolts and screws

16 * Chassis √ √ √ √ √
fasteners are properly tightened.
17 Sidestand/ • Check operation.
Centerstand • Lubricate. √ √ √ √ √
18 * Front fork • Check operation and for oil leakage

√ √ √ √ √
19 * Shock absorber • Check operation and shock absorber for

oil leakage. √ √ √ √ √
assembly
• Change.
20 * Engine oil √ √ √ √ √ √
• Check oil level and vehicle for oil leakage.
21 Engine oil filter • Replace.

element √ Every 10000 km (on odometer)
22 Front and rear • Check operation

brake switches √ √ √ √ √ √
Moving parts and

• Lubricate. √ √ √ √ √ √
25 * cables
• Check operation and free play.
• Adjust the throttle cable free play if
Throttle grip housing necessary. √ √ √ √ √ √
26 * and cable • Lubricate the throttle grip housing and
cable.
• Check the air cut-off valve, reed valve,

Air induction and hose for damage.
27 * system √ √ √ √ √
• Replace any damaged parts if
necessary.
Lights, signals and • Check operation.

28 * switches • Adjust headlight beam (if necessary).
√ √ √ √ √ √
NOTE:
l The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l Hydraulic brake service
l Regularly check and, if necessary, correct the brake fluid level.
l Every two years replace the internal components of the brake master cylinder and caliper, and change the
brake fluid.
l Replace the brake hoses every four years and if cracked or damaged.
3-2
ENGINE
ssssssssssssssssssssssss
ENGINE a. Turn the crankshaft counterclockwise.
b. Align the TDC mark “a” on the magneto rotor
ADJUSTING THE VALVE CLEARANCE with the stationary pointer “b” on the magneto
The following procedure applies to all of the cover.
valves.
NOTE:
l Valve clearance adjustment should be made b
on a cold engine, at room temperature.
l When the valve clearance is to be measured or
adjusted, the piston must be at top dead center

(TDC) on the compression stroke.
1. Remove: a
l Seat
Refer to “GENERAL CHASSIS” on page 4-1. c. Check that the cam lobes are positioned as
l Fuel tank shown in the illustration.
Refer to “GENERAL CHASSIS” on page 4-2.
2. Disconnect:
l Air induction system hose
Refer to “AIR INDUCTION SYSTEM” on

page 6-9
3. Remove:
l Cylinder head cover
l Cylinder head cover gasket
Refer to “CYLINDER HEAD” on page 5-5 NOTE:

4. Remove: At this position, both the valves must have some
valve clearance.
l Timing mark accessing screw “1”
l Crankshaft end accessing screw “2”

d. Measure the valve clearance with a thickness
gauge “1”.
Out of specification → Adjust.
1
1
5. Measure:
l Valve clearance
Valve clearance (cold)

Intake 6. Adjust:
0.08-0.12 mm l Valve clearance
Exhaust
a. Loosen the locknut “1”.
0.12-0.16 mm
b. Insert a thickness gauge “2” between the end
of the adjusting screw and the valve tip.
3-3
ENGINE
2 8. Install:
lDowel
1 lCylinder head cover gasket New
l Cylinder head cover
Refer to “CYLINDER HEAD” on page 5-5.

9. Connect:
l Air induction system hose
Refer to “AIR INDUCTION SYSTEM” on

page 6-9.
c. Turn the adjusting screw “3” in direction “a” or 10.Install:
“b” until the specified valve clearance is ob- l Fuel tank
tained. l Side Cover
l Seat
a Refer to “GENERAL CHASSIS” on page 4-2.
b 3 ADJUSTING THE ENGINE IDLING SPEED
3 NOTE:
Prior to adjusting the engine idling speed, the air
filter element should be clean, and the engine
should have adequate compression.
1. Start the engine and let it warm up for several
minutes.
2. Install:
l Digital tachometer
Direction “a” (onto the spark plug lead)
Valve clearance is increased.
Direction “b”
Valve clearance is decreased.
Tappet screw holder

YSST-706
Tappet adjusting socket
YSST-806A
l Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica-
tion.
Locknut
13 Nm (1.3 m·kg, 9 Ib ·ft) 3. Check:
T.
R.
l Engine idling speed

d. Measure the valve clearance again. Out of specification → Adjust.
e. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust- Engine idling speed
ment steps until the specified clearance is 1300–1500 r/min
obtained.
4. Adjust:
7. Install: l Engine idling speed
l Crankshaft end accessing screw

(along with the O-ring New ) a. Turn the throttle stop screw “1” in direction
l Timing mark accessing screw “a” or “b” until the specified engine idling
speed is obtained.
(along with the O-ring New )
3-4
ENGINE
3. Check :
l Engine idling speed
If out of specification Ÿ adjust
Refer to “ADJUSTING THE ENGINE IDLING
SPEED” on page 3-4.
4. Insert :
l Sampling probe “2” of ‘CO’ tester
1 (calibrated) to the exhaust pipe “3” using
b a
suitable adapter “4”
Direction “a”
Engine idling speed is increased.
Direction “b”
Engine idling speed is decreased.
8. Remove:
‘CO’ density :
2.0 - 6.0 %
If out of specification Ÿ adjust

5. Adjust :
‘CO’ density through pilot screw
Adjustment Steps
Turn the Pilot Screw “5” in or out until the

specified ‘CO’ density is achieved.
Turning Out Ÿ ‘CO’ density Increases

9. Adjust: Turning In Ÿ ‘CO’ density Decareses
l Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA- l Reset idling speed as per specifications
BLE FREE PLAY” on page 3-6.
Throttle cable free play

3.0–5.0 mm
5
CO MEASUREMENT AND ADJUSTMENT’
1. Start the Engine and let it warm up by
running approximately 4 kms.
2. Attach :
l Tachometer to the Spark Plug lead
3-5
ENGINE
CAUTION: c. Tighten the locknut.

Do not disturb settings of the Carburetor if 1
the Engine performance is O.K.
l If required, must record the existing seting
(No. of turns) of the Pilot Screw.
l To counter check the setting of the Pilot
Screw, follow the ‘CO’ adjustment a
b
procedure.
l Ensure proper clamping of the blind plug
6. Adjust :
5
l Idling speed by Throttle Stop Screw “1”
Engine Idling R.P.M. NOTE:

1300 to 1500 RPM l If the specified throttle cable free play cannot be
obtained on the carburetor side of the cable,
use the adjusting nut on the handlebar side.
ADJUSTING THE THROTTLE CABLE FREE
l Keep the handlebar in straight position.
PLAY
NOTE: ssssssssssssssssssssssss
Prior to adjusting the throttle cable free play, the
Handlebar side
engine idling speed should be adjusted.
a. Slide back the rubber cover “1”
1. Check: b. Loosen the locknut “2”.
l Throttle cable free play “a” c. Turn the adjusting nut “3” in direction “a” or “b”
Out of specification → Adjust. until the specified carburetor cable free play is
obtained.
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.

3.0–5.0 mm
2. Adjust: b 3
l Throttle cable free play
ssssssssssssssssssssssss 1 a
2
Carburetor side
a. Loosen the locknut “1” on the accelerator ca- d. Tighten the locknut
ble. e. Slide the rubber cover to its original position.
b. Turn the adjusting nut “2” in direction “a” or “b” WARNING
until the specified throttle cable free play is After adjusting the throttle cable free play,
obtained. start the engine and turn the handlebar to the
right or left to ensure that this does not
Direction “a” cause the engine idling speed to change.
Throttle cable free play is increased.
Direction “b” ssssssssssssssssssssssss
Throttle cable free play is decreased.
3-6
ENGINE
CHECKING THE SPARK PLUG NOTE:

Before installing the spark plug, clean the spark
1. Disconnect: plug and gasket surface.
l Spark plug cap
2. Remove: 8. Connect:
l Spark plug cap
l Spark plug
CAUTION:
CHECKING THE IGNITION TIMING
NOTE:
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well Prior to checking the ignition timing, check the
with compressed air to prevent it from falling wiring connections of the entire ignition system.
into the cylinder. Make sure all connections are tight and free of
corrosion.
3. Check:
l Spark plug type (NGK / CPR8EA-9)
1. Remove:
l Timing mark accessing screw “1”
Incorrect → Change.
4. Check:
l Electrode “1”
Damage/wear → Replace the spark plug. 1

l Insulator “2”
5. Clean:
l Spark plug
(with a spark plug cleaner or wire brush)

6. Measure:
l Spark plug gap “a”
(with a wire thickness gauge)

Out of specification → Regap. Center plug spanner
YSST-625
Spark plug gap
0.8–0.9 mm 2. Connect:
l Timing light “1”
l Digital tachometer to HT lead.
Timing light
7. Install:
l Spark plug
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
R.
3. Check:
l Ignition timing
3-7
ENGINE
CAUTION:
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en- Before removing the spark plug, use com-
gine idling speed. pressed air to blow away any dirt accumulat-
ed in the spark plug wells to prevent it from
Engine idling speed falling into the cylinder.
1300–1500 r/min
5. Install:
b. Check that stationary pointer “a” in the magn- l Compression gauge “1”
eto cover is within the firing range “b” on the
magneto rotor. Compression gauge
Incorrect firing range → Check the ignition
system.
1
a
4. Remove:
l Timing light
6. Measure:
5. Install: l Compression pressure
l Timing mark accessing screw Out of specification → Refer to steps (c) and
(along with the O-ring New ) (d).
MEASURING THE COMPRESSION Compression Pressure

PRESSURE 1200 Kpa (at sea level)
NOTE:
Insufficient compression pressure will result in a
loss of performance. a. Set the main switch to ON”.
b. With the throttle wide open, crank the engine
1. Measure: until the reading on the compression gauge
l Valve clearance
stabilizes.
Out of specification → Adjust. c. If the compression pressure is above the
Refer to “ADJUSTING THE VALVE CLEAR- maximum specification, check the cylinder
ANCE” on page 3-3. head, valve surfaces and piston crown for
2. Start the engine, warm it up for several min- carbon deposits.
utes, and then turn it off. Carbon deposits → Eliminate.
d. If the compression pressure is below the min-
3. Disconnect: imum specification, pour a teaspoonful of en-
l Spark plug cap gine oil into the spark plug bore and measure
4. Remove: again.
l Spark plug Refer to the following table.
3-8
ENGINE
Compression pressure (with oil applied into

the cylinder) Type
SAE20W40 (YAMALUBE-4 stroke
Reading Diagnosis motor oil)
Higher than without Piston ring(s) wear or
oil damage → Replace CAUTION:
Piston, valves, cylin- Do not allow foreign materials to enter the
der head gasket or crankcase.
Same as without oil
piston possibly defec-
tive → Repair/Replace 4. Start the engine, warm it up for several min-
utes, and then turn it off.
ssssssssssssssssssssssss 5. Check the engine oil level again.
7. Remove:
NOTE:
l Compression gauge
Before checking the engine oil level, wait a few
8.Install: minutes until the oil has settled.
l Spark plug
CHANGING THE ENGINE OIL

Spark plug 1. Start the engine, warm it up for several min-
13 Nm (1.3 m·kg, 9.4 ft·lb) utes, and then turn it off.
T.
R.
2. Place a container under the engine oil drain

9.Connect: bolt.
l Spark plug cap
3. Remove:
l Engine oil filler cap “1”
CHECKING THE ENGINE OIL LEVEL
l Engine oil drain plug “2”
1. Stand the vehicle on a level surface.
NOTE:
l Place the vehicle on the centerstand.
l Make sure the vehicle is upright.
2. Start the engine, warm it up for several min-
utes, and then turn it off. 1
3. Check:
l Engine oil level
The engine oil level should be between the

minimum level mark “a” and maximum level
mark “b”.
2
Below the minimum level mark → Add the 4. Drain:
recommended engine oil to the proper level. l Engine oil
(completely from the crankcase)

NOTE:
5. If the oil filter element is also to be replaced,
l Before checking the engine oil level, wait a few perform the following procedure.
minutes until the oil has settled. ssssssssssssssssssssssss
l Do not screw the dipstick “1” in when checking
a. Remove the oil filter element cover “1” and oil
the oil level. filter element “2”.
b. Install new O-ring “3”.
b
a
2 New 3 1
3-9
ENGINE
c. Install the new oil filter element and the oil fil- engine oil comes out after one minute, turn
ter element cover. the engine off so that it will not seize.
c. Check the engine oil passages, the oil filter
Oil filter element cover bolt element and the oil pump for damage or leak-
10 Nm (1.0 m·kg, 7.2 ft·lb) age. Refer to “OIL PUMP” on page 5-43.
T.
R.
d. Start the engine after solving the problem(s)

ssssssssssssssssssssssss and check the engine oil pressure again.
7. Install: e. Tighten the oil check bolt to specification.
l Drain plug washer
Oil check bolt
l Engine oil drain plug
7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
Engine oil drain plug
20 Nm (2.0 m·kg, 14 ft·lb) ssssssssssssssssssssssss
T.
R.
ADJUSTING THE CLUTCH CABLE FREE

8. Fill:
PLAY
l Crankcase
1. Check:
(with the specified amount of the recom-
l Clutch cable free play “a”
mended engine oil)
Engine Oil Amount/ Quantity Clutch lever free play

Periodic oil change 10.0–15.0 mm
1.00 lt
Total amount of Engine Oil
1.20 lt
9. Install:
l Engine oil filler cap
10.Start the engine, warm it up for several min-

utes, and then turn it off.
11.Check:
l Engine
2. Adjust:
(for engine oil leaks)
l Clutch cable free play
12.Check: Handlebar side

l Engine oil level a. Pull back the rubber cover “1”
Refer to “CHECKING THE ENGINE OIL b. Loosen the locknut “2”.
LEVEL” on page 3-9. c. Turn the adjusting bolt “3” in direction “a” or
“b” until the specified clutch cable free play is
13.Check:
obtained.
l Engine oil pressure
Direction “a”
a. Slightly loosen the oil check bolt “1”.
Clutch cable free play is increased.
Direction “b”
Clutch cable free play is decreased.
1 2 3
a
1
b
b. Start the engine and keep it idling until engine
oil starts to seep from the oil check bolt. If no
3-10
ENGINE
d. Tighten the locknut.

e. Place the rubber cover in its original position.
NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
Engine side
a. Loosen the locknut “1”.
b. Turn the adjusting nut “2” in direction “a” or “b” 1
until the specified clutch cable free play is ob-
tained. 1. Remove:
l Seat
Direction “a” Refer to “GENERAL CHASSIS” on page 4-1.

Clutch cable free play is increased. 2. Remove:
Direction “b” l Air filter case cover “1”
Clutch cable free play is decreased. l Air filter element
1
NOTE:
Keep handle straight.
1 a
b 3. Clean:
l Air filter element “1”
Apply compressed dry air from inner to outer

surface of the air filter element.
c. Tighten the locknut.
Locknut
9 Nm (0.9 m·kg, 6.5 ft·lb)
T.
R.
ssssssssssssssssssssssss 1
CLEANING THE AIR FILTER ELEMENT 4. Check:
NOTE: l Air filter element
There is a check hose “1” at the bottom of the air Damage → Replace.
filter case. If dust and/or water collects in this 5. Install:
hose, clean the air filter element and air filter l Air filter element
case. l Air filter case cover
(along with a gaskets)
3-11
ENGINE
1
CAUTION:
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine.
NOTE:
Make sure the air filter element is properly in-
stalled in the air filter case.
CHECKING THE CARBURETOR BODY JOINT

AND AIR FILTER CASE JOINT
1. Remove: 3. Install:
l Seat l Fuel tank
l Fuel tank l Seat
Refer to “GENERAL CHASSIS” on page 4-2. Refer to “GENERAL CHASSIS” on page 4-2.
2. Check: CHECKING THE EXHAUST SYSTEM
l Carburetor body joint “1”
1. Check:
l Air filter case joint “2”
l Muffler “1”
Cracks/damage → Replace. Cracks/damage → Replace.
l Exhaust pipe gasket “2”
Exhaust gas leaks → Replace.

1 2. Check:
l Tightening torque
l Muffler nuts “3”
l Muffler bolt “4”

l Muffler bolt “5”
Muffler nut
15 Nm (Left below)
T.
Muffler bolt
R.
20 Nm (2.0m.kg,15ft.lb)
Muffler bolt (Right below)
12 Nm (1.2m.kg, 9ft.lb)
3. Install: 2
l Fuel tank
l Side cover
2
l Seat
Refer to “GENERAL CHASSIS” on page 4-2. 3

CHECKING THE CYLINDER HEAD
BREATHER HOSE 4
1. Remove: 5
l Seat 3
l Side cover (left)
4 1
2. Check:
l Cylinder head breather hose “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
3-12
ENGINE
CHECKING THE FUEL COCK FILTER
1. Check
• Fuel hose “1”
Cracks/damage - Replace.
3 1
• Fuel filter “2”

Contaminants/damage - Replace the cock
assembly.
a. Turn the fuel cock to the “OFF”.

b. Remove the fuel cock filter cup “3”.
c. Drain the fuel.
d. Checking the fuel cock filter.
if dirty -> clean
damage->replace
e. Install the fuel cock filter cup.
3-13
CHASSIS
CHASSIS CHECKING THE BRAKE FLUID LEVEL

NOTE:
ADJUSTING THE REAR DRUM BRAKE
1. Check: Place the vehicle on the centerstand.
Brake pedal free play “a” Make sure the vehicle is upright.
Out of specification → Adjust. 2. Check:
Brake fluid level
Free Play : Below the minimum level mark, add the reco-
15 ~ 20 mm
mmended brake fluid to the proper level.
Recommended fluid
DOT 3 or DOT 4
Max.
Min.
2. Adjust:
Brake pedal free play
a. Turn the adjusting nut “1” in direction “a” or “b”
until the specified brake pedal free play is ob- WARNING
tained. Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
Direction “a” deteriorate, causing leakage and poor
Brake pedal free play is increased. brake performance.
Direction “b” Refill with the same type of brake fluid that
Brake pedal free play is decreased. is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
a Cover all painted parts because brake fluid
may damage painted surfaces and plastic
parts. Therefore, cover all painted components
1 b to avoid spillage over them always clean up
CAUTION: any spilt brake fluid immediately.
After adjusting the brake pedal free play,
make sure there is no brake drag.
NOTE:
In order to ensure a correct reading of the brake
3. Adjust: fluid level, make sure the top of the brake fluid
Rear brake light switch reservoir is horizontal.
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-15.
3-14
CHASSIS
CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the
2
brake pads.
1. Operate the brake. 1
2. Check:
Front brake pad
Wear indicators “1” almost touch the brake
disc → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-20.
ADJUSTING THE REAR BRAKE LIGHT

SWITCH
NOTE:
The rear brake light switch is operated by move-
ment of the brake pedal. The rear brake light
CHECKING THE FRONT BRAKE HOSE switch is properly adjusted when the brake light
1. Check: comes on just before the braking effect starts.
Brake hose “1” 1. Check:
Cracks/damage/wear → Replace. Rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
Rear brake light operation timing
a. Hold the main body “1” of the rear brake light

U
1 switch so that it does not rotate and turn the
T
U
T
adjusting nut “2” in direction “a” or “b” until the
rear brake light comes on at the proper time.
2
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
2. Check:
Brake hose clamp
Loose Connection → Tighten the clamp bolt.
3. Hold the vehicle upright and apply the front
brake several times.
4. Check:
Brake hose
Brake fluid leakage → Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-16. BLEEDING THE HYDRAULIC BRAKE
SYSTEM
CHECKING THE REAR BRAKE SHOES
WARNING
1. Operate the brake.
2. Check: Bleed the hydraulic brake system whenever:
Brake shoe wear indicator “1” the system is disassembled.
a brake hose is loosened, disconnected or
Reaches the wear limit mark “2” → Replace
replaced.
the brake shoes as a set.
the brake fluid level is very low.
Refer to “REAR BRAKE” on page 4-26.
brake operation is faulty.
3-15
CHASSIS
1. Remove: g. Loosen the bleed screw.

Brake master cylinder reservoir cap “1” NOTE:
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the
throttle grip.
1
h. Tighten the bleed screw and then release the
brake lever.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
NOTE:
R.
Be careful not to spill any brake fluid or allow k. Fill the brake fluid reservoir to the proper level
the brake master cylinder reservoir to overflow. with the recommended brake fluid.
When bleeding the hydraulic brake system, Refer to “CHECKING THE BRAKE FLUID
make sure there is always enough brake fluid LEVEL” on page 3-14.
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic WARNING
brake system, considerably lengthening the After bleeding the hydraulic brake system,
bleeding procedure. check the brake operation.
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles 3. Install:
in the hose have disappeared. Brake master cylinder reservoir cap
2. Bleed:
Hydraulic brake system ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
a. Fill the brake fluid reservoir to the proper level The drive chain slack must be checked at the
with the recommended brake fluid. tightest point on the chain.
b. Install the brake master cylinder reservoir di-
aphragm. CAUTION:
c. Connect a clear plastic hose “1” tightly to the
A drive chain that is too tight will overload
bleed screw “2”.
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
2 its.
1 WARNING
Securely support the vehicle so that there is
no danger of it falling over.
NOTE:
d. Place the other end of the hose into a con-
Place the vehicle on the centerstand so that the
tainer.
rear wheel is elevated.
e. Slowly apply the brake lever several times.
f. Fully pull the brake lever without releasing it.
3-16
CHASSIS
2. Spin the rear wheel several times and find the NOTE:
tightest position of drive chain. To maintain the proper wheel alignment, adjust
3. Check: both sides evenly.
Drive chain slack “a”
Out of specification → Adjust. e. Tighten the wheel axle nut.
Wheel axle nut

90 Nm (9.0 m·kg, 65 ft·lb)
T.
R.
5. Adjust:
Refer to “ADJUSTING THE REAR DRUM
BRAKE” on page 3-14.
Drive chain slack
30-40 mm 6. Align the rear axle
NOTE: a. To maintain correct axle alignment.
Measure the drive chain slack halfway between Reference lines “1” on the swingarm should
the drive axle and the rear wheel axle. be matched with an outer diameter of the
washer ”2”at both the sides.
4. Adjust:
Drive chain slack
ssssssssssssssssssssssss 1
a. Loosen the brake rod adjusting nut “1”. 2
b. Loosen the wheel axle nut “2”
b. After adjusting, be sure to tighten each chain
2 adjusting locknut. Then tighten the axle nut to
the specified torque.
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
1 chain should be serviced, especially when the
c. Turn the adjusting nut "3” to adjust the chain vehicle is used in dusty areas.
slackness. Use recomended chain cleaner and
lubricant that is suitable for O-ring chains.
Direction “a”
Drive chain is tightened.
Direction “b” Recommended lubricant
Drive chain is loosened. Chain lubricant suitable for
O-ring chains
1. Remove all deposits of dust, soil, mud , oil

etc during washing and dry it with air blow.
2. Spray the chain cleaning solvent to remove
a grease deposition for 5 minutes.
3. Wipe the chain with clean cloth and wait
b
3-17
CHASSIS
b. Tighten the lower ring nut “4” with a steering

nut wrench “5”.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
4 Spray the Lubricant inside the chain between 4

inner/ outer plates, roller and bushes.
5 After spraying wait for 15 minutes.
6 Excess lubricant should be wiped with a Steering nut socket
clean cloth before riding.
YSST-721
CHECKING AND ADJUSTING THE

STEERING HEAD Lower ring nut (initial tightening
1. Stand the vehicle on a level surface. torque)
T.
R.
33 Nm (3.3 m·kg, 24 ft·lb)

WARNING
Securely support the vehicle so that there is c. Loosen the lower ring nut “4” completely, and
no danger of it falling over. then tighten it to specification with a steering
nut wrench.
NOTE:
Place the vehicle on a suitable stand so that the WARNING
front wheel is elevated. Do not overtighten the lower ring nut.
2. Check:
l Steering head
Lower ring nut (final tightening
Grasp the bottom of the front fork legs and torque)
T.
R.
22 Nm (2.2 m·kg, 16 ft ·lb)

gently rock the front fork.
Binding/looseness → Adjust the steering
head. d. Check the steering head for looseness or
3. Remove: binding by turning the front fork all the way in
l Upper bracket both directions. If any binding is felt, remove
Refer to “STEERING HEAD” on page 4-43. the lower bracket and check the upper and
lower bearings.
4. Adjust: Refer to “STEERING HEAD” on page 4-43.
l Steering head e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
a. Remove the lock washer “1”, the upper ring g. Finger tighten the upper ring nut “2”, and then
nut “2”, and the rubber washer “3”. align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
NOTE:
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
3-18
CHASSIS
5. Install:
Upper bracket WARNING
Refer to “STEERING HEAD” on page 4-43. The tyre pressure should only be checked
and regulated when the tyre temperature
CHECKING THE FRONT FORK equals the ambient air temperature.
1. Stand the vehicle on a level surface. The tyre pressure must be adjusted accord-
ing to the total weight (including cargo, rid-
WARNING er, passenger and accessories) and the
Securely support the vehicle so that there is anticipated riding speed.
no danger of it falling over. Operation of an overloaded vehicle could
cause tyre damage, an accident or an injury.
2. Check:
NEVER OVERLOAD THE VEHICLE.
l Inner tube
Damage/scratches → Replace.
l Oil seal
Oil leakage → Replace. Tyre air pressure (measured on

3. Hold the vehicle upright and apply the front cold tyres)
brake. Front
4. Check: 200 kPa (28 psi) (2.00 kgf/cm²)
l Front fork operation
Rear
Push down hard on the handlebar several 225 kPa (33 psi) (2.25 kgf/cm²)
times and check if the front fork rebounds
smoothly.
Rough movement → Repair. WARNING
Refer to “FRONT FORK” on page 4-35. It is dangerous to ride with a worn-out tyre.
When the tyre tread reaches the wear limit, re-
place the tyre immediately.
2. Check:
l Tyre surfaces
Damage/wear → Replace the tyre.
CHECKING THE TYRES

The following procedure applies to both of the
tyres.
1. Tyre tread depth
1. Check:
2. Side wall
• Tyre pressure
3. Wear indicator
Out of specification → Regulate.
3-19
CHASSIS
WARNING CHECKING THE WHEELS

Do not use a tube tyre on a wheel de-
wheels.
signed only for tubeless tyres to avoid tyre
1. Check:
fail-ure and personal injury from sudden
l Wheel
deflation.
Damage/out-of-round → Replace.
After extensive tests, the tires listed below
have been approved by YAMAHA for WARNING
this model. The front and rear tyres should Never attempt to make any repairs to the
always be by the same manufacturer and of wheel.
the same design. No guarantee concerning
NOTE:
handling characteristics can be given if a
tyre combination other than one approved After a tyre or wheel has been changed or re-
by YAMAHA is used on this vehicle. placed, always balance the wheel.
CHECKING AND LUBRICATING THE

Front tyre CABLES
Size The following procedure applies to all of the in-
100/80-17 M/C 52 P
ner and outer cables.
Manufacturer/model
MRF/ZAPPER-X
WARNING
Damaged outer cable may cause the cable to
Rear tyre corrode and interfere with its movement. Re-
Size place damaged outer cable and inner cables
140/60-R17 M/C 63P as soon as possible.
Manufacturer/model
MRF/ZAPPER revz 1. Check:
l Outer cable
Damage → Replace.
2. Check:
WARNING l Cable operation
New tyres have a relatively low grip on the Rough movement → Lubricate.
road surface until they have been slightly
worn. Therefore, approximately 100 km Recommended lubricant
should be traveled at normal speed before Engine oil or a suitable cable lu-
bricant
any high-speed riding is done.
NOTE: NOTE:
For tyres with a direction of rotation mark“1”: Hold the cable end upright and pour a few drops
l Install the tyre with the mark pointing in the di- of lubricant into the cable sheath or use a suit-
rection of wheel rotation. able lubricating device.
l Align the mark “2” with the valve installation
point.
LUBRICATING THE CLUTCH LEVER
Lubricate the pivoting point and metal-to-metal
moving parts of the lever.
Recommended lubricant
Lithium-soap-based grease
3-20
CHASSIS
LUBRICATING THE BRAKE LEVER Rear shock absorber adjuster

Lubricate the pivoting point and metal-to-metal YSST-821
moving parts of the lever.
Silicone grease
LUBRICATING THE PEDALS

moving parts of the pedals.
LUBRICATING THE SIDESTAND

moving parts of the sidestand.
LUBRICATING THE REAR SUSPENSION

moving parts of the rear suspension.
Recommended lubricant CAUTION:

Lithium-soap-based grease Never go beyond the maximum or minimum
adjustment positions.
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY 1. Adjust:
The following procedure applies for the • spring preload
rear shock absorber assembly adjustment.
a. Turn the adjusting ring “1” in direction a or b.
b. Align the desired position on the adjusting
WARNING ring with the stopper “2”.
• Securely support the vehicle so that thereis no
danger of it falling over. Spring preload is
Direction a increased (suspension
is harder).
Spring preload is
Direction b decreased (suspension
is softer).
b Adjusting positions
a Minimum (soft) : 1
Standard : 4
Maximum (hard) : 7
3-21
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM 4. Remove

• Head light “1” from head light stay “2”
CHECKING AND CHARGING THE BATTERY
Refer to “ELECTRICAL COMPONENTS” on
page 7-34. 1
CHECKING THE FUSES
Refer to “ELECTRICAL COMPONENTS” on
page 7-34.
REPLACING THE HEADLIGHT BULBS
The following procedure applies to the low beam
as well as high beam headlight bulb.
1. Remove
• Side cover “1”.
2
1 5. Remove:
• Headlight bulb cover“1”
• Headlight bulb holder “2”
2. Disconnect
• Turn signal indicator connection “1” from
both the end. 1 2
1
6. Remove:
• Headlight bulb “1
3. Remove
• Head light mounting bolt “1” from both the
end.
• Head light beam adjustment bolt “2”.
WARNING
2
Since the headlight bulb gets extremely hot, keep
flammable products and your hands away from
the bulb until it has cooled down.
3-22
ELECTRICAL SYSTEM
4. Install: REPLACING AUXILIARY LIGHT BULB

• Headlight bulb
Secure the new headlight bulb with the headlight 1. Remove
bulb holder. • Headlight side covers (Refer to replacing
the head light bulb) on page 3-22.
CAUTION: • Turn signal light connections (Refer to
Avoid touching the glass part of the headlight bulb replacing theheadlightbulb)onpage3-22.
to keep it free from oil, otherwise the 2. Remove
transparency of the glass, the life of the bulb and • Auxiliary bulb “1” as shown in illustration.
the luminous flux will be adversely affected. If the
headlight bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer thinner.
5. Install:
• Headlight bulb holder
6. Install: 1
• Headlight bulb cover
ADJUSTING THE HEADLIGHT BEAMS

The following procedure applies to the
adjustment of the headlight beam.
Loosen the headlight adjusting screw and move
the headlight in the following manner to adjust the
headlight beam REPLACING TAIL/BRAKE LIGHT BULB
Direction “a” 1. Remove

Headlight beam is lowered. • Screw “1”
Direction “b” • Lens “2”
Headlight beam is raised.
2
b
a
2. Push the bulb “1” gently and rotate counter
clockwise.
3-23
ELECTRICAL SYSTEM
For tail light replacement :-

3. Remove
• Taillight coupler “1”
• Screws “2” from inner side of the fender
REPLACING TURN SIGNAL INDICATOR

LIGHT BULB
1. Remove
• Screw “1” from indicator light
• Lens “2” from light
2. Push the bulb “3” and rotate counter
clockwise.
2 1
3-24
CHASSIS
GENERAL CHASSIS.......................................................................................4-1
INSTALLING THE AIR FILTER CASE ...................................................4-5
FRONT WHEEL...............................................................................................4-6
REMOVING THE FRONT WHEEL........................................................4-8
DISASSEMBLING THE FRONT WHEEL..............................................4-8
CHECKING THE FRONT WHEEL ........................................................4-8
ASSEMBLING THE FRONT WHEEL....................................................4-9
INSTALLING THE FRONT WHEEL (DISC) ........................................4-9
REAR WHEEL...............................................................................................4-12
REMOVING THE REAR WHEEL (DRUM).........................................4-14
CHECKING THE REAR WHEEL ........................................................4-14
CHECKING THE REAR WHEEL DRIVE HUB..................................4-14
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ......4-14
ASSEMBLING THE REAR WHEEL .................................................4-15
INSTALLING THE WHEEL (DRUM) .................................................4-15
FRONT BRAKE.............................................................................................4-16
INTRODUCTION................................................................................4-19
CHECKING THE FRONT BRAKE DISC .............................................4-19
REPLACING THE FRONT BRAKE PADS ..........................................4-20
REMOVING THE FRONT BRAKE CALIPER......................................4-21
DISASSEMBLING THE FRONT BRAKE CALIPER............................4-21
CHECKING THE FRONT BRAKE CALIPER ......................................4-21
ASSEMBLING THE FRONT BRAKE CALIPER.................................4-22
INSTALLING THE FRONT BRAKE CALIPER ....................................4-22
REMOVING THE FRONT BRAKE MASTER CYLINDER...................4-23
CHECKING THE FRONT BRAKE MASTER CYLINDER....................4-23
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...............4-23
INSTALLING THE FRONT BRAKE MASTER CYLINDER...................4-23
REAR BRAKE.........................................................................................4-26
CHECKING THE REAR BRAKE SHOES ...........................................4-27
ASSEMBLING THE REAR BRAKE SHOES PLATE .........................4-27
CHECKING THE REAR BRAKE DRUM WEAR LIMIT ....................4-28
HANDLEBAR ................................................................................................4-30
REMOVING THE HANDLEBARS ......................................................4-32
CHECKING THE HANDLEBAR .........................................................4-32
INSTALLING THE HANDLEBAR ........................................................4-32
FRONT FORK................................................................................................4-35
REMOVING THE FRONT FORK LEGS..............................................4-38
DISASSEMBLING THE FRONT FORK LEGS....................................4-38
CHECKING THE FRONT FORK LEGS ..............................................4-39
ASSEMBLING THE FRONT FORK LEGS..........................................4-39
INSTALLING THE FRONT FORK LEGS ............................................4-42
CHASSIS
STEERING HEAD..........................................................................................4-43
REMOVING THE LOWER BRACKET.................................................4-45
CHECKING THE STEERING HEAD...................................................4-45
INSTALLING THE STEERING HEAD.................................................4-45
REAR SHOCK ABSORBER ASSEMBLY ....................................................4-47

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................4-48
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................4-48
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ..............4-48
SWINGARM...................................................................................................4-49
REMOVING THE SWINGARM................................................4-51
CHECKING THE SWINGARM ...........................................................4-51
INSTALLING THE SWINGARM .........................................................4-51
CHAIN DRIVE................................................................................................4-53
CHECKING THE DRIVE CHAIN .........................................................4-54
INSTALLING THE DRIVE CHAIN .......................................................4-55
GENERAL CHASSIS
GENERAL CHASSIS
2 Nm (0.2 m l kg, 1 ft l Ib) 1
T.
25 Nm (2.5 m l kg, 18 ft l Ib)
R.
T.
R.
2 Nm (0.2 m l kg, 1 ft l Ib) 3

T.
R.
4
2
2 Nm (0.2 m l kg, 1 ft l Ib)
T.
R.
7 Nm (0.7 m l kg, 5 ft l Ib)

T.
R.
5
2 Nm (0.2 m l kg, 1 ft l Ib)
T.
R.
6
8
2 Nm (0.2 m l kg, 1 ft l Ib)
T.
R.
2 Nm (0.2 m l kg, 1 ft l Ib) 2

T.
R.
Order Job/Parts to remove Qty Remarks
1 Seat 1
2 Side cover 1 & side cover 2 1/1
3 Side cover 3 & side cover 4 1/1
4 Tail cover 1
5 Seat Handle 1
6 Mud protector 1
7 Air scoop bracket 1
8 Air scoop 1
9 Footrest protector 1
For installation, reverse the removal proce-

dure.
4-1
GENERAL CHASSIS
Removing the fuel tank

2 Nm (0.2 m l kg, 1 ft l Ib)
T.
R.
2 1
2
4 Nm (0.4 m l kg, 3 ft l Ib)
T.
R.
4 Nm (0.4 m l kg, 3 ft l Ib)
T.
R.
5

Side cover 1 & 2, Seat Refer to “GENERAL CHASSIS” on page
4-1.
1 Fuel tank cap 1

2 Fuel tank side cover LH & RH 2
3 Fuel tank top cover 1
NOTE :
Disconnect fuel pipe & fuel drain pipe before
4 Fuel tank assy. 1 removing the fuel tank assy.
5 Fuel tank bracket 1 For installation, reverse the removal proce-

dure.
4-2
GENERAL CHASSIS
Removing the head light / meter assy.
2 Nm (0.2 m l kg, 1 ft l Ib)

T.
R.
2 Nm (0.2 m l kg, 1 ft l Ib)

T.
R.
6
2 Nm (0.2 m l kg, 1 ft l Ib)
T.
R.
3 5 2 Nm (0.2 m l kg, 1 ft l Ib)
T.
R.
4
1 2
7 Nm (0.7 m l kg, 5 ft l Ib)

T.
R.
1 Head light side cover 2

2 Head light assy. 1
3 License plate 1 Disconnect
4 License plate stay 1
5 Meter connector 1
6 Meter 1
7 Headlight stay 1
dure.
4-3
GENERAL CHASSIS
Removing the air filter assy.

1
2 Nm (0.2 m l kg, 1 ft l Ib)

T.
R.
4 3
23 Nm (2.3 m l kg, 17 ft l Ib)
T.
R.
5
8
6 7 7 Nm (0.7 m l kg, 5 ft l Ib)
T.
R.

Refer to “GENERAL CHASSIS” on page
Seat, Side cover 1 & 2
4-1.
1 Air filter case cap 1
2 Air filter case cover 1
3 Air filter seal 2
4 Air filter 1
5 Resonator 1
6 Air filter hose clamp 1
7 Air filter hose 1
8 Air filter case 1

dure.
4-4
GENERAL CHASSIS
INSTALLING THE AIR FILTER CASE

1. Install:
l Air filter case joint clamp
NOTE:
Align the projection “a” on the air filter case with
the slot “b” in the air filter case joint clamp.
4-5
FRONT WHEEL
FRONT WHEEL
Removing the front wheel and brake discs
30 Nm (3.0 m l kg, 22 ft l Ib) LS

T.
R.
LT
(5 1
(
7 Nm (0.7 m l kg, 5 ft l Ib)
T.
R.
6
2
7
LS
T.
R.
60 Nm (6.0 m l kg, 43 ft l Ib)

1 Speed sensor lead holder 1
2 Front wheel axle nut 1
3 Front wheel axle 1
4 Front wheel 1
5 Speed sensor 1
6 Collar 1
7 Brake disc 1
dure.
4-6
FRONT WHEEL
Disassembling the front wheel
4 3
LS
2
New 1

1 Oil seal 1
2 Bearing 1
3 Spacer 1
4 Bearing 1
For assembly, reverse the disassembly pro-
cedure.
4-7
FRONT WHEEL
REMOVING THE FRONT WHEEL

WARNING
2. Elevate:
l
Front wheel
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
3. Remove: sssssssssssssssssssssssssssssssssssss
l
Front wheel CHECKING THE FRONT WHEEL
l
Speed sensor unit 1. Check:
l
Collar l
Wheel axle
NOTE: Roll the wheel axle on a flat surface.
Do not squeeze the brake lever when removing Bends → Replace.
the front wheel.
WARNING
Do not attempt to straighten a bent wheel ax-
DISASSEMBLING THE FRONT WHEEL le.
1. Remove:
l
Oil seal
l
Wheel bearings
sssssssssssssssssssssssssssssssssssss
a. Clean the outside of the front wheel hub.

b. Remove the oil seal “1” with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
2. Check:
l
Tyre
l
Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TYRES” on page
3-19 and “CHECKING THE WHEELS” on
page 3-20.
3. Measure:
l
Radial wheel runout“1”
l
Lateral wheel runout“2”
c. Remove the wheel bearings with a bearing Over the specified limits → Replace.
puller.
Radial wheel runout limit
1.0 mm
Lateral wheel runout limit
0.5 mm
4-8
FRONT WHEEL
INSTALLING THE FRONT WHEEL (DISC)

1. Install:
l
Front brake disc
Front brake disc bolt

30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
LOCTITE®
NOTE:
4. Check:
Tighten the brake disc bolts in stages and in a
l
Wheel bearings
crisscross pattern.
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
l
Oil seal
2. Check:
l
Front brake disc
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-19.
ASSEMBLING THE FRONT WHEEL 3. Lubricate:
1. Install: l
Wheel axle
l
Wheel bearings New
l
Oil seal lip
l
Speed sensor lip
l
Oil seal New
ssssssssssssssssssssssssssssssssssssssss
a. Install the new wheel bearings and oil seal in Lithium-soap-based grease
the reverse order of disassembly.
4. Install:
CAUTION: l
Front wheel
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made NOTE:
only with the outer race “3”.
Install the tyre and wheel with the mark“1” point-
NOTE: ing in the direction of wheel rotation.
Use a socket “4” that matches the diameter of
the wheel bearing outer race and oil seal.
4-9
FRONT WHEEL
5. Install:
l
Speed sensor unit
NOTE:
Make sure the speed sensor and the
wheel hub are installed with the two projections
meshed into the two slots respectively.
6. Install:
l
Front wheel
NOTE:
Make sure the slot “a” in the outer tube fits over
the stopper “b” on the speed sensor unit.
7. Tighten:
l
Wheel axle
Wheel axle
60 Nm (6.0 m·kg, 43 ft·lb)
T.
R.
WARNING
Make sure the brake hose is routed properly.
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebar(s) several times
and check if the front fork rebounds smooth-
ly.
4-10
FRONT WHEEL
4-11
REAR WHEEL
Removing the rear wheel and brake shoe assembly

90 Nm (9.0 m l kg, 65 ft l Ib) LS 6
7
.
T
R.
10
New
11
3 4 1
13
5 2 12
10
14
8
9
LS
Order Job/Parts to remove Q ty Remarks

1 Brake rod adjusting nut 1
2 Brake rod 1
3 Spring 1
4 Pin 1
5 Tension bar 1
6 Nut 1
7 Washer 1
8 Rear wheel axle 1
9 Washer 1
10 Drive chain puller 2
11 Collar 1
12 Collar 1
13 Rear wheel 1
14 Brake shoe assembly 1
dure.
4-12
REAR WHEEL
Disassembling the rear wheel

10 Nm (1.0 m l kg, 7 ft l Ib)
.
T
R.
S
S
S
9
8
7
5
1
2
New
3
LS
43 Nm (4.3 m l kg, 31 ft l Ib)

4
.
T
R.

1 Rear wheel sprocket 1
2 Collar 1
3 Oil seal 1
4 Bearing 1
5 Rear wheel drive hub 1
6 Rear wheel drive hub damper 4
7 Bearing 2
8 Spacer 1
9 Oil seal 1
cedure.
4-13
REAR WHEEL
3. Measure:
REMOVING THE REAR WHEEL (DRUM)
Radial wheel runout
Lateral wheel runout
WARNING Refer to “CHECKING THE FRONT WHEEL”
Securely support the vehicle so that there is on page 4-8.
CHECKING THE REAR WHEEL DRIVE HUB
NOTE: 1. Check:
Place the vehicle on a suitable stand so that the Rear wheel drive hub
rear wheel is elevated. Cracks/damage → Replace.
2. Remove: Rear wheel drive hub dampers
Brake rod adjusting nut “1” Damage/wear → Replace.
Brake rod “2”
Spring “3” CHECKING AND REPLACING THE REAR
Pin “4” WHEEL SPROCKET
NOTE: 1. Check:
Press down on the brake pedal to remove the Rear wheel sprocket
pin from the brake rod. More than 1/4 tooth “a” wear → Replace the
drive chain, drive sprocket, and rear wheel
sprocket as a set.
Bent teeth → Replace the drive chain, drive
sprocket, and rear wheel sprocket as a set.
4
1
2
3
3. Remove:
Rear wheel
NOTE:
Push the rear wheel forward and remove the b. Correct
drive chain from the rear wheel sprocket. 1. Drive chain roller
2. Rear wheel sprocket
CHECKING THE REAR WHEEL
2. Replace:
1. Check:
Rear wheel sprocket
Wheel axle sssssssssssssssssssssssssssssssssssss
Rear wheel a. Remove the self-locking nuts and the rear

Wheel bearings wheel sprocket.
Oil seal b. Clean the rear wheel drive hub with a clean
Refer to “CHECKING THE FRONT WHEEL” cloth, especially the surfaces that contact the
on page 4-8. sprocket.
2. Check: c. Install the new rear wheel sprocket.
Tire
Rear wheel Rear wheel sprocket nut
Damage/wear → Replace. 43 Nm (4.3 m·kg, 31 ft·lb)
T.
R.
Refer to “CHECKING THE TIRES” on page

3-19 and “CHECKING THE WHEELS” on
page 3-20.
4-14
REAR WHEEL
NOTE: 5. Tighten:
l Install the rear wheel sprocket with its manu- Wheel axle nut
facture’s marks facing outward.
Wheel axle nut
Tighten the self-locking nuts in stages and in a 90 Nm (8.0 m·kg, 58 ft·lb)
T.
l
R.
crisscross pattern.
6. Adjust:

15.0–20.0 mm
sssssssssssssssssssssssssssssssssssss
INSTALLING THE REAR WHEEL (DRUM)

1. Lubricate:
Oil seal lip
2. Install:
Rear wheel sprocket
Refer to “CHECKING AND REPLACING
THE REAR WHEEL SPROCKET” on page
4-14.
3. Lubricate:
Wheel axle
Wheel bearings
4. Adjust:
Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-16.
Drive chain slack

30–40 mm
4-15
FRONT BRAKE
FRONT BRAKE
Removing the front brake pads

1 Brake hose holder 1
2 Front brake caliper bolt 2
3 Front brake caliper 1
4 Brake pad clip 2
5 Brake pad pin 1
6 Front brake pad 2
7 Brake pad spring 1
dure.
4-16
FRONT BRAKE
Removing the front brake master cylinder

10 Nm (1.0 m l kg, 7 ft l Ib)
.
R.
1
7 Nm (0.7 m l kg, 5 ft l Ib) 10

.
R.
3 4
S
11
9 7
5 6
7
8
New
26 Nm (2.6 m l kg, 19 ft l Ib)
.
R.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-15.
1 Right rear view mirror 1
2 Brake master cylinder reservoir cap 1
3 Brake master cylinder reservoir diaphragm hold-
3 er 1
4 Brake master cylinder reservoir diaphragm 1

5 Front brake light switch 1
6 Brake hose union bolt 1
7 Copper washer 2
8 Front brake hose 1
9 Brake lever 1
10 Front brake master cylinder holder 1
11 Front brake master cylinder 1
dure.
4-17
FRONT BRAKE
Disassembling the front brake master cylinder
4
1
5
3 7

1 Dust boot 1
2 Push rod 1
3 Spring 1
4 Circlip 1
5 Piston assy 1
6 Spring 1
7 Master cylinder body 1

cedure.
4-18
FRONT BRAKE
sssssssssssssssssssssssssssssssssssssss
INTRODUCTION a. Place the vehicle on a suitable stand so that

the front wheel is elevated.
WARNING
b. Before measuring the front brake disc deflec-
Disc brake components rarely require disas- tion, turn the handlebar to the left or right to
sembly. Therefore, always follow these pre- ensure that the front wheel is stationary.
ventive measures: c. Remove the brake caliper.
Never disassemble brake components un- d. Hold the dial gauge at a right angle against
less absolutely necessary. the brake disc surface.
If any connection on the hydraulic brake e. Measure the deflection 5 mm below
system is disconnected, the entire brake the edge of the brake disc.
system must be disassembled, drained, sssssssssssssssssssssssssssssssssssssss
cleaned, properly filled, and bled after reas-
sembly. 4. Measure:
Never use solvents on internal brake com- Brake disc thickness
ponents. Measure the brake disc thickness at a few dif-
Use only clean or new brake fluid for clean- ferent locations.
ing brake components. Out of specification → Replace.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
Flush with water for 15 minutes and get im-
mediate medical attention.
CHECKING THE FRONT BRAKE DISC Brake disc thickness limit

3.5 mm
1. Remove:
Front wheel 5. Adjust:
Refer to “FRONT WHEEL” on page 4-6. Brake disc deflection
2. Check: sssssssssssssssssssssssssssssssssssssss
Brake disc a. Remove the brake disc.

Damage/galling → Replace. b. Rotate the brake disc by one bolt hole.
3. Measure: c. Install the brake disc.
Brake disc deflection
Out of specification → Correct the brake disc Front brake disc bolt
deflection or replace the brake disc. 30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
LOCTITE®
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
Brake disc deflection limit

0.10 mm
4-19
FRONT BRAKE
NOTE:
Always install new brake pads and a new brake
pad spring as a set.
a. Connect a clear plastic hose “1” tightly to the

bleed screw “2”. Put the other end of the hose
into an open container.
d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
6. Install: b. Loosen the bleed screw and push the brake

Front wheel caliper pistons into the brake caliper with your
Refer to “FRONT WHEEL” on page 4-6. finger.
c. Tighten the bleed screw.
REPLACING THE FRONT BRAKE PADS
NOTE: Bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
When replacing the brake pads, it is not neces-

R.
sary to disconnect the brake hose or disassem- d. Install new brake pads and a new brake pad
ble the brake caliper. spring.
1. Measure: sssssssssssssssssssssssssssssssssssssss
Brake pad wear limit“a” 3. Check:

Out of specification → Replace the brake Brake fluid level
pads as a set. Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Brake pad lining thickness (inner) Refer to “CHECKING THE BRAKE FLUID
4.5 mm LEVEL” on page 3-14.
Limit
0.8 mm Max.
Brake pad lining thickness (outer) Min.
4.5 mm
Limit
0.8 mm
a 4. Check:
Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
2. Install: tem.
Brake pads Refer to “BLEEDING THE HYDRAULIC
Brake pad spring BRAKE SYSTEM” on page 3-15.
4-20
FRONT BRAKE
b. Remove the brake caliper piston seals and

REMOVING THE FRONT BRAKE CALIPER
dust seals.
NOTE:
Before disassembling the brake caliper, drain sssssssssssssssssssssssssssssssssssssss
the brake fluid from the entire brake system. CHECKING THE FRONT BRAKE CALIPER
1. Remove: Recommended brake component replace-
Brake hose union bolt ment schedule
Copper washers
Brake pads If necessary
Brake hose
NOTE: Piston seals Every two years
Put the end of the brake hose into a container Dust seals Every two years
and pump out the brake fluid carefully. Brake hose Every four years
Every two years and
Brake fluid whenever the brake
DISASSEMBLING THE FRONT BRAKE
is disassembled
CALIPER
1. Remove: 1. Check:
Brake caliper pistons “1” Brake caliper pistons “1”
Brake caliper piston seals“2” Rust/scratches/wear → Replace the brake
Brake caliper dust seals“3” caliper pistons.
Brake caliper cylinders“2”
Scratches/wear → Replace the brake caliper
assembly.
Brake caliper body “3”
1 Cracks/damage → Replace the brake caliper
2 assembly.
3 Brake fluid delivery passages
(brake caliper body)
1 Obstruction → Blow out with compressed air.
2
WARNING
a. Blow compressed air into the brake hose joint Whenever a brake caliper is disassembled,
opening “a” to force out the pistons from the replace the piston seals and dust seals.
brake caliper.
WARNING 3
Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper. 2 2
Never try to pry out the brake caliper pis-
ton.
1
2. Check:
Brake caliper bracket
4-21
FRONT BRAKE
ASSEMBLING THE FRONT BRAKE CALIPER 3. Install:

Brake pad spring
WARNING Brake pads
Before installation, all internal brake com- Brake caliper
ponents should be cleaned and lubricated Brake hose holder
with clean or new brake fluid.
Never use solvents on internal brake com- Brake caliper bolt
ponents as they will cause the piston seals 35 Nm (3.5 m·kg, 25 ft·lb)
T.
R.
and dust seals to swell and distort. Brake hose holder
7 Nm (0.7 m·kg, 5 ft ·lb)
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals and
dust seals.
Refer to “REPLACING THE FRONT BRAKE
Recommended fluid PADS” on page 4-20.
DOT 3 or DOT 4 4. Fill:
Brake master cylinder reservoir
(with the specified amount of the recom-
INSTALLING THE FRONT BRAKE CALIPER mended brake fluid)
1. Install:
Brake caliper Recommended fluid
(temporarily) DOT 3 or DOT 4
Copper washers New
Brake hose WARNING
Brake hose union bolt Use only the designated brake fluid. Other
Brake hose union bolt
deteriorate, causing leakage and poor
26 Nm (2.6 m·kg, 19 ft·lb)
T.
brake performance.
R.
Refill with the same type of brake fluid that

2. Remove: is already in the system. Mixing brake fluids
Brake caliper “1” may result in a harmful chemical reaction,
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
1 and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
Brake system
Refer to “BLEEDING THE HYDRAULIC
6. Check:
Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-14.
4-22
FRONT BRAKE
Max. CHECKING THE FRONT BRAKE MASTER

Min. CYLINDER
1. Check:
Brake master cylinder“1”
Damage/scratches/wear → Replace.
Brake fluid delivery passages“2”
(brake master cylinder body)
Obstruction → Blow out with compressed air.
1
7. Check:
tem.
Refer to “BLEEDING THE HYDRAULIC 2
REMOVING THE FRONT BRAKE MASTER

CYLINDER 2. Check:
NOTE: Brake master cylinder kit
Before removing the front brake master cylinder, Damage/scratches/wear → Replace.
drain the brake fluid from the entire brake sys- 3. Check:
tem. Brake master cylinder reservoir
1. Disconnect: Cracks/damage → Replace.
Front brake light switch“1” Brake master cylinder reservoir diaphragm
NOTE:
4. Check:
Push the fastener to remove the front brake light Brake hose
switch from the brake master cylinder. Cracks/damage/wear → Replace.
ASSEMBLING THE FRONT BRAKE MASTER

CYLINDER
WARNING
Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake com-
ponents.
2. Remove:
Brake hose union bolt Recommended fluid
Copper washers DOT 3 or DOT 4
Brake hose
NOTE:
INSTALLING THE FRONT BRAKE MASTER
To collect any remaining brake fluid, place a CYLINDER
container under the master cylinder and the end 1. Install:
of the brake hose. Brake master cylinder“1”
Brake master cylinder holder“2”
Brake master cylinder holder bolt

10 Nm (1.0 m·kg, 7 ft ·lb)
T.
R.
4-23
FRONT BRAKE
3. Fill:
Brake master cylinder reservoir
2 (with the specified amount of the recom-
mended brake fluid)
Recommended fluid
DOT 3 or DOT 4
WARNING
Use only the designated brake fluid. Other
1 deteriorate, causing leakage and poor
brake performance.
2. Install: Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
Copper washers“1” New
may result in a harmful chemical reaction,
Brake hose “2”
Brake hose union bolt“3”
Brake hose union bolt not enter the brake master cylinder reser-
26 Nm (2.6 m·kg, 19 ft·lb) voir. Water will significantly lower the boil-
T.
R.
ing point of the brake fluid and could cause

vapor lock.
WARNING
CAUTION:
Proper brake hose routing is essential to in-
sure safe vehicle operation. Brake fluid may damage painted surfaces
and plastic parts.Therefore, always clean up
NOTE: any spilt brake fluid immediately.
Install the brake hose to the front brake master 4. Bleed:
cylinder within the angle shown in the illustra- Brake system
tion. Refer to “BLEEDING THE HYDRAULIC
While holding the brake hose, tighten the brake BRAKE SYSTEM” on page 3-15.
hose union bolt as shown. 5. Check:
Turn the handlebar to the left and right to make Brake fluid level
sure the brake hose does not touch other parts Below the minimum level mark “a” → Add the
(e.g., wire harness, cables, leads). Correct if recommended brake fluid to the proper level.
necessary. Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-14.
Max.
Min.
1
3
6. Check:
tem.
4-24
FRONT BRAKE
Refer to “BLEEDING THE HYDRAULIC

4-25
REAR BRAKE
REAR BRAKE
Disassembling the brake shoe 10 Nm (1.0 m kg,

l 7 ft l Ib)
4
3 LS
2
5
S LS
New
(6)
43 Nm (4.3 m l kg, 31 ft l Ib) LS

Brake shoe assembly Refer to “REAR WHEEL” on page 4-12.
1 Brake shoe 2
2 Brake shoe spring 2
3 Brake camshaft lever 1
4 Brake shoe wear indicator 1
5 Brake camshaft 1
6 Brake shoe plate 1
cedure.
4-26
REAR BRAKE
CHECKING THE REAR BRAKE SHOES a

1. Check:
• Brake shoe lining
Glazed areas → Repair.
Sand the glazed areas with coarse sandpa-
per.
NOTE:
After sanding the glazed areas, clean the brake
shoe with a cloth.
2. Measure: 4. Check:
• Brake shoe lining thickness “a” • Brake drum inner surface
Out of specification → Replace. Oil deposits → Clean.
Remove the oil with a rag soaked in lacquer
Lining thickness thinner or solvent.
4.0 mm (0.16 in) Scratches → Repair.
Limit Lightly and evenly polish the scratches with
2.0 mm (0.08 in) an emery cloth.
5. Check:
• Brake camshaft
ASSEMBLING THE REAR BRAKE SHOE

PLATE
1. Install:
• Brake camshaft “1”
• Brake shoe wear indicator “2”
• Brake camshaft lever “3”
Brake camshaft lever bolt

WARNING
10 Nm (1.0 m.kg, 7.2 ft.lb)
T.
R.
Do not allow oil or grease on the brake

shoes.
a. Install the brake camshaft so its punch mark
NOTE: “a” is positioned as shown.
Replace the brake shoes as a set, if either is
worn to the wear limit. 1
3. Measure:
• Brake drum inside diameter “a” a
Out of specification → Replace the wheel.
Brake drum inside diameter

130.0 mm
Limit
131.0 mm
b. Align the projection “b” on the brake shoe
wear indicator with the notch in the brake
camshaft.
4-27
REAR BRAKE
New 1 S
A A
B B
c. Align the slot “c” in the brake camshaft lever New 1
with the notch in the brake camshaft.
A-A
3
c
B-B
d. Check that the brake shoes are properly po-

sitioned. CHECKING THE REAR BRAKE DRUM WEAR
LIMIT
2. Install: NOTE:
• Brake shoe springs “1” New After the new brake shoes are installed, the
• Brake shoes brake drum inside diameter can be checked as
NOTE: to whether it is within the wear limit “a” by means
of the brake drum wear indicator on the brake
• Lubricate the pivot pin with a thin coat of sili-
shoe plate.
cone grease.
• Do not to damage the springs during installa-
tion.
• Install the brake shoe springs as shown.
a
WARNING
Do not apply grease to the brake shoe lin-
ings.
1. Check:
• Position at which to install the brake camshaft
lever
Reinstall the brake camshaft lever if its in-
stalled position is out of specification.
2. Check:
• Brake pedal free play
If the free play is out of specification.
4-28
REAR BRAKE
3. While pressing the brake pedal all the way

down, push the brake camshaft lever fully in
the arrow indicated direction and check that
the brake shoe wear indicator does not reach
the brake drum wear indicator.
Not reaching → Still usable.
Reaching → Replace the wheel.
4-29
HANDLEBARS
HANDLEBAR
Removing the handlebar
10 Nm (1.0 m • kg, 7 ft • Ib)
T.
R.
1
2 26 Nm (2.6 m • kg, 19 ft • Ib)
T.
R.
7
16 LS
5
3
LS 1
LS
4 10
13
17
8 6
9 12 2
15
14 11
LS
7 Nm (0.7 m • kg, 5 ft • Ib)

T.
R.

1 Rearview mirror 2
2 Grip end 2
3 Right handlebar switch 1
4 Throttle cable 1
5 Throttle grip 1
6 Front brake light switch 1
7 Front brake master cylinder holder 1
8 Front brake master cylinder assembly 1
9 Clutch cable 1
10 Clutch switch coupler 1 Disconnect.
11 Starter cable 1
12 Left handlebar switch 1
13 Handlebar grip 1
14 Clutch lever 1
4-30
HANDLEBARS
Removing the handlebar

10 Nm (1.0 m • kg, 7 ft • Ib)
T.
R.
1
2 26 Nm (2.6 m • kg, 19 ft • Ib)
T.
R.
7
16 LS
5
3
LS 1
LS
4 10
13
17
8 6
9 12 2
15
14 11
LS
T.
R.
7 Nm (0.7 m • kg, 5 ft • Ib)

15 Clutch lever holder 1
16 Upper handlebar holder 2
17 Handlebar 1
dure.
4-31
HANDLEBARS
REMOVING THE HANDLEBARS INSTALLING THE HANDLEBAR

1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface.
WARNING WARNING
Securely support the vehicle so that there is Securely support the vehicle so that there is
no danger of it falling over. no danger of it falling over.
2. Remove: 2. Install:
• Front brake light switch “1” • Handlebar “1”
NOTE: • Upper handlebar holders “2”
Push the fastener to remove the front brake light
Upper handlebar holder bolt
switch from the brake master cylinder. 26 Nm (2.6 m ·kg, 19 ft ·lb)
T.
R.
CAUTION:
First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
NOTE:
3. Remove: Align the match marks “a” on the handlebar with
• Handlebar grip “1” the upper surface of the lower handlebar hold-
NOTE: ers.
Blow compressed air between the left handlebar
and the handlebar grip, and gradually push the 2
grip off the handlebar. 2
CHECKING THE HANDLEBAR

1. Check:
• Handlebar
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
3. Install:
bar as this may dangerously weaken it.
• Clutch lever holder “1”
NOTE:
Align the slit of the clutch lever holder with the
match mark “a” on the handlebar.
4-32
HANDLEBARS
1
a
4. Install:
• Left handlebar switch “1” 6. Install:
NOTE: • Clutch cable
Align the projections “a” on the left handlebar NOTE:
switch with the holes “b” in the handlebar. Lubricate the end of the clutch cable with a thin
coat of lithium-soap-based grease.
a
7. Install:
b
1 • Brake master cylinder
• Brake master cylinder holder
Refer to “FRONT BRAKE” on page 4-23.
8. Install:
• Throttle grip “1”
• Throttle cable “2”
• Right handlebar switch “3”
• Grip end
5. Install: NOTE:
• Handlebar grip “1” • Lubricate the end of the throttle cable and the
• Grip end “2” inside of the throttle grip with a thin coat of the
a. Apply a thin coat of rubber adhesive onto the lithium-soap-based grease, and then install the
left end of the handlebar. throttle grip onto the handlebar.
b. Slide the handlebar grip over the left end of • Route the throttle cable through the slot in the
the handlebar. right handlebar switch, and then install the ca-
c. Wipe off any excess rubber adhesive with a ble.
clean rag. • Align the projection “a” on the right handlebar
switch with the hole “b” in the handlebar.
WARNING • There should be 1–3 mm of clearance “c”
Do not touch the handlebar grip until the rub- between the throttle grip and the grip end.
ber adhesive has fully dried.
NOTE:
There should be less than 3 mm of clearance
“a” between the handlebar grip and the grip end.
4-33
HANDLEBARS
3 1
b
2
a
9. Adjust:
• Clutch cable free play
Refer to “ADJUSTING THE CLUTCH CABLE
FREE PLAY” on page 3-10.
Clutch lever free play

10.0–15.0 mm
10.Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-6.

3.0–5.0 mm
4-34
FRONT FORK
FRONT FORK
Removing the front fork legs 25 Nm (2.5 m kg,
• 18 ft • Ib)
T.
R.
3 2
25 Nm (2.5 m kg,
• 18 ft • Ib)
T.
R.
6 Nm (0.6 m • kg, 4 ft • Ib)

T.
R.

The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-6.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Lower bracket pinch bolt 1 Loosen.
4 Front fork leg 1
dure.
4-35
FRONT FORK
Disassembling the front fork legs
New 1
2 12
4 6 New
7 New
13
14 New
10 15
11
9

The following procedure applies to both of
the front fork legs.
1 Cap bolt 1
2 O-ring 1
3 Spacer 1
4 Washer 1
5 Fork spring 1
6 Dust seal 1
7 Oil seal clip 1
8 Damper rod bolt 1
9 Copper washer 1
10 Damper rod 1
11 Taper spindle 1
12 Inner tube 1
13 Oil seal 1
14 Oil seal washer 1
4-36
FRONT FORK
Disassembling the front fork legs
New 1
2 12
4 6 New
7 New
13
14 New
10 15
11
9
15 Outer tube 1
cedure.
4-37
FRONT FORK
REMOVING THE FRONT FORK LEGS 2. Drain:

The following procedure applies to both of the • Fork oil
front fork legs. NOTE:
1. Stand the vehicle on a level surface. Stroke the inner tube several times while drain-
WARNING ing the fork oil.
2. Loosen:
• Upper bracket pinch bolt “1”
• Lower bracket pinch bolt “2”
WARNING
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
NOTE:
3. Remove:
For easy removal of cap bolt, loosen the upper • Dust seal “1”
pinch bolt first then loosen the cap bolt slightly • Oil seal clip “2”
without loosening the lower pinch bolt while (with a flat-head screwdriver)
front fork is fitted on vehicle.
CAUTION:
Do not scratch the inner tube.
1 1
4. Remove:
• Damper rod bolt “1”
• Damper rod
3. Remove:
• Front fork leg
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
1. Remove:
• Rubber cap
• Clip “1”
• Front fork cap “2”
(with O-ring)
• Fork spring
4-38
FRONT FORK
NOTE: 3. Check:
While holding the damper rod with the damper • Damper rod
rod holder “2” and T-handle “3”, loosen the Damage/wear → Replace.
damper rod bolt. Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage → Replace.
CAUTION:
When disassembling and assembling the
front fork leg, do not allow any foreign mate-
rial to enter the front fork.
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
T-Handle
YSST-813 WARNING
Make sure the oil levels in both front fork
CHECKING THE FRONT FORK LEGS legs are equal.
The following procedure applies to both of the Uneven oil levels can result in poor han-
front fork legs. dling and a loss of stability.
1. Check:
• Inner tube NOTE:
• Outer tube • When assembling the front fork leg, be sure to
Bends/damage/scratches → Replace. replace the following parts:
– Outer tube bushing
WARNING – Oil seal
Do not attempt to straighten a bent inner – Dust seal
tube as this may dangerously weaken it. – Clip
• Before assembling the front fork leg, make
2. Measure:
sure all of the components are clean.
• Spring free length “a”
Out of specification → Replace. 1. Install:
• Damper rod
Fork spring free length
254.4 mm CAUTION:
Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
2. Lubricate:
• Inner tube’s outer surface
4-39
FRONT FORK
Recommended oil TFF Oil Seal Installation Tool

Fork oil 10W or equivalent YSST-875
3. Tighten:
• Damper rod bolt “1” CAUTION:
Damper rod bolt Make sure the numbered side of the oil seal
28 Nm (2.8 m·kg, 20 ft·lb) faces up.
T.
R.
NOTE:
NOTE: • Before installing the oil seal, lubricate its lips
While holding the damper rod with the damper with lithium-soap-based grease.
rod holder “2” and T-handle “3”, tighten the • Lubricate the outer surface of the inner tube
damper rod bolt. with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
4. Install:
• Outer tube bushing “1” New
• Washer “2”
(with the TFF Oil seal installation Tool)
TFF Oil Seal InstallationTool

YSST-875
5. Install:
6. Install:
• Oil seal “1” New
(TFF Installation Tool “2”) • Oil seal clip “1” New
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
New
4-40
FRONT FORK
7. Install:
• Dust seal “1” New
(with the TFF oil seal installation tool “2”)
TFF Oil Seal Installation Tool

YSST-875
10.Before measuring the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual
air.
11.Measure:
8. Fill: • Front fork leg oil level “a”
• Front fork leg (from the top of the inner tube, with the inner
(with the specified amount of the recom- tube fully compressed and without the fork
mended fork oil) spring)
Out of specification → Correct.
Level
Recommended oil 87.0 mm
Fork oil 10W or equivalent
Quantity
459 cm³
CAUTION:
l Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
l When disassembling and assembling the
front fork leg, do not allow any foreign ma-

terial to enter the front fork.
9. After filling the front fork leg, slowly stroke the 12.Install:
inner tube “1” up and down (at least ten • Fork spring “1”
times) to distribute the fork oil. NOTE:
NOTE: Install the spring with the smaller pitch “a” facing
Be sure to stroke the inner tube slowly because down.
the fork oil may spurt out.
a
1
4-41
FRONT FORK
13.Install: WARNING
• O-ring New Make sure the brake hose, clutch cable, and
(to front fork cap) leads are routed properly.
• Front fork cap
• Clip New
NOTE:
• Before installing the front fork cap, lubricate its
O-ring with grease.
• Insert the front fork cap into the inner tube, and 2
then install the clip, making sure that the cap is
securely held in place with the clip.
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. Install:
• Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts. 1
2. Tighten:
• Upper bracket pinch bolt “1”
Lower bracket pinch bolt

25 Nm (2.5 m·kg, 18 ft·lb)
T.
R.
• Lower bracket pinch bolt “2”
Upper bracket pinch bolt

25 Nm (2.5 m·kg, 18 ft·lb)
T.
R.
NOTE:
• To give the proper torque to cap bolt, first of all
tighten the lower pinch bolt then tighten the
cap bolt before tightening the upper pinch bolt.
4-42
STEERING HEAD
STEERING HEAD
Removing the lower bracket 110 Nm (11.0 m • kg, 80 ft • lb)
T.
R.
1
22 Nm (2.2 m • kg, 16 ft • lb)
T.
R.
2
13
LS 11
3
14 4
New 15 5
6
8
12 9
10
7
7 Nm (0.7 m • kg, 5 ft • lb)

T.
R.
22 Nm (2.2 m • kg, 16 ft • lb)

T.
R.
1st 33 Nm (3.3 m • kg, 24 ft • lb)

T.
2nd 22 Nm (2.2 m • kg, 16 ft • lb)

R.

Refer to “GENERAL CHASSIS” on page
Head light assy.
4-1.
Front fork legs Refer to “FRONT FORK” on page 4-40.
1 Steering stem bolt 1
2 Upper bracket 1
3 Lock washer 1
4 Upper ring nut 1
5 Rubber washer 1
6 Lower ring nut 1
7 Lower bracket 1
8 Bearing cover 1
9 Upper bearing inner race 1
10 Upper bearing 1
11 Lower bearing 1
12 Upper bearing outer race 1
4-43
STEERING HEAD
Removing the lower bracket
22 Nm (2.2 m • kg, 16 ft • lb)
T.
R.
1
22 Nm (2.2 m • kg, 16 ft • lb)
T.
R.
2
13
LS 11
3
14 4
New 15 5
6
8
12 9
10
7
7 Nm (0.7 m • kg, 5 ft • lb)

T.
R.
22 Nm (2.2 m • kg, 16 ft • lb)

T.
R.
1st 33 Nm (3.3 m • kg, 24 ft • lb)

T.
2nd 22 Nm (2.2 m • kg, 16 ft • lb)

R.
13 Lower bearing outer race 1

14 Lower bearing inner race 1
15 Dust seal 1
dure.
4-44
STEERING HEAD
b. Remove the bearing race from the lower

REMOVING THE LOWER BRACKET
bracket with a floor chisel “2” and hammer.
c. Install a new dust seal and new bearing rac-
WARNING es.
Securely support the vehicle so that there is CAUTION:
If the bearing races are not installed proper-
2. Remove: ly, the steering head pipe could be damaged.
• Upper ring nut
• Rubber washer NOTE:
• Lower ring nut “1” • Always replace the bearings and bearing races
• Lower bracket as a set.
NOTE:
• Whenever the steering head is disassembled,
replace the dust seal.
Remove the lower ring nut with the steering nut
wrench “2”.
Steering nut socket

YSST-721
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
1
4. Check:
CHECKING THE STEERING HEAD
• Upper bracket
1. Wash:
• Lower bracket
• Bearings
(along with the steering stem)
• Bearing races
Bends/cracks/damage → Replace.
Recommended cleaning solvent
Kerosene INSTALLING THE STEERING HEAD
1. Lubricate:
2. Check: • Upper bearing
• Bearings • Lower bearing
• Bearing races • Bearing races
Damage/pitting → Replace.
3. Replace: Recommended lubricant
• Bearings Lithium-soap-based grease
• Bearing races
sssssssssssssssssssssssssssssssssssssss 2. Install:
a. Remove the bearing races from the steering • Lower ring nut
head pipe with a long rod “1” and hammer. • Rubber washer
4-45
STEERING HEAD
• Upper ring nut

• Lock washer
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-18.
3. Install:
• Upper bracket
• Steering stem nut
4. Install:
• Front fork legs
Refer to “FRONT FORK” on page 4-35.
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
• Steering stem nut
Handle crown nut

110 Nm (11.0 m · kg, 80 ft·lb)
T.
R.
4-46
REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly
60 Nm (6.0 m • kg, 43 ft • lb)
T.
R.
1
2
6
3
4
5
3
40 Nm (4.0 m • kg, 29 ft • lb)
T.
R.

Seat, Side cover 1 & 2, mud protector Refer to “GENERAL CHASSIS” on page 4-1.
1 Rear shock absorber assembly upper nut/bolt 1/1
2 Washer 1
3 Rear shock absorber assembly lower nut/bolt 1/1
4 Washer 1
5 Spacer 1
6 Rear shock absorber assembly 1
dure.
4-47
REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY
WARNING
NOTE:
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• Rear shock absorber
Oil leaks → Replace the rear shock absorber
assembly.
• Spring
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bushing
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bolts
Bends/damage/wear → Replace.
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Install:
• Rear shock absorber assembly
2. Tighten:
• Rear shock absorber assembly upper nut
Rear shock absorber assembly

upper nut
T.
R.
40 Nm (4.0 m·kg, 29 ft·lb)
• Rear shock absorber assembly lower nut
Rear shock absorber assembly

lower nut
T.
R.
60 Nm (6.0 m·kg, 43 ft·lb)
3. Adjust
• Rear shock absorber assy. (Refer to “ADJUS-
TING THE REAR SHOCK ABSORBER” on
page 3-21)
4-48
SWINGARM
SWINGARM
Removing the swingarm
60 Nm (6.0 m • kg, 43 ft • lb)

T.
R.
10 Nm (1.0 m • kg, 7 ft • lb)
T.
R.
2
4
10 Nm (1.0 m • kg, 7 ft • lb)
T.
R.
30 Nm (3.0 m • kg, 22 ft • lb)

T.
R.
Rear wheel
Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER ”
on page 5-1.
Rear fender Refer to “REAR WHEEL” on page 4-12.
1 Pivot shaft nut 1
2 Pivot shaft 1
3 Right footrest bracket 1
4 Left footrest bracket 1
5 Seal guard 1
6 Swing arm 1
7 Oil seal 2
8 Thrust cover 2
9 Bush 2
10 Bearing 2
dure.
4-49
SWINGARM
Removing the swingarm

T.
R.
60 Nm (6.0 m • kg, 43 ft • lb)
10 Nm (1.0 m • kg, 7 ft • lb)
T.
R.
2
4
10 Nm (1.0 m • kg, 7 ft • lb)
T.
R.
30 Nm (3.0 m • kg, 22 ft • lb)

T.
R.

11 Bearing 2
dure.
4-50
SWINGARM
REMOVING THE SWINGARM WARNING

1. Stand the vehicle on a level surface. Do not attempt to straighten a bent pivot
WARNING shaft.
NOTE:
2. Measure:
• Swingarm side play
a. Measure the tightening torque of the pivot 3. Wash:

shaft nut. • Pivot shaft
• Dust covers
Pivot shaft nut • Spacers
60 Nm (6.0 m·kg, 43 ft·lb) • Bearings
T.
R.
b. Measure the swingarm side play “A” by mov- Recommended cleaning solvent
ing the swingarm from side to side. Kerosene
c. If the swingarm side play is observed,
check the spacers, bearings, and dust 4. Check:
covers. • Dust covers
• Spacers
• Oil seals
• Bearings
Damage/pitting → Replace.
INSTALLING THE SWINGARM

1. Lubricate:
• Bearings
• Spacers
• Dust covers
• Pivot shaft
CHECKING THE SWINGARM Lithium-soap-based grease
1. Check:
• Swingarm 2. Install:
Bends/cracks/damage → Replace. • Bearings “1”
2. Check:
• Pivot shaft Installed depth “a”
0.5–1.5 mm
Roll the pivot shaft on a flat surface.
Bends → Replace.
4-51
SWINGARM
a 1 2 1 a
A B
2. Swingarm
A. Left side
B. Right side
4. Install:
• Rear shock absorber assembly
• Relay arm
• Rear wheel
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-47 and “REAR WHEEL”
on page 4-12.
5. Adjust:
• Drive chain slack
Drive chain slack

30–40 mm
4-52
CHAIN DRIVE
CHAIN DRIVE
Removing the drive chain
1
3
2
10 Nm (1.0 m • kg, 7 ft • lb)
T.
R.
10 Nm (1.0 m • kg, 7 ft • lb)

T.
R.

Rear wheel Refer to “REAR WHEEL” on page 4-12.
Right footrest bracket, Left footrest bracket Refer to “SWINGARM” on page 4-49.
Rear fender comp.
1 Chain case cover 1
2 Drive sprocket retainer 1
3 Drive sprocket 1
4 Drive chain 1
dure.
4-53
CHAIN DRIVE
CHECKING THE DRIVE CHAIN

1. Measure:
• 15-link section “a” of the drive chain
Out of specification → Replace the drive
chain.
15-link length limit

191.5 mm
a. Measure the length “a” between the inner 3. Clean:

sides of the pins and the length “b” between • Drive chain
the outer sides of the pins on a 15-link section sssssssssssssssssssssssssssssssssssssss
of the drive chain as shown in the illustration.

a.Wipe the drive chain with a clean cloth.
b.Spray the chain cleaning chemical on entire
chain and clean it completely.
Recommended chain cleaner

Suitable for O-ring chains
b. Calculate the length “c” of the 15-link section 4. Check:

of the drive chain using the following formula. • Drive chain rollers “1”
Drive chain 15-link section length “c” = Damage/wear → Replace the drive chain.
(length “a” between pin inner sides + length • Drive chain side plates “2”
“b” between pin outer sides)/2 Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain.
NOTE:
• When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a different
location each time.
5. Lubricate:
• Drive chain
Chain lubricant
Suitable for O-ring chains
2. Check:
• Drive chain l Wipe the excess lubricant.
Stiffness → Clean and lubricate or replace.
4-54
CHAIN DRIVE
6. Check:
• Drive sprocket
Refer to “REAR WHEEL” on page 4-12.
INSTALLING THE DRIVE CHAIN

1. Lubricate:
• Drive chain
chain lubricant
suitable for O-ring chains
2. Install:
• Drive chain
• Drive sprocket
• Drive sprocket retainer
Drive sprocket retainer bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
3. Install:
• Swingarm
Refer to “SWINGARM” on page 4-49.
• Rear wheel
Refer to “REAR WHEEL” on page 4-12.
4. Adjust:
• Drive chain slack
Drive chain slack

30–40 mm
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
4-55
ENGINE
ENGINE REMOVAL ........................................................................................5-1

INSTALLING THE ENGINE..........................................................5-4
INSTALLING THE SHIFT ARM .............................................................5-4
CYLINDER HEAD............................................................................................5-5
REMOVING THE CYLINDER HEAD....................................................5-7
CHECKING THE CYLINDER HEAD .....................................................5-7
CHECKING THE CAMSHAFT SPROCKET AND
TIMING CHAIN GUIDE ........................................................................5-8
CHECKING THE TIMING CHAIN TENSIONER....................................5-8
CHECKING THE DECOMPRESSION SYSTEM.................................5-9
INSTALLING THE CYLINDER HEAD .................................................5-9
CAMSHAFT...................................................................................................5-12
REMOVING THE ROCKER ARMS AND CAMSHAFT.........................5-13
CHECKING THE CAMSHAFT.............................................................5-13
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ......5-13
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................5-14
VALVES AND VALVE SPRINGS..................................................................5-15

REMOVING THE VALVES..................................................................5-16
CHECKING THE VALVES AND VALVE GUIDES ..............................5-16
CHECKING THE VALVE SEATS.........................................................5-17
CHECKING THE VALVE SPRINGS....................................................5-18
INSTALLING THE VALVES ................................................................5-19
CYLINDER AND PISTON..............................................................................5-21

REMOVING THE PISTON .................................................................5-22
CHECKING THE CYLINDER AND PISTON ......................................5-22
CHECKING THE PISTON RINGS.......................................................5-23
CHECKING THE PISTON PIN ...........................................................5-24
INSTALLING THE PISTON AND CYLINDER ....................................5-24
MAGNETO AND STARTER CLUTCH...................................................5-26

REMOVING THE MAGNETO.........................................................5-28
REMOVING THE STARTER CLUTCH ..............................................5-28
CHECKING THE STARTER CLUTCH................................................5-28
INSTALLING THE STARTER CLUTCH..............................................5-29
INSTALLING THE MAGNETO............................................................5-29
ELECTRIC STARTER...................................................................................5-31
DISASSEMBLING THE STARTER MOTOR......................................5-33
CHECKING THE STARTER MOTOR .................................................5-33
ASSEMBLING THE STARTER MOTOR.............................................5-34
CLUTCH ........................................................................................................5-35
REMOVING THE CLUTCH ................................................................5-38
CHECKING THE FRICTION PLATES.................................................5-38
CHECKING THE CLUTCH PLATES...................................................5-38
CHECKING THE CLUTCH SPRINGS.................................................5-39
CHECKING THE CLUTCH HOUSING................................................5-39
CHECKING THE CLUTCH BOSS.......................................................5-39
CHECKING THE PRESSURE PLATE ................................................5-39
CHECKING THE CLUTCH PUSH LEVER
AND SHORT CLUTCH PUSH ROD....................................................5-39
CHECKING THE PRIMARY DRIVE GEAR.........................................5-39
CHECKING THE PRIMARY DRIVEN GEAR ......................................5-40
INSTALLING THE CLUTCH................................................................5-40
OIL PUMP......................................................................................................5-43
CHECKING THE OIL PUMP ...............................................................5-45
ASSEMBLING THE OIL PUMP...........................................................5-45
INSTALLING THE OIL PUMP .............................................................5-46
SHIFT SHAFT.........................................................................................5-47
CHECKING THE SHIFT SHAFT .........................................................5-48
CHECKING THE STOPPER LEVER ..................................................5-48
INSTALLING THE SHIFT SHAFT .......................................................5-48
BALANCER GEAR........................................................................................5-49
REMOVING THE PRIMARY DRIVE GEAR AND
BALANCER GEARS..........................................................................5-51
CHECKING THE BALANCER GEARS
AND PRIMARY DRIVE GEAR ...........................................................5-51
ASSEBLING THE BALANCER DRIVEN GEAR ...............................5-51
INSTALLING THE PRIMARY DRIVE GEAR AND
BALANCER GEARS...........................................................................5-51
CRANKCASE................................................................................................5-53
SEPARATING THE CRANKCASE.....................................................5-56
CHECKING THE CRANKCASE..........................................................5-56
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE..........5-56
CHECKING THE OIL STRAINER .......................................................5-56
CHECKING THE BEARINGS AND OIL SEAL .....................................5-56
INSTALLING THE BEARING RETAINER...........................................5-57
ASSEMBLING THE CRANKCASE.....................................................5-57
CRANKSHAFT ..............................................................................................5-58
REMOVING THE CRANKSHAFT ......................................................5-59
CHECKING THE CRANKSHAFT........................................................5-59
INSTALLING THE CRANKSHAFT......................................................5-59
TRANSMISSION............................................................................................5-61
CHECKING THE SHIFT FORKS.........................................................5-64
CHECKING THE SHIFT DRUM ASSEMBLY......................................5-64
CHECKING THE TRANSMISSION.....................................................5-64
CHECKING THE CLUTCH PUSH RODS ...........................................5-65
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ..........................5-65
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ....5-65
ENGINE REMOVAL
ENGINE REMOVAL
Removing the muffler
2
12 Nm (1.2 m • kg, 9 ft • Ib)
T.
R.
4
3
15 Nm (1.5 m • kg, 11 ft • Ib)
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.

1 Air duct 2
2 Air shroud 1
3 Muffler 1
4 Exhaust pipe gasket 1

dure.
5-1
ENGINE REMOVAL
Disconnecting the leads and couplers

3
4
8 2
10
5
10 Nm (1.0 m • kg, 7 ft • Ib)

7 9
10 Nm (1.0 m • kg, 7 ft • Ib)
T.
R.
T.
R.
CAUTION:
First, disconnect the negative battery
lead, and then the positive battery lead.
Refer to “CHECKING AND CHARGING
Negative battery lead/Positive battery lead
THE BATTERY” on page 7-34.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-9.
Fuel tank Refer to “FUEL TANK ” on page 4-2.
1 Spark plug cap 1 Disconnect

2 Starting motor lead 1 Disconnect
3 Starter cable 1 Disconnect
4 Throttle cable 1 Disconnect
5 TPS 1 Disconnect
6 Stator coil coupler/crankshaft sensor coupler 1/1 Disconnect
7 Neutral switch connector 1 Disconnect
8 Clutch cable 1 Disconnect
9 Negative battery lead 1 Disconnect
10 Shift arm 1 Disconnect
dure.
5-2
ENGINE REMOVAL
Removing the engine

30 Nm (3.4 m • kg, 22 ft • Ib)
T.
R.
3
4
2
5
1 3
55 Nm (5.5 m • kg, 40 ft • Ib)

T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)

T.
R.

Mufler Refer to “ENGINE REMOVAL” on page 5-1.
Fuel tank Refer to “GENERAL CHASSIS ” on page 4-2.
1 Engine mounting bolt/nut (front side) 4/4

2 Engine mounting bolt/nut (rear lower side) 1/1
3 Engine mounting bolt/nut (rear upper side) 1/1
4 Engine mounting bolt/nut (upper side) 3/3
5 Engine 1

dure.
5-3
ENGINE REMOVAL
INSTALLING THE ENGINE INSTALLING THE SHIFT ARM

1. Install: 1. Install:
• Engine “1” • Shift arm “1”
• Engine mounting bolt (upper side) “2”
• Engine mounting nut (rear upper side) “3”
• Engine mounting bolt (rear lower side) “4” Shift arm bolt
• Engine mounting nut (front side) “5” 10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
NOTE:
1
Do not fully tighten the bolts and nuts.
2. Tighten:
• Engine mounting nut (upper side)
Engine mounting nut (rear upper

side)
T.
R.
30 Nm (3.0 m·kg, 22 ft·lb)
• Engine mounting nut (rear lower side)
Engine mounting nut (rear lower

side)
T.
R.
55 Nm (5.5 m·kg, 40 ft·lb)
• Engine mounting nut (front side)
Engine mounting nut (front side)

55 Nm (5.5 m·kg, 40 ft·lb)
T.
R.
5-4
CYLINDER HEAD
CYLINDER HEAD
Removing the cylinder head 22 Nm (1.0 m • kg, 16 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9 ft • Ib) 10 Nm (1.0 m • kg, 7 ft • Ib) 8 Nm (0.8 m • kg, 6 ft • Ib)
T.
R.
T.
T.
R.
R.
5 9 Nm (0.9 m • kg, 7 ft • Ib)
T.
R.
E 8
E
6 8 Nm (0.8 m • kg, 6 ft • Ib)
T.
R.
1 New 9
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
New 10 LS
LS
7 New 11
2
M
12 14
13 4
LS
15
14 10 Nm (1.7 m • kg, 7 ft • Ib)
T.
R.
3
7 Nm (7.0 m • kg, 5 ft • Ib)
T.
R.

Seat, side cover 1, side cover 2 Refer to “GENERAL CHASSIS” on page
4-1.
Fuel tank
Throttle cable, starter cable, clutch cable Disconnect
Refer to “ENGINE REMOVAL” on page 5-2.
Carburetor/intake manifold Refer to “CARBURETOR ” on page 6-1.

Muffler Refer to “ENGINE REMOVAL” on page 5-1.
1 Spark plug cap 1 Disconnect
2 Spark plug 1
3 Crankshaft end accessing screw 1
5-5
CYLINDER HEAD
Removing the cylinder head 22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7 ft • Ib) 8 Nm (0.8 m • kg, 6 ft • Ib)
T.
R.
T.
R.
5 9 Nm (0.9 m • kg, 7 ft • Ib)
T.
R.
E 8
E 8 Nm (0.8 m • kg, 6 ft • Ib)
T.
R.
6
1 New 9
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
New 10 LS
LS
7 New 11
2
M
12 14
13 4
LS
15
14 10 Nm (1.7 m • kg, 7 ft • Ib)
T.
R.
3
7 Nm (0.7 m • kg, 5 ft • Ib)
T.
R.

4 Timing mark accessing screw 1
5 Cylinder head cover 1
6 Cylinder head cover gasket 1
7 Dowel pin 1
8 Timing chain tensioner 1
9 Timing chain tensioner gasket 1
10 Camshaft sprocket 1
11 Decompression cam 1
12 Cylinder head 1
13 Cylinder head gasket 1
14 Dowel pin 2
15 Timing chain guide (exhaust side) 1
dure.
* Yamaha bond No. 1215 (Three Bond No. 1215)
5-6
CYLINDER HEAD
REMOVING THE CYLINDER HEAD

1. Align:
• “I” mark “a” on the magneto rotor 1
(with the stationary pointer “b” on the magneto
cover)
ssssssssssssssssssssssssss 2
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark “c” on the cam-
3. Remove:
shaft sprocket with the mark “d” on the
• Camshaft sprocket
camshaft bearing stopper plate.
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
b
4. Remove:
• Cylinder head
NOTE:
a • Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove them.
d
4 2
6 2
c
3 1
5
CHECKING THE CYLINDER HEAD

c 1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
• Valve seats
ssssssssssssssssssssssssss
2. Loosen:
• Camshaft sprocket bolt “1”
NOTE:
While holding the magneto rotor nut with a
wrench “2”, loosen the camshaft sprocket bolt.
5-7
CYLINDER HEAD
2. Check:
• Cylinder head a. 1/4 tooth
Damage/scratches → Replace. b. Correct
• Cylinder head water jacket 1. Timing chain contact link
Mineral deposits/rust → Eliminate. 2. Camshaft sprocket
3. Measure:
• Cylinder head warpage 2. Check:
Out of specification → Resurface the cylinder • Timing chain guide (exhaust side)
head. Damage/wear → Replace.
Warpage limit CHECKING THE TIMING CHAIN TENSIONER

0.03 mm 1. Check:
ssssssssssssssssssssssssss • Timing chain tensioner
a. Place a straightedge “1” and a thickness Cracks/damage/rough movement → Re-
gauge “2” across the cylinder head. place.
a. Lightly press the timing chain tensioner rod

into the timing chain tensioner housing by
hand.
NOTE:
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver “1” until
it stops.
b. Measure the warpage.

c. If the limit is exceeded, resurface the cylinder
head as follows. 1
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times. b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
ssssssssssssssssssssssssss c. Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner hous-
CHECKING THE CAMSHAFT SPROCKET
ing smoothly. If there is rough movement, re-
AND TIMING CHAIN GUIDE
place the timing chain tensioner.
1. Check:
More than 1/4 tooth wear “a” → Replace the
camshaft sprocket, timing chain and crank-
shaft as a set.
5-8
CYLINDER HEAD
B 2
CHECKING THE DECOMPRESSION SYSTEM
1. Check:
• Decompression system
a. Check the decompression system with the

camshaft sprocket and the decompression
cam installed to the camshaft.
b. Check that the decompression lever “1”
moves smoothly.
c. Without operating the decompression lever,
check that the decompression cam “2”
projects from the camshaft (exhaust cam) as INSTALLING THE CYLINDER HEAD
shown in the illustration “A”. 1. Install:
d. Move the decompression lever “1” in the di- • Cylinder head
rection of the arrow shown and check that the NOTE:
decompression cam does not project from Pass the timing chain through the timing chain
the camshaft (exhaust cam) as shown in the cavity.
illustration “B”.
2. Tighten:
• Cylinder head bolts “1”
1
Cylinder head bolt
22 Nm (2.2 m·kg, 16 ft·lb)
T.
R.
• Cylinder head bolts “2”
Cylinder head bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
NOTE:
A • Lubricate the cylinder head bolts with engine
oil.
• Tighten the cylinder head bolts in the proper
2
tightening sequence as shown and torque
them in two stages.
2
3. Install:
a. Turn the crankshaft counterclockwise.
b. Align the “I” mark “a” on the magneto rotor
with the stationary pointer “b” on the magneto
cover.
5-9
CYLINDER HEAD
c. Align the “I” mark “c” on the camshaft sprock- c. Tighten the timing chain tensioner bolts “3” to
et with the stationary pointer “d” on the cylin- the specified torque.
der head.
d. Install the timing chain onto the camshaft Timing chain tensioner bolt
sprocket, and then install the camshaft 9 Nm (0.9 m ·kg, 7 ft ·lb)
T.
R.
sprocket onto the camshaft.
2
3
d
d. Remove the screwdriver, make sure the tim-

NOTE: ing chain tensioner rod releases.
When installing the camshaft sprocket, be sure ssssssssssssssssssssssssss
to keep the timing chain as tight as possible on
5. Turn:
the exhaust side.
• Crankshaft
(several turns counterclockwise)
CAUTION: 6. Check:
Do not turn the crankshaft when installing • “I” mark “a”
the camshaft(s) to avoid damage or improper Align the “I” mark on the magneto rotor with
valve timing. the stationary pointer “b” on the magneto
e. While holding the camshaft, temporarily tight- cover.
en the camshaft sprocket bolt. • “I” mark “c”
f. Remove the wire from the timing chain. Align the “I” mark on the camshaft sprocket
ssssssssssssssssssssssssss with the stationary pointer “d” on the cylinder
head.
4. Install:
Out of alignment → Correct.
• Timing chain tensioner gasket New Refer to the installation steps above.
• Timing chain tensioner
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod ful- b
ly clockwise with a thin screwdriver “1”.
b. With the timing chain tensioner rod turned all
the way into the timing chain tensioner hous-
ing (with the thin screwdriver still installed), in-
stall the gasket and the timing chain tensioner a
“2” onto the cylinder block.
5-10
CYLINDER HEAD
7. Tighten:
• Camshaft sprocket bolt
Camshaft sprocket bolt

20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
CAUTION:
Be sure to tighten the camshaft sprocket bolt
to the specified torque to avoid the possibil-
ity of the bolt coming loose and damaging
the engine.
8. Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-3.
5-11
CAMSHAFT
CAMSHAFT
Removing the rocker arms and camshaft 22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7 ft • Ib)
T.
R.
7 6 1
13 Nm (1.3 m • kg, 9 ft • Ib)
T.
R.
3
2 2
1
M
4
E

Cylinder head Refer to “CYLINDER HEAD” on page 5-5.
1 Locknut 2
2 Adjusting screw 2
3 Camshaft bearing retainer 1
4 Camshaft 1
5 Rocker arm shaft 2
6 Intake rocker arm 1
7 Exhaust rocker arm 1
dure.
5-12
CAMSHAFT
REMOVING THE ROCKER ARMS AND Camshaft lobe dimensions

CAMSHAFT
Intake a
1. Loosen: 31.342-31.442 mm
• Locknut “1” Limit
• Valve clearance adjusting screw “2” 31.342 mm
• Rocker arm shaft “3”
2 Intake b
25.166-25.266 mm
1 Limit
25.136 mm
3 Exhaust a
31.110-31.210 mm
Limit
31.080 mm
2. Remove: Exhaust b
• Camshaft “1” 25.096-25.196 mm
Limit
NOTE:
25.066 mm
Screw 8-mm bolt “2” into the threaded end of
the camshaft and then pull out the camshaft.
a
CHECKING THE CAMSHAFT
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
3. Check:
• Camshaft oil passage
Obstruction → Blow out with compressed air.
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
• Rocker arm
5-13
CAMSHAFT
2. Check:
• Rocker arm shaft Rocker-arm-to-rocker-arm-shaft
Blue discoloration/excessive wear/pit- clearance
ting/scratches → Replace or check the lubri- 0.009–0.034 mm
Limit
cation system. 0.08 mm
3. Measure:
• Rocker arm inside diameter “a”
Out of specification → Replace. INSTALLING THE CAMSHAFT AND ROCKER
ARMS
Rocker arm inside diameter 1. Lubricate:
9.985–10.000 mm • Rocker arms
Limit • Rocker arm shafts
10.030 mm
Rocker arm inner surface
Molybdenum disulfide oil
Rocker arm shaft
Engine oil
2. Lubricate:
• Camshaft
Camshaft
Camshaft bearing
4. Measure: Engine oil
• Rocker arm shaft outside diameter “a”
Out of specification → Replace. 3. Install:
• Intake and exhaust rocker arms
Rocker arm shaft outside diame- • Rocker arm shafts
ter
9.966–9.976 mm
Limit
9.950 mm
5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.
Out of specification → Replace the defective
part(s).
5-14
VALVES AND VALVE SPRINGS

Removing the valves and valve springs
1
1
2
3
2
3 6 New
New 6
7
7 M
M
M
4
5

Rocker arms/Camshaft Refer to “CAMSHAFT” on page 5-12.
1 Valve cotter 4
2 Upper spring seat 2
3 Valve spring 2
4 Intake valve 1
5 Exhaust valve 1
6 Valve stem seal 2
7 Lower spring seat 2
8 Valve guide 2
dure.
5-15
REMOVING THE VALVES NOTE:

Identify the position of each part very carefully so
valves and related components.
that it can be reinstalled in its original place.
NOTE:
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS ”
on page 5-17.
a. Pour a clean solvent “a” into the intake and CHECKING THE VALVES AND VALVE
exhaust ports. GUIDES
b. Check that the valves properly seal. The following procedure applies to all of the
valves and valve guides.
NOTE:
1. Measure:
There should be no leakage at the valve seat “1”. • Valve-stem-to-valve-guide clearance
Out of specification → Replace the cylinder
head
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
Valve-stem-to-valve-guide clear-
ssssssssssssssssssssssssss ance (intake)
2. Remove: 0.010–0.037 mm
• Valve cotters “1” Limit
NOTE: 0.080 mm
Valve-stem-to-valve-guide clear-
Remove the valve cotters by compressing the ance (exhaust)
valve spring with the valve spring compressor 0.025–0.052 mm
and the valve spring compressor attachment“2”. Limit
0.100 mm
YSST-603
YSST-803A
1
3. Remove:
• Upper spring seat “1”
• Valve spring “2”
• Valve “3”
• Valve stem seal “4” Valve & Valve guide clearance = a–b
• Lower spring seat “5”
5-16
2. Eliminate:
CHECKING THE VALVE SEATS
• Carbon deposits
(from the valve face and valve seat)
valves and valve seats.
3. Check:
1. Eliminate:
• Valve face
• Carbon deposits
Pitting/wear → Grind the valve face.
(from the valve face and valve seat)
• Valve stem end
2. Check:
Mushroom shape or diameter larger than the
• Valve seat
body of the valve stem → Replace the valve.
Pitting/wear → Replace the cylinder head.
4. Measure:
3. Measure:
• Valve margin thickness D “a”
• Valve seat width C “a”
Out of specification → Replace the valve.
Out of specification → Replace the cylinder
Valve margin thickness D (intake) head.
0.50–0.90 mm
Valve margin thickness D (ex- Valve seat width C (intake)
haust) 0.90–1.10 mm
0.50–0.90 mm Valve seat width C (exhaust)
0.90–1.10 mm
5. Measure: ssssssssssssssssssssssssss
• Valve stem runout
Out of specification → Replace the valve. a. Install the valve into the cylinder head.
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.010 mm
b. Press the valve through the valve guide and

onto the valve seat to make a clear impres-
sion.
c. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
5-17
4. Lap:
• Valve face
• Valve seat
NOTE:
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
a. Apply a coarse lapping compound “a” to the
valve face.
e. Apply a fine lapping compound to the valve
CAUTION: face and repeat the above steps.
f. After every lapping procedure, be sure to
Do not let the lapping compound enter the
clean off all of the lapping compound from the
gap between the valve stem and the valve
valve face and valve seat.
guide.
b. Apply molybdenum disulfide oil onto the g. Install the valve into the cylinder head.
valve stem. h. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
i. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be- ssssssssssssssssssssssssss
tween your hands. CHECKING THE VALVE SPRINGS
valve springs.
1. Measure:
• Valve spring free length “a”
Out of specification → Replace the valve
spring.
5-18
Free length (intake) Spring tilt (intake)

39.40 mm 2.5°/1.7 mm
Limit Spring tilt (exhaust)
37.40 mm 2.5°/1.7 mm
Free length (exhaust)
39.40 mm
Limit
37.40 mm
INSTALLING THE VALVES

valves and related components.
2. Measure: 1. Deburr:
• Compressed valve spring force “a” • Valve stem end
Out of specification → Replace the valve (with an oil stone)
spring.
Installed compression spring

force (intake)
160-184
Installed compression spring
force (exhaust)
160-184
Installed length (intake)
34.50 mm
Installed length (exhaust)
34.50 mm 2. Lubricate:
• Valve stem “1”
• Valve stem seal “2” New
(with the recommended lubricant)
b. Installed length
3. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
spring.
3. Install:
• Lower spring seat “1”
5-19
• Valve stem seal “2” New

• Valve “3”
• Valve spring “4” 1
• Upper spring seat “5”
(into the cylinder head)
NOTE:
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up. 5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
b. Smaller pitch
4. Install:
• Valve cotters “1”
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor “2”.

YSST-603
YSST-803A
5-20
CYLINDER AND PISTON
CYLINDER AND PISTON

Removing the cylinder and piston
7
E
8
9 6
5
E
New 4 4 New
1
E
2 New

1 Cylinder 1
2 Cylinder gasket 1
3 Dowel pin 2
4 Piston pin circlip 2
5 Piston pin 1
6 Piston 1
7 Top Ring . 1
8 2nd ring 1
9 Oil Ring 1
dure.
5-21
CYLINDER AND PISTON
REMOVING THE PISTON

1. Remove:
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent CHECKING THE CYLINDER AND PISTON
the piston pin clip from falling into the crank- 1. Check:
case. • Piston wall
• Before removing the piston pin, deburr the pis- • Cylinder wall
ton pin clip’s groove and the piston pin bore ar- Vertical scratches → Replace the cylinder,
ea. and replace the piston and piston rings as a
set.
2. Measure:
• Piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder
bore gauge.
2 1
2. Remove: NOTE:
• Top ring Measure cylinder bore “C” by taking side-to-side
• 2nd ring and front-to-back measurements of the cylinder.
• Oil ring Then, find the average of the measurements.
Bore
NOTE: 58.000-58.010 mm
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
5-22
CYLINDER AND PISTON
“C” = maximum of D1–D CHECKING THE PISTON RINGS

2
“T” = maximum of D1 or D2 - maximum of D5 1. Measure:
or D6 • Piston ring side clearance
Out of specification → Replace the piston
“R” = maximum of D1, D3 or D5 - minimum of and piston rings as a set.
D2, D4 or D6 NOTE:
b. If out of specification, replace the cylinder, Before measuring the piston ring side clearance,
and replace the piston and piston rings as a eliminate any carbon deposits from the piston
set. ring grooves and piston rings.
c. Measure piston skirt diameter “D” “a”with the
micrometer. Piston ring
Top ring
Ring side clearance
0.030–0.065 mm
Limit
0.100 mm
2nd ring
Ring side clearance
0.020–0.055 mm
Limit
0.100 mm
b. 5.0 mm (0.20 in) from the bottom edge of the

piston
Piston
Diameter D
53.970-53.985 mm
d. If out of specification, replace the piston and

piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
• Piston-to-cylinder clearance = 2. Install:
Cylinder bore “C” - • Piston ring
Piston skirt diameter “D” (into the cylinder)
NOTE:
Piston-to-cylinder clearance Level the piston ring into the cylinder with the
0.020-0.035 piston crown.
Limit
0.15 mm
f. If out of specification, replace the cylinder,

and replace the piston and piston rings as a
set.
a. 40 mm
5-23
CYLINDER AND PISTON
3. Measure: 3. Measure:
• Piston ring end gap • Piston pin bore diameter “b”
Out of specification → Replace the piston Out of specification → Replace the piston.
ring.
NOTE:
Piston pin bore inside diameter
15.002-15.013
The oil ring expander spacer end gap cannot be
measured. If the oil ring rail gap is excessive, re- Limit
place all three piston rings. 15.043 mm
Piston ring
Top ring
End gap (installed)
0.10–0.25 mm
Limit
0.40 mm
2nd ring
End gap (installed)
0.10–0.25 mm
Limit
0.40 mm
Oil ring 4. Calculate:
End gap (installed) • Piston-pin-to-piston-pin-bore clearance
0.20–0.70 mm Out of specification → Replace the piston pin
and piston as a set.
• Piston-pin-to-piston-pin-bore clearance =
CHECKING THE PISTON PIN Piston pin bore diameter “b” -
1. Check: Piston pin outside diameter “a”
• Piston pin
Blue discoloration/grooves → Replace the INSTALLING THE PISTON AND CYLINDER
piston pin and then check the lubrication sys- 1. Install:
tem. • Top ring “1”
2. Measure: • 2nd ring “2”
• Piston pin outside diameter “a” • Oil ring expander “3”
Out of specification → Replace the piston pin. • Lower oil ring rail “4”
• Upper oil ring rail “5”
Piston pin outside diameter NOTE:
14.995-15.000 mm
Be sure to install the piston rings so that the
Limit manufacturer marks or numbers face up.
14.975 mm
5-24
CYLINDER AND PISTON
e a
120º
b
120º 120º
90º
d 45º c
A 45º
2. Install: a. Top ring
• Piston “1” b. Oil ring expander
• Piston pin “2” c. Upper oil ring rail
• Piston pin clips “3” New d. Lower oil ring rail
NOTE: e. 2nd ring
A. exhaust side
• Apply engine oil the piston pin.
• Make sure the arrow mark “a” on the piston 5. Install:
points towards the exhaust side of the cylinder. • Dowel pins
• Before installing the piston pin clip, cover the • Cylinder head gasket New
crankcase opening with a clean rag to prevent • Cylinder “1”
the clip from falling into the crankcase.
NOTE:
• While compressing the piston rings with one
1 hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
a 2 (intake side) through the timing chain cavity.
1
3 New
3. Lubricate:
• Piston
• Piston rings
• Cylinder
Recommended lubricant Piston Base

Engine oil YSST-604
4. Offset:
• Piston ring end gaps
5-25
MAGNETO AND STARTER CLUTCH

Removing the magneto and starter clutch
1
2
10 Nm (1.0 m l kg, 7 ft Ib) l
T.
R.
LT
LT
9
10 Nm (1.0 m kg, 7 ft Ib)
l l
T.
R.
12 8
7 New
10
14 3 LS
17 8
19 16 15
E New
E
13 4
E 6
New 18 New
5
E
14 Nm (1.4 m kg, 10 ft Ib)
l l
T.
R.
New LS
20
E
11
10 Nm (1.0 m kg, 7 ft Ib)
l l
70 Nm (7.0 m kg, 51 ft lb)
T.
R.
l l
T.
R.

Drain.
page 3-9.
Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-53.
1 Stator coil coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Neutral switch lead connector 1 Disconnect.
4 Timing mark accessing screw 1
5 Crankshaft end accessing screw 1
6 Magneto cover 1
7 Magnetor cover gasket 1
8 Dowel pin 2
9 Crankshaft position sensor 1
10 Stator coil 1
11 Magneto rotor 1
5-26
Removing the magneto and starter clutch

1
2
10 Nm (1.0 m kg, 7 ft Ib)
l l
T.
R.
LT
LT
9
10 Nm (1.0 m kg, 7 ft Ib)
l l
T.
R.
12 8
7 New
10
14 3 LS
17 8
19 16 15
E New
E
13 4
E 6
New 18 New
5
E
14 Nm (1.4 m kg, 10 ft Ib)
l l
T.
R.
New LS
20
E
11
10 Nm (1.0 m kg, 7 ft Ib)
l l
70 Nm (7.0 m kg, 51 ft lb)
T.
R.
l l
T.
R.

12 Woodruff key 1
13 Starter clutch gear 1
14 Bearing 1
15 Washer 1
16 Starter clutch idle gear shaft 1
17 Washer 1
18 Circlip 1
19 Starter clutch idle gear 1
20 Starter clutch assembly 1
dure.
5-27
REMOVING THE MAGNETO

1. Remove:
• Magneto rotor nut 2
• Washer
NOTE:
• While holding the magneto rotor using magneto
holder “1”, loosen the magneto rotor nut.
REMOVING THE STARTER CLUTCH

1. Remove:
• Starter clutch bolts “1”
1
NOTE:
• While holding the magneto rotor with the
magneto holder, remove the Starter clutch
bolts “1”
Magneto Holder
YSST-601B
2. Remove:
• Magneto rotor “1”
(with the flywheel puller “2”)
CHECKING THE STARTER CLUTCH
• Woodruff key
1. Check:
CAUTION: • Starter clutch rollers “1”
To protect the end of the crankshaft, place an • Starter clutch spring caps “2”
appropriate sized socket between the fly- • Starter clutch springs “3”
wheel puller set center bolt and the crank- Damage/wear → Replace the starter clutch
shaft. assembly.
NOTE:
Make sure the magneto puller is centered over
the magneto rotor.
Magneto puller
YSST-628
5-28
1 2 NOTE:
3
• While holding the magneto rotor, tighten the
1 starter clutch bolts “1”.
• Stake the end “a” of each starter clutch bolt.
2
3
3 1
2 1
2. Check:
• Starter clutch idle gear
• Starter clutch gear
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• Starter clutch gear contacting surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• Starter clutch operation
sssssssssssssssssssssssss
a. Install the starter clutch gear “1” onto the a
starter clutch and hold the magneto rotor.
b. When turning the starter clutch gear clock- a
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear counter- a
clockwise “B”, it should turn freely, otherwise
the starter clutch is faulty and must be re-
placed.
A 1 INSTALLING THE MAGNETO
1. Install:
• Woodruff key
B • Magneto rotor
• Washer
• Magneto rotor nut
NOTE:
• Clean the tapered portion of the crankshaft and
the magneto rotor hub.
• When installing the magneto rotor, make sure
the woodruff key is properly sealed in the key-
way of the crankshaft.
INSTALLING THE STARTER CLUTCH
1. Install: 2. Tighten:
• Starter clutch assembly • Magneto rotor nut “1”
• Starter clutch bolts “1” New
Magneto rotor nut
Starter clutch bolt 70 Nm (7.0 m·kg, 50 ft·lb)
T.
R.
14 Nm (1.4 m·kg, 10 ft·lb)

T.
R.
5-29
NOTE:
• While holding the magneto rotor “2”, tighten 7
the magneto rotor nut “1”. 1,6 8
5
1 9
4
3
2,10
2
3. Apply:
• Sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)
Yamaha bond No. 1215

TG-1215
LS
4. Install:
• Magneto cover
Magneto cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
NOTE:
Tighten the magneto cover bolts in the proper
tightening sequence as shown.
5-30
ELECTRIC STARTER
ELECTRIC STARTER
Removing the starter motor
2 Nm (0.2 m • kg, 1 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7 ft • Ib)
T.
R.
(2)

1 Starter motor 1
2 Starter motor lead 1 Disconnect.
dure.
5-31
ELECTRIC STARTER
Disassembling the starter motor
11
2 9
10
3
1
4 5
6
7
8

1 O-ring 1
2 Yoke gasket 1
3 Carbon brush assembly 1
4 Carbon brush holder assy 1
5 Oil seal 1
6 Circlip 1
7 Plate 1
8 Washer 1
9 Bearing 1
10 Starting motor front cover 1
11 Starting motor assy. 1
cedure.
5-32
ELECTRIC STARTER
DISASSEMBLING THE STARTER MOTOR NOTE:

1. Remove: The mica of the commutator must be undercut to
• Starter motor yoke “1” ensure proper operation of the commutator.
• Starter motor front cover/brush holder set “2”
NOTE:
Before disassembling the starter motor, make
alignment marks “a” on the starter motor yoke
and starter motor front cover/brush holder set.
2
4. Measure:
• Armature assembly resistances (commutator
and insulation)
Out of specification → Replace the starter
motor.
a sssssssssssssssssssssssss
a. Measure the armature assembly resistances
CHECKING THE STARTER MOTOR with the multimeter.
1. Check:
• Commutator Multimeter
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• Commutator diameter “a”
Out of specification → Replace the starter Armature coil
motor. Commutator resistance “1”
0.0315–0.0385 Ω at 20 °C (68 °F)
Limit
17.6 mm
b. If any resistance is out of specification, re-
place the starter motor.
3. Measure:
• Mica undercut “a” sssssssssssssssssssssssss
Out of specification → Scrape the mica to the 5. Measure:
proper measurement with a hacksaw blade • Brush length “a”
that has been grounded to fit the commutator. Out of specification → Replace the starter
motor front cover/brush holder set.
Mica undercut (depth)
2.10 mm Brush Length “a”
7.5 mm
Limit
4.0 mm
5-33
ELECTRIC STARTER
6. Check:
• Gear teeth
Damage/wear → Replace the gear.
7. Check:
• Bearing
• Oil seal
Damage/wear → Replace the starter motor
front cover/brush holder set.
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor front cover/brush holder set “1”
• Starter motor yoke “2”
NOTE:
Align the marks “a” on the starter motor yoke and
starter motor front cover/brush holder set made
during disassembly.
5-34
CLUTCH
CLUTCH
Removing the clutch cover
9 Nm (0.9 m • kg, 7 ft • Ib)
T.
R.
1
8
New 7
New 2
5 4
6 New
LS
3
LS (4) (6)
T.
T.
R.
R.

Drain.
page 3-9.
1 Clutch cable 1 Disconnect.
2 Oil seal 2
3 Oil filter cover 1
4 Oil filter 1
5 Dowel pin 2
6 Clutch cover 1
7 Clutch cover gasket 1
dure.
5-35
CLUTCH
Removing the clutch
70 Nm (7.0 m kg, 51 ft lb)
T.
R.
11 New
8 Nm (0.8 m kg, 6 ft Ib)

T.
R.
E
3 10 12
6
4
5
1
15
(4) 7
2 8 13
(4) 9
8
7 14
8
7
E

1 Locknut 1
2 Clutch spring 4
3 Pressure plate 1
4 Short clutch push rod 1
5 Clutch push rod holder 1
6 Ball 1
7 Friction plate 1 2
8 Clutch plate 3
9 Friction plate 2 2
10 Clutch boss nut 1
11 Lock washer 1
12 Clutch boss 1
13 Thrust washer 1
14 Clutch housing 1
15 Conical spring washer 1
dure.
5-36
CLUTCH
Removing the push lever
2
3 New
LS
E
4 New
5

Clutch housing Refer to “CLUTCH” on page 5-35.
1 Clutch push lever 1
2 Clutch push lever spring 1
3 Circlip 1
4 Oil seal 1
5 Bearing 1
dure.
5-37
CLUTCH
REMOVING THE CLUTCH

1. Straighten the lock washer tab.
2. Loosen:
• Clutch boss nut “1”
NOTE:
While holding the clutch boss “2” with the clutch
hub holder “3”, loosen the clutch boss nut.
Clutch hub holder

YSST-733
2
A B
3 X Y
CHECKING THE FRICTION PLATES A. Friction plate 1

The following procedure applies to all of the fric- B. Friction plate 2
tion plates.
1. Check: X = The gap between the friction lining material in
• Friction plate friction plate 1.
Damage/wear → Replace the friction plates Y = The gap between the friction lining material in
as a set. friction plate 2.
2. Measure:
• Friction plate thickness NOTE:
Out of specification → Replace the friction The gap X must be less than the gap Y in friction
plates as a set. plate 1 & friction plate 2 respectively.
NOTE:
Measure the friction plate at four places. CHECKING THE CLUTCH PLATES
Friction plate 1 & 2 thickness clutch plates.
2.90–3.10 mm 1. Check:
Wear limit • Clutch plate
2.80 mm Damage → Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch
plates as a set.
5-38
CLUTCH
Clutch plate thickness

1.85-2.15 mm
Warpage limit
0.20 mm
2. Check:
• Bearing
Damage/wear → Replace the bearing and
clutch housing.
CHECKING THE CLUTCH BOSS

CHECKING THE CLUTCH SPRINGS 1. Check:
The following procedure applies to all of the • Clutch boss splines
clutch springs. Damage/pitting/wear → Replace the clutch
1. Check: boss.
• Clutch spring NOTE:
Damage → Replace the clutch springs as a Pitting on the clutch boss splines will cause er-
set. ratic clutch operation.
2. Measure:
• Clutch spring free length “a”
Out of specification → Replace the clutch
springs as a set.
Clutch spring free length

41.60 mm
Minimum length
40.60 mm
CHECKING THE PRESSURE PLATE

1. Check:
• Pressure plate
CHECKING THE CLUTCH PUSH LEVER AND

SHORT CLUTCH PUSH ROD
1. Check:
CHECKING THE CLUTCH HOUSING • Clutch push lever
1. Check: • Short clutch push rod
• Clutch housing dogs “1” Damage/wear → Replace the defective
Damage/pitting/wear → Deburr the clutch part(s).
housing dogs or replace the clutch housing.
NOTE: CHECKING THE PRIMARY DRIVE GEAR
Pitting on the clutch housing dogs will cause er- 1. Remove:
ratic clutch operation. • Primary drive gear
Refer to “BALANCER GEAR” on page 5-49.
5-39
CLUTCH
2. Check: NOTE:
• Primary drive gear Be sure the thrust washer sharp-edged conner
Damage/wear → Replace the primary drive “a” is positioned opposite side to the clutch boss.
gear and clutch housing as a set.
Excessive noise during operation → Replace
the primary drive gear and clutch housing as 1
a set.
3. Install:
• Primary drive gear
a
Refer to “BALANCER GEAR” on page 5-49.
CHECKING THE PRIMARY DRIVEN GEAR

1. Check:
• Primary driven gear “1”
Damage/wear → Replace the primary drive 3. Install:
gear and clutch housing as a set. • Clutch boss “1”
Excessive noise during operation → Replace • Lock washer “2” New
the primary drive gear and clutch housing as • Clutch boss nut
a set. NOTE:
• Lubricate the clutch boss nut threads and lock
washer mating surfaces with engine oil.
1
• Align the notch “a” in the lock washer with a low
rib “b” on the clutch boss.
New 2 1
INSTALLING THE CLUTCH

1. Install: a
• Conical spring washer “1”
NOTE:
4. Tighten:
Install the conical spring washer as shown in the
• Clutch boss nut “1”
illustration.
Clutch boss nut
70 Nm (7.0 m·kg, 50 ft·lb)
T.
1
R.
NOTE:
While holding the clutch boss “2” with the clutch
hub holder “3”, tighten the clutch boss nut.
Clutch hub holder

YSST-733
2. Install:
• Clutch housing
• Thrust washer “1”
5-40
CLUTCH
1 2
5. Bend the lock washer tab along a flat side of 9. Adjust:

the nut. • Clutch mechanism free play
6. Lubricate:
• Friction plates a. Check that projection “a” on the clutch push
• Clutch plates lever “1” aligns with mark “b” shown on the
(with the recommended lubricant) crankcase in the illustration by pushing the
clutch push lever manually in direction “c” un-
Recommended lubricant til it stops.
Engine oil
7. Install:
• Clutch damper spring seat “1” a
• Clutch damper spring “2” c
• Friction plate 2 b
• Clutch plates 1
• Friction plates 1
NOTE:
• Install the clutch damper spring seat and clutch
damper spring as shown in the illustration. b. If projection “a” is not aligned with mark “b”,
• First, install a friction plate and then alternate align them as follows:
between a clutch plate and a friction plate. • Loosen the locknut “2”.
• With the clutch push lever fully pushed in di-
rection “c”, turn the short clutch push rod “3”
in or out until projection “a” aligns with mark
“b”.
12 • Hold the short clutch push rod to prevent it
from moving and then tighten the locknut to
specification.
Locknut (short clutch push rod)

8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
R.
8. Install:
• Pressure plate
• Clutch springs “1”
• Clutch spring bolts “2” 2
Clutch spring bolt
8 Nm (0.8 m · kg, 6 ft ·lb)
T.
R.
NOTE:
3
Tighten the clutch spring bolts in stages and in a
crisscross pattern. sssssssssssssssssssssssss
5-41
CLUTCH
10.Install:
• Oil seal “1”
• Oil seal “2”
1
a
b
11.Install:
• Clutch cover
Clutch cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
NOTE:
Tighten the clutch cover bolts in the proper tight-
ening sequence as shown.
1,9
8 10
11
7 12
13
5
4 3,15 2,14
13.Adjust:
• Clutch cable free play
Refer to “ADJUSTING THE CLUTCH CABLE
FREE PLAY” on page 3-10.
5-42
OIL PUMP
OIL PUMP
Removing the oil pump
4 Nm (0.4 m • kg, 3 ft • Ib)

T.
R.
2
4 Nm (0.4 m • kg, 3 ft • Ib)
T.
R.
LT
LT

T.
R.
T.
R.

Primary drive gear/Balancer drive gear Refer to “BALANCER GEAR” on page 5-49.
1 Oil baffle plate 1
2 Oil pump assembly 1
3 Oil pump drive gear 1
dure.
5-43
OIL PUMP
Disassembling the oil pump
1
E

1 Oil pump housing cover 1
2 Pin 1
3 Oil pump driven gear 1
4 Oil pump inner rotor 1
5 Oil pump outer rotor 1
6 Oil pump housing 1
cedure.
5-44
OIL PUMP
CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip

1. Check: clearance
• Oil pump drive gear Less than 0.15 mm
• Oil pump driven gear Limit
• Oil pump housing 0.20 mm
• Oil pump housing cover Outer-rotor-to-oil-pump-housing
Cracks/damage/wear → Replace the defec- clearance
tive part(s). 0.13–0.19 mm
2. Measure: Limit
0.15 mm
• Inner-rotor-to-outer-rotor-tip clearance “a”
Oil-pump-housing-to-inner-and-
• Outer-rotor-to-oil-pump-housing clearance outer-rotor clearance
“b” 0.06–0.11 mm
• Oil-pump-housing-to-inner-rotor-and-outer- Limit
rotor clearance “c” 0.15 mm
Out of specification → Replace the oil pump.
3. Check:
• Oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Oil pump inner rotor
• Oil pump outer rotor
• Oil pump driven gear
1. Inner rotor
2. Outer rotor Engine oil
3. Oil pump housing
2. Install:
• Oil pump outer rotor
• Oil pump inner rotor “1”
• Oil pump driven gear
• Pin “2”
NOTE:
When installing the inner rotor, align the pin “2”
in the oil pump shaft with the groove “a” in the in-
ner rotor “1”.
5-45
OIL PUMP
1
2
a
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-45.
INSTALLING THE OIL PUMP

1. Install:
• Oil pump assembly
Oil pump assembly screw

4 Nm (0.4 m·kg, 2.4 ft·lb)
T.
R.
CAUTION:
After tightening the screws, make sure the
oil pump turns smoothly.
5-46
SHIFT SHAFT
SHIFT SHAFT
Removing the shift shaft and stopper lever
6
LS
New 2
E 3
LT
4
5
1
9 Nm (0.9 m • kg, 7 ft • Ib)
T.
R.

Shift arm
1 Shift shaft 1
2 Circlip 1
3 Shift shaft spring 1
4 Stopper lever 1
5 Stopper lever spring 1
6 Oil seal 1
dure.
5-47
SHIFT SHAFT
CHECKING THE SHIFT SHAFT

1. Check:
• Shift shaft
Bends/damage/wear → Replace.
• Shift shaft spring
CHECKING THE STOPPER LEVER

1. Check:
• Stopper lever
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
• Stopper lever spring
INSTALLING THE SHIFT SHAFT

1. Install:
• Stopper lever “1”
• Stopper lever spring “2”
NOTE:
• Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss “3”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
2 1
2. Install:
• Shift shaft “1”
NOTE:
Hook the end of the shift shaft spring onto the
shift shaft spring stopper“2”.
2 1
5-48
BALANCER GEAR
BALANCER GEAR
Removing the primary drive gear and balancer gears
5
15
13 10
4 14
3 9
1
12
E 11
60 Nm (6.0 m • kg, 43 ft • Ib)
T.
R.
7 New
2 45 Nm (4.5 m • kg, 33 ft • Ib)
T.
R.

1 Primary drive gear nut 1
2 Balancer driven gear nut 1
3 Washer 1
4 Primary drive gear 1
5 Balancer drive gear 1
6 Straight key 1
7 Lock washer 1
8 Balancer driven gear plate 1 1
9 Balancer driven gear 1
10 Buffer boss 1
11 Spring 4
12 Dowel pin 2
13 Straight key 1
14 Balancer driven gear plate 2 1
5-49
BALANCER GEAR
Removing the primary drive gear and balancer gears
5
15
13 10
4 14
3 9
1
12
E 11
60 Nm (6.0 m • kg, 43 ft • Ib)
T.
R.
8
45 Nm (4.5 m • kg, 33 ft • Ib)
T.
R.
7 New
2
15 Spacer 1
dure.
5-50
BALANCER GEAR
REMOVING THE PRIMARY DRIVE GEAR ASSEMBLING THE BALANCER DRIVEN

AND BALANCER GEARS GEAR
1. Loosen: 1. Assemble:
• Primary drive gear nut “1” • Dowel pins “1”
NOTE: • Springs “2”
Place the leather piece plate or leather piece “a” (to the buffer boss)
between balancer drive gear “2” and balancer NOTE:
driven gear “3”, and then loosen the primary Install the dowel pins and springs alternately as
drive gear nut. shown as.
1 1
a
2
2. Straighten the lock washer tab. 2. Assemble:
3. Loosen: • Buffer boss “1”
• Balancer driven gear nut “1” • Balancer driven gear “2”
NOTE: NOTE:
Place the aluminum plate “a” between balancer Align the punch mark “a” in the buffer boss with
drive gear “2” and balancer driven gear “3”, and the punch mark “b” in the balancer driven gear.
then loosen the balancer driven gear nut.
a
2
1
1
3 b a 2
INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER GEARS
1. Install:
CHECKING THE BALANCER GEARS AND • Balancer driven gear “1”
PRIMARY DRIVE GEAR
• Lock washer New
1. Check:
• Balancer drive gear “2”
• Balancer drive gear
• Primary drive gear
• Balancer driven gear
• Washer “3”
• Buffer boss
• Balancer driven gear nut
• Spring
• Primary drive gear nut
• Dowel pin
Cracks/damage/wear → Replace. NOTE:
2. Check: • Align the punch mark “a” in the balancer drive
• Primary drive gear gear “2” with the punch mark “b” in the balancer
Refer to “CHECKING THE PRIMARY DRIVE driven gear “1”.
GEAR” on page 5-39. • Be sure the washer sharp-edged conner “c” is
positioned opposite side to the primary drive
gear.
5-51
BALANCER GEAR
b
2 3
1
2
1
4
a b
3. Bend the lock washer tab along a flat side of

the nut.
3
2. Tighten:
• Balancer driven gear nut “1”
• Primary drive gear nut “2”
Balancer driven gear nut

45 Nm (4.5 m·kg, 33 ft·lb)
T.
R.
Primary drive gear nut

60 Nm (6.0 m·kg, 43 ft·lb)
NOTE:
• Place the aluminum plate “a” between balanc-
er drive gear “3” and balancer driven gear “4”,
and then tighten the balancer driven gear nut.
• Place the aluminum plate “b” between balanc-
er drive gear “3” and balancer driven gear “4”,
and then tighten the primary drive gear nut.
1
a
5-52
CRANKCASE
CRANKCASE
Separating the crankcase
10 Nm (1.0 m • kg, 7 ft • Ib)

T.
R.
4 10 Nm (1.0 m • kg, 7 ft • Ib)
T.
R.
5 6
5
7
10 Nm (1.0 m • kg, 7 ft • Ib)

T.
R.

Engine
Refer to “CYLINDER AND PISTON” on page
Cylinder/Piston 5-21.
Oil pump assembly Refer to “OIL PUMP” on page 5-43.
Shift shaft Refer to “SHIFT SHAFT” on page 5-47.
Refer to “ELECTRIC STARTER” on page

Starter motor
5-31.
Balancer gears Refer to “BALANCER GEAR” on page 5-49.
Magneto rotor Refer to “MAGNETO AND STARTER

CLUTCH” on page 5-26.
1 Timing chain guide (intake side) 1
2 Chain cover 1
3 Timing chain 1
4 Right crankcase 1
5-53
CRANKCASE
Separating the crankcase
10 Nm (1.0 m • kg, 7 ft • Ib)

T.
R.
4 10 Nm (1.0 m • kg, 7 ft • Ib)
T.
R.
5 6
10 Nm (1.0 m • kg, 7 ft • Ib)
T.
R.
3
5
7
10 Nm (1.0 m • kg, 7 ft • Ib)

T.
R.

5 Dowel pin 2
6 Left crankcase 1
7 Nozzle 1
dure.
5-54
CRANKCASE
Removing the oil seal and bearings
3 E
7 Nm (0.7 m • kg, 5 ft • Ib)
T.
R.
3 E
2
3
3
3 3
LT
LS

Crankshaft/Balancer Refer to “CRANKSHAFT” on page 5-58.
Transmission Refer to “TRANSMISSION” on page 5-61.
1 Oil seal 1
2 Bearing retainer 1
3 Bearing 7
dure.
5-55
CRANKCASE
SEPARATING THE CRANKCASE CAUTION:

1. Remove: Tap on one side of the crankcase with a soft-
• Crankcase bolts face hammer. Tap only on reinforced por-
NOTE: tions of the crankcase, not on the crankcase
Loosen each bolt 1/4 of a turn at a time, in stag- mating surfaces. Work slowly and carefully
es and in the proper sequence as shown. and make sure the crankcase halves sepa-
rate evenly.
A 2
CHECKING THE CRANKCASE
1
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase
B • Oil delivery passages
10,15 Obstruction → Blow out with compressed air.
9
8
CHECKING THE TIMING CHAIN AND TIMING
7 CHAIN GUIDE
11 4,14
1. Check:
12 • Timing chain
6
3,13 5 Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
A. Right crankcase
B. Left crankcase
2. Turn:
• Shift drum segment
NOTE:
Turn the shift drum segment “1” to the position
shown in the illustration. In this position, the shift
drum segment teeth will not contact the crank-
case during crankcase separation.
2. Check:
• Timing chain guide (intake side)
1 Damage/wear → Replace.
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
3. Remove: CHECKING THE BEARINGS AND OIL SEAL

• Right crankcase 1. Check:
• Bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
5-56
CRANKCASE
Rough movement → Replace. 3. Install:

• Oil seal • Right crankcase
Damage/wear → Replace. NOTE:
Turn the shift drum segment “1” to the position
INSTALLING THE BEARING RETAINER shown in the illustration. In this position, the shift
1. Install: drum segment teeth will not contact the crank-
• Bearing retainer “1” case during crankcase installation.
NOTE:
• Install the bearing retainer “1” with its “OUT”
mark “a” facing outward. 1
• Apply locking agent (LOCTITE®) to the
threads of the bearing retainer bolt.
Bearing retainer bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
LOCTITE
4. Install:
a • Crankcase bolts
Crankcase bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
1
R.
NOTE:
Tighten each bolt 1/4 of a turn at a time, in stag-
es and in the proper sequence as shown.
• M6 × 70 mm : “7–9”, “11”
ASSEMBLING THE CRANKCASE • M6 × 55 mm : “14”, “15”
1. Thoroughly clean all the gasket mating sur- • M6 × 45 mm : “1–5”, “10”
faces and crankcase mating surfaces. A
2. Apply:
• Sealant 1,6 7
(onto the crankcase mating surfaces) 8
Yamaha bond No. 1215 5 9

2,12
4 10
NOTE: 3,13 11
Do not allow any sealant to come into contact
with the oil gallery. B
14
15
A. Left crankcase
B. Right crankcase
5-57
CRANKSHAFT
CRANKSHAFT
Removing the crankshaft and balancer
LS
LS
New
New
Crankcase Separate.
Refer to “CRANKCASE” on page 5-53.
1 Balancer 1
2 Crankshaft 1
dure.
5-58
CRANKSHAFT
REMOVING THE CRANKSHAFT

1. Remove:
• Crankshaft “1”
NOTE:
• Remove the crankshaft with the crankcase
separating tool “2”.
• Make sure the crankcase separating tool is
centered over the crankshaft.
CAUTION: 2. Measure:
• To protect the end of the crankshaft, place • Big end side clearance
an appropriate sized socket between the Out of specification → Replace the crank-
crankcase separating tool bolt and the shaft.
crankshaft.
Big end side clearance D
• Do not tap on the crankshaft.
0.110–0.410 mm
Crankcase separating tool 3. Measure:

YSST-265
• Crankshaft width
Out of specification → Replace the crank-
shaft.
Width A
47.95–48.00 mm
2
4. Check:
• Crankshaft sprocket
Damage/wear → Replace the crankshaft.
• Bearing
Cracks/damage/wear → Replace the crank-
shaft.
1
5. Check:
• Crankshaft journal
CHECKING THE CRANKSHAFT Scratches/wear → Replace the crankshaft.
1. Measure: • Crankshaft journal oil passage
• Crankshaft runout Obstruction → Blow out with compressed air.
Out of specification → Replace the crank-
shaft, bearing or both.
INSTALLING THE CRANKSHAFT
NOTE: 1. Install:
Turn the crankshaft slowly. • Crankshaft “1”
Runout limit C
0.030 mm
5-59
CRANKSHAFT
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
NOTE:
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft bot-
toms against the bearing.
5-60
TRANSMISSION
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
1
4
8
2
5 9 E
2 6
E
3

Separate.
Crankcase
Refer to “CRANKCASE” on page 5-53.
1 Shift fork guide bar 2
2 Spring 4
3 Shift drum assembly 1
4 Shift fork-R 1
5 Shift fork-C 1
6 Shift fork-L 1
7 Drive axle assembly 1
8 Main axle assembly 1
9 Long clutch push rod 1
dure.
5-61
TRANSMISSION
Disassembling the main axle
7
M
6 M
5
4
2
1

1 2nd pinion gear 1
2 5th pinion gear 1
3 3rd pinion gear 1
4 Circlip 1
5 Toothed washer 1
6 4th pinion gear 1
7 Main axle/1st pinion gear 1
cedure.
5-62
TRANSMISSION
Disassembling the drive axle

5
6
7
8
9
10
11
12
13
M
4
3 M
2
1
1 Circlip 1
2 Washer 1
3 2nd wheel gear 1
4 5th wheel gear 1
5 Washer 1
6 1st wheel gear 1
7 Collar 1
8 Washer 1
9 4th wheel gear 1
10 Circlip 1
11 Washer 1
12 3rd wheel gear 1
13 Drive axle 1
cedure.
5-63
TRANSMISSION
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY

The following procedure applies to all of the shift 1. Check:
forks. l Shift drum groove
1. Check: Damage/scratches/wear → Replace the shift
l
Shift fork cam follower “1” drum assembly.
l
Shift fork pawl “2” l Shift drum segment “1”
Bends/damage/scoring/wear → Replace the Damage/wear → Replace the shift drum as-
shift fork. sembly.
l Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
sembly.
2. Check:
l
Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
CHECKING THE TRANSMISSION
WARNING 1. Measure:
Do not attempt to straighten a bent shift fork l Main axle runout
guide bar. (with a centering device and dial gauge “1”)
Out of specification → Replace the main axle.
Main axle runout limit

0.03 mm
3. Check:
l
Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
2. Measure:
l Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive axle.
Drive axle runout limit

0.03 mm
5-64
TRANSMISSION
ASSEMBLING THE MAIN AXLE AND DRIVE

AXLE
1. Install:
Toothed washer “1”
l
l
Circlip “2” New
NOTE:
l
Be sure to install the circlip so that its sharp
edge “a” is facing away from the toothed wash-
er and gear.
3. Check: l
Be sure the circlip ends “b” are positioned at
l
Transmission gears the axle spline groove“c”.
Blue discoloration/pitting/wear → Replace
the defective gear(s).
l Transmission gear dogs b
Cracks/damage/rounded edges → Replace New 2
the defective gear(s).
a 1 c
2. Install:
2nd pinion gear “1”
l
NOTE:
Press the 2nd pinion gear into the main axle “2”,
4. Check: as shown in the illustration.
l Transmission gear engagement
(each pinion gear to its respective wheel Installed depth “a”
gear) 106.85–107.05 mm
Incorrect → Reassemble the transmission
axle assemblies.
5. Check: a
l Transmission gear movement
Rough movement → Replace the defective
part(s).
CHECKING THE CLUTCH PUSH RODS 2

1. Check:
l Long clutch push rod 1
Cracks/damage/wear → Replace the long
clutch push rod. INSTALLING THE SHIFT FORKS AND SHIFT
2. Measure: DRUM ASSEMBLY
l
Push rod bending limit 1. Install:
Out of specification → Replace the long Shift fork-L “1”
l
clutch push rod. Shift fork-C “2”

l
Shift fork-R “3”

l
Push rod bending limit

0.500 mm Shift drum assembly “4”
l
Springs
l
Shift fork guide bar “5”

l
Shift fork guide bar “6”

l
5-65
TRANSMISSION
NOTE:
The embossed marks on the shift forks should
face towards the right side of the engine and be
in the following sequence:“R”, “C”, “L”.
3
1 5
6
4
2. Check: 2
Transmission
l
Rough movement → Repair.

NOTE:
l Apply engine oil to each gear and bearing thor-
oughly.
l Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
5-66
FUEL SYSTEM
CARBURETOR
REMOVING THE CARBURETOR ………………………………………...................................…. 6-1
DISASSEMBLING THE CARBURETOR ………………………………….................................… 6-2
CHECKING THE CARBURETOR ……………………………………....................…..............….. 6-4
ASSEMBLING THE CARBURETOR ……………………………………................................…... 6-6
INSTALLING THE CARBURETOR …………………………………….................................…..... 6-7
MEASURING AND ADJUSTING THE FUEL LEVEL……………….....................….............…... 6-7
CHECKING THE FUEL COCK………………………….…………………..................................… 6-8
AIR INDUCTION SYSTEM

AIR INDUCTION SYSTEM….………………………………..............................…..............……... 6-9
REMOVING THE AIR INDUCTION SYSTEM …………….……….....................…..............….... 6-10
CHECKING THE AIR INDUCTION SYSTEM……………………………………....................…... 6-11
CARBURETOR
CARBURETOR
Removing the carburetor
2
5
8
6
3
3
4 4
7
1
Seat, Side cover 1 & 2, fuel hose Refer to “GENERAL CHASSIS” on

page 4-1
1 Fuel over flow pipe 1 Disconnect
2 Fuel hose 1
3 Carburetor joint clamp screw 1 Loosen
4 Carburetor clamp 1
5 Throttle cable 1
6 Starter cable 1
7 TPS coupler 1
8 Carburetor assembly 1
For installation, reverse the

removal procedure
6-1
CARBURETOR
Disassembling the carburetor
1
4
39 3
25
35 36 37 38
29
28
30 27
13 26
12
19
10 16 34
11 18 33
32
17 24
15 23 31
22
21
9 14
20
8
7
Disassembling the carburetor Remove the parts in the order listed

1. Diaphragm cover 1
2. Diaphragm spring 1
3. Needle valve set 1
4. Piston valve 1
5. Diaphragm 1
6. Ring 1
7. Drain plug 1
8. Float chamber 1
9. O ring 1
10. Main jet 1
11. Needle jet holder 1
12. O ring 1
13. Main nozzle 1
6-2
CARBURETOR
1
4
39 3
25
35 36 37 38
29
28
30 27
13 26
12
19
10 16 34
11 18 33
32
17 24
15 23 31
22
21
9 14
20
8
7
14. Float Pin 1

15. Float 1
16. Needle Assy. 1
17. Throttle Stop Scerw 1
18. Washer 1
19. Spring 1
20. Pilot Screw 1
21. O-ring 1
22. Spring 1
23. Washer 1
24. O-ring 1
25. Net Filter 1
26. Plunger Cap 1
27. Guide Holder 1
6-3
CARBURETOR
1
4
39 3
25
35 36 37 38
29
28
30 27
13 26
12
19
10 16 34
11 18 33
32
17 24
15 23 31
22
21
9 14
20
8
7
28. O ring 1
29. Plunger spring 1
30. Plunger 1
31. Spring washer 1
32. Throttle stopper 1
33. Stop washer 1
34. Spring 1
35. TPS 1
36. O ring 1
37. Lock washer 1
38. Washer 1
39. Washer 1
removal procedure
6-4
CARBURETOR
Checking the carburetor 4. Check:

1. Check: • Float chamber body “1”
• Carburetor body “1” Dirt - Clean.
• Float chamber “2”
• Jet housing “3”
Cracks/damage -Replace.
1
3 5. Check:
• Float chamber rubber gasket “1”
Cracks/damage/wear - Replace.
2
NOTE :
2. Check: Always replace the gasket with new one.
• Fuel passages
Obstruction - Clean.
6. Check:
• Float “1”
Damage - Replace.
NOTE :
l Wash the carburetor in a petroleum based
solvent. 1
l Do not use any caustic carburetor cleaning
solution.
l Blow out all of the passages and jets with
7. Check:
compressed air. • Needle valve “1”
• Needle valve seat “2”
3. Check: • O-ring “3”
• Diaphragm valve assembly “1” Damage/obstruction/wear --Replace the
Cracks/damage - Replace needle valve “1”, needle valve seat “2” and
O-ring “3” as a set.
1
6-5
CARBURETOR
8. Check:
• Filter net “1”
Damage/obstruction ----Replace 1
1 2
9. Check:
• Main jet “1”/ jet holder “2” /O ring “3”
/main nozzle “4”
Damage/obstruction - Replace
2 3 4
1
ASSEMBLING THE CARBURETOR
10. Check: CAUTION:

• Pilot jet “1” • Before assembling the carburetor, wash all
Damage/obstruction - Replace the parts in a petroleum-based solvent.
• Always use a new gasket.
1
1. Install:
• Throttle screw set “1”
11. Check: • Pilot jet “2”
• Pilot screw set “1” • Main nozzle “3”
Damage/wear - Replace • O ring “4”
• Needle jet holder “5”
1 • Main jet “6”
12. Check:
• Throttle screw set “1”
Damage/wear - Replace
1
1
2
13. Check: 6
• YTPS “1” 3
Damage/faulty - Replace 4 5
• Butterfly/butterfly shaft “2” movement
Obstruction/damage/wear - Replace the
carburetor
6-6
CARBURETOR
2. Install: 4. Install:
• Pilot screw set “1” • Float “1”
• Filter net “2” • Float pin “2”
• Screw “3”
• Float chamber gasket “4”
• Float chamber “5”
1
3
2
2
1
5
4
5. Install:
• Diaphragm valve assembly “1”
3. Install: CAUTION:
• Needle valve assembly “1” Do not over tight any screw, as it may damage
gaskets and O-rings. This may lead to fuel
leakage.
NOTE :
Make sure the raised portion “A” provided on
diaphragm must align with the slot “B” given in
carburetor body.
6-7
CARBURETOR
6. Install:
• Diaphragm spring “1”
• Diaphragm cover “2“ & tighten its bolts
4
1
2. Adjust:
• Fuel level
a. Remove the carburetor.
INSTALLING THE CARBURETOR b. Check the needle valve seat and needle
1. Connect all the wires and cables. valve.
Refer to "ENGINE REMOVAL" on page 5-2. c. If either is worn, replace them as a set.
2. Adjust d. If both are fine, adjust the float level by
• Throttle cable free play slightly bending the float tang “1”.
Refer to “ADJUSTING THE THROTTLE e. Install the carburetor.
FREE PLAY” on page 3-6 f. Measure the fuel level again.
3. Adjust: g. Repeat steps a to f until the fuel level is
• Engine idle speed within specification.
1300 to 1500 r/min. ssssssssssssssssssssssssss
Refer to "ADJUSTING THE ENGINE IDLING
SPEED" on page 3-4
MEASURING AND ADJUSTING THE FUEL

LEVEL
1. Measure:
• Fuel level “a”
Out of specification - adjust. 1
Fuel level (below the float cham-

ber mating surface)
6.0 ~ 7.0 mm
ssssssssssssssssssssssssss CHECKING THE FUEL COCK
1. Check:
a. Stand the vehicle on a level surface. • Fuel cock
b. Place the vehicle on a suitable stand to Cracks/damage/wear - replace.
ensure that the vehicle is standing straight
up.
c. Install the fuel level gauge “1” on to the fuel
drain pipe “2”
d. Loosen the fuel drain screw “3”
e. Hold the fuel level gauge vertically next to
the float chamber “4”
f. Measure the fuel level “a”.
6-8
5
1
2 4
3
3
2
5
4
1
1 Air induction system hose ( from air filter).

2 Air induction system vacuum hose.
3 Air induction system pipe (to engine)
4 Air Filter
5 Air induction system assy.
6-9
Removing the Air Induction System

1
4
2
Seat. side cover 1 & side cover 2 Refer to "GENERAL CHASSIS"

on page 4-1
Fuel tank Refer to "GENERAL CHASSIS"
on page 4-2
1 Air induction system hose (from air filter) 1
2 Air induction system vacuum hose 1
3 Air induction pipe (to cylinder head cover) 1
4 Air induction assy. 1

removal procedure
6-10
CHECKING THE AIR INDUCTION SYSTEM
• 3-way joint
Air injection
2. Check:
The air induction system burns unburned ex-
• Reed valve
haust gases by injecting fresh air (secondary air)
• Reed valve stopper
into the exhaust port, reducing the emission of
• Reed valve seat
hydrocarbons. When there is negative pressure
Cracks/damage → Replace the reed valve
at the exhaust port, the reed valve opens, allow-
assembly.
ing secondary air to flow into the exhaust port.
3. Check:
The required temperature for burning the un-
• Air cut-off valve
burned exhaust gases is approximately 600 to
700 °C.
4. Check:
Air cut-off valve • Air cut-off valve operation
The air cut-off valve is operated by the intake Does not operate → Replace.
sssssssssssssssssssssssssssss
gas pressure through the piston valve dia- a. Blow air through the end of the air induction
phragm. Normally, the air cut-off valve is open to system hose (3-way joint to air cut-off valve)
allow fresh air to flow into the exhaust port. Dur- and check that air flows from the air cut-off
ing sudden deceleration (the throttle valve sud- valve (to cylinder head side).
denly closes), negative pressure is generated
and the air cut-off valve is closed in order to pre- Air cut-off valve opens
vent after-burning. Perform step (b).
Additionally, at high engine speeds and when Air cut-off valve closes
the pressure decreases, the air cut-off valve au- Replace the air cut-off valve.
tomatically closes to guard against a loss of per-
formance due to self-EGR.
b. Install a vacuum/pressure pump to the air-cut

A off valve “1” and apply negative pressure to
the valve.
A. From the air filter case
Vacuum/pressure pump gauge
B. Air flow to exhaust port
set
C. To the intake manifold
1. Check: c. Blow air through the end of the air induction
• Hoses system hose (3-way joint to air cut-off valve)
Loose connections → Connect properly. and check that air does not flow and out
through the air cut-off valve (to cylinder head
side).
6-11
Air cut-off valve opens

Replace the air cut-off valve.
Air cut-off valve closes
Air cut-off valve is OK.
NOTE :
This test is to be performed when the pressure is
under - 50 kpa.
sssssssssssssssssssssssssssss
6-12
ELECTRICAL SYSTEM
IGNITION SYSTEM .........................................................................................7-1

CIRCUIT DIAGRAM .............................................................................7-1
TROUBLESHOOTING ........................................................................7-3
ELECTRIC STARTING SYSTEM...............................................................7-5

CIRCUIT DIAGRAM .............................................................................7-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION.................7-7
TROUBLESHOOTING ...................................................................7-9
CHARGING SYSTEM....................................................................................7-11
CIRCUIT DIAGRAM ...........................................................................7-11
TROUBLESHOOTING ......................................................................7-13
LIGHTING SYSTEM......................................................................................7-14
CIRCUIT DIAGRAM ...........................................................................7-14
SIGNALING SYSTEM ...................................................................................7-17

CIRCUIT DIAGRAM ...........................................................................7-17
SELF DIAGNOSTIC FUNCTION ....................................................................7-23

SELF DIAGNOSTIC FUNCTION .....................................................7-23
ENGINE TROUBLE WARNING LIGHT FAULT CODE INDICATION ..7-23
FAULT CODE TABLE .....................................................7-24
CHECKING THE ENGINE TROUBLE WARNING LIGHT BULB ..7-24
TROUBLESHOOTING METHOD.....................................................7-24
TROUBLESHOOTING DETAIL .........................................................7-25
ELECTRICAL COMPONENTS......................................................................7-28
CHECKING THE SWITCHES ............................................................7-30
CHECKING THE BULBS AND BULB SOCKETS ................................7-33
CHECKING THE FUSE......................................................................7-34
CHECKING AND CHARGING THE BATTERY....................................7-34
CHECKING THE RELAYS ................................................................7-37
CHECKING THE TURN SIGNAL RELAY ............................................7-38
CHECKING THE SPARK PLUG CAP..................................................7-39
CHECKING THE IGNITION COIL ......................................................7-39
CHECKING THE IGNITION SPARK GAP............................................7-40
CHECKING THE CRANKSHAFT POSITION SENSOR.....................7-40
CHECKING THE STARTER MOTOR OPERATION...........................7-40
CHECKING THE STATOR COIL ......................................................7-41
CHECKING THE RECTIFIER/REGULATOR......................................7-41
CHECKING THE HORN.....................................................................7-42
CHECKING THE FUEL SENDER .......................................................7-42
CHECKING THE THROTTLE POSITION SENSOR...........................7-43
CHECKING THE SPEED SENSOR..................................................7-43
Sb
LY
G BL
B Br R
W W W - W (BLACK)
1 W W R
3 LY Or Or
B Br CRK+ IG 8
B
W W
Sb
Sb
R
LY G 20
7
W W BL LY BL
Sb
30 31
CIRCUIT DIAGRAM
26
Sb 6 START STOP LIGHT L
2 4 VCC 19 BL L Y
OFF OFF OFF Y
MAIN SIG
15A
START RUN PO BL
ON SGND
R
Y
L
ON
IGNITION SYSTEM
OFF Br RW
YW
LWWB TC
Lg
B L DIAG
21 LW
R
(BLACK) GND VB
LB
LW
WB
B
Br
Rw
L
RwBr
Br
B
RW
5 WBLW B - - Or BL L
LW
23 L B RWYWLg - LY Y
RW
Sb
LW (BLACK) RW
22 27
RB LB
RW LB LB Sb RW
(Black)
13 NEUTRAL
B
RB
Br Sb
B
Br
Br
24
RB
OrW Br B L - YW Lg W
Br
Br2 Y Dg GB Ch - Bl Sb TACHO
Br 11 B RB
9 (BLACK) 28
- -
B1 B
P 10 GY GY
+ GND (Black) (Black)
12 - -
7-1
Br W
SPEED
Br Br YW
ILLMI TC
B
L
(RED) (RED) VCC
BrW
BrW BL
Y
GY
SGND
Br
GB
FUEL+
GB
L
Y
OrW
Br
WB
P
BrW
FUEL -
14
BL
L
W
Dg Br Br Dg DIMMER 34 HORN 35 FLASHER 36 29

PASS ILLUMI
BrW WB WB BrW OFF HI OFF L GB
Ch P P Ch ON LO ON NL OrW
N W L
25
Y NR BL
12V21W/35W
Y
G R 18
OrW
G
B DIAG Lg
B L W
BL
Y
G
B
Ch
Dg
TURN
Dg
Ch
Y HI BEAM
Ch
Dg
Ch
Dg
L
Y
G
B
16 17 32 33
L L G
12V5W
- - Y B
B B
12V35W/35W
12V10W
12V10W
12V10W
12V10W
15
B
(BLACK) (BLACK)
B
B
B
B
IGNITION SYSTEM
IGNITION SYSTEM
1. AC magneto
3. R/R unit
4. Main fuse
5. Battery
6. Main switch
7. CDI unit
8. Ignition coil
19. TPS
20. Spark plug
21. +Ve lead wire
22. –Ve lead wire
30. Stop switch
7-2
IGNITION SYSTEM
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
• Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover 1 & 2
3. Fuel tank
1. Check the fuse. NG →

Refer to “CHECKING THE FUSE” Replace the fuse.
on page 7-34.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY ” on • Recharge or replace the battery.
page 7-34.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-7.
OK ↓
4. Check the spark plug cap. NG →

Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 7-39.
OK ↓
5. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 7-39.
OK ↓
6. Check the crankshaft position sen- NG →
sor.
Replace the crankshaft position sen-
Refer to “CHECKING THE CRANK-
sor/stator assembly.
SHAFT POSITION SENSOR” on
page 7-40.
OK ↓
7. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-30.
OK ↓
8. Check the TPS NG →
Refer to “CHECKING THE Replace the TPS
TPS ” on page 7-43.
OK ↓
7-3
IGNITION SYSTEM
9. Check the engine stop switch. NG →

The engine stop switch is faulty. Replace
Refer to “CHECKING THE
the right handlebar switch.
OK ↓
10.Check the entire ignition system NG →
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem wiring.
page 7-1.
OK ↓
Replace the CDI.
7-4
Sb
LY
G BL
B Br R
W W W - W (BLACK)
1 W W R
3 LY Or Or
B Br CRK+ IG 8
B
W W
Sb
Sb
R
LY G 20
7
W W BL LY BL
Sb
26 30 31
6 START STOP LIGHT L
CIRCUIT DIAGRAM
Sb VCC
2 4 19 BL L Y
OFF OFF OFF Y
MAIN SIG
15A
START RUN PO BL
ON SGND
R
Y
L
ON
OFF Br RW
YW
LW WB TC
Lg
STARTING CIRCUIT
B L DIAG
21 LW
R
(BLACK) GND VB
LB
LW
WB
B
Br
Rw
L
Rw Br
Br
B
RW
5 WB LW B - - Or BL L
LW
RW
Sb
LW (BLACK) RW
22 27
RB LB
RW LB LB Sb RW
(Black)
13 NEUTRAL
B
RB
Br Sb
B
Br
Br
24
RB
Br
Br 11 B RB
9 (BLACK) 28
- -
B1 B
P 10 GY GY
12 - - Br W
7-5
SPEED
Br Br YW
ILLMI TC
B
L
(RED) (RED) VCC
BrW
BrW BL
Y
GY
SGND
Br
GB
FUEL+
GB
L
Y
OrW
Br
WB
P
BrW
FUEL -
14 34
BL
L
W
Dg Br Br Dg DIMMER HORN 35 FLASHER 36 29

PASS ILLUMI
N W L
25
Y NR BL
12V21W/35W
Y
G R 18
OrW
G
B DIAG Lg
B L W
BL
Y
G
B
Ch
Dg
TURN
Dg
Ch
Y HI BEAM
Ch
Dg
Ch
Dg
L
Y
G
B
16 17 32 33
L L G
12V5W
- - Y B
B B
12V35W/35W
12V10W
12V10W
12V10W
12V10W
15
B
(BLACK) (BLACK)
B
B
B
B
ELECTRIC STARTING SYSTEM
2. Neutral switch
4. Main fuse
5. Battery
6. Main switch
21. +Ve lead wire
22. – Ve lead wire
23. Starter relay
24. Starting motor
26. Start switch
27. Starting cut off relay
28. Clutch switch
30. Stop switch
7-6
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the
starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met, the starting circuit cut-off relay
is closed and the engine can be started by pressing the start switch “ ”.
2
3
9
5
8
10
7 6
a b
7-7
a. WHEN THE TRANSMISSION IS IN

NEUTRAL
b. WHEN CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
1. Battery
2. Fuse
3. Main switch
4. Stop switch
5. Starting cut off relay
6. Clutch switch
7. Neutral switch
8. Start switch
9. Starter relay
10. Starting motor
7-8
TROUBLESHOOTING
The starter motor fails to turn.
NOTE:
1. Seat
2. Sde cover 1 and side cover 2

on page 7-34.
OK ↓
page 7-34.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION ” on page
with step 5.
7-40.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-33.
OK ↓
5. Check the starting circuit cut-off re- NG →
lay.
Replace the starting circuit cut-off relay.
Refer to “CHECKING THE RE-
LAYS” on page 7-37.
OK ↓
6. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 7-37.
OK ↓
OK ↓
7-9
8. Check the engine stop switch. NG →

The engine stop switch is faulty. Replace
the right handlebar switch.
OK ↓
9 .Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
10.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
11.Check the start switch. NG →
The start switch is faulty. Replace the right
handlebar switch.
OK ↓
12.Check the entire starting system NG →
wiring. Properly connect or repair the starting sys-
page 7-5.
OK ↓
The starting system circuit is OK.
7-10
Sb
LY
G BL
B Br R
W W W - W (BLACK)
1 W W R
3 LY Or Or
B Br CRK+ IG 8
B
W W
Sb
Sb
R
LY G 20
7
W W BL LY BL
Sb
26 30 31
CIRCUIT DIAGRAM
2 4 VCC 19 BL L Y
OFF OFF OFF Y
MAIN SIG
15A
START RUN PO BL
ON SGND
R
Y
L
ON
OFF Br RW
YW
LWWB TC
Lg
B L DIAG
21 LW
R
(BLACK) GND VB
CHARGING SYSTEM
LB
LW
WB
B
Br
Rw
L
RwBr
Br
B
RW
LW
RW
Sb
LW (BLACK) RW
22 27
RB LB
RW LB LB Sb RW
(Black)
13 NEUTRAL
B
RB
Br Sb
B
Br
Br
24
RB
Br
Br 11 B RB
9 (BLACK) 28
- -
B1 B
P 10 GY GY
12 - - Br W
SPEED
7-11
Br Br YW
ILLMI TC
B
L
(RED) (RED) VCC
BrW
BrW BL
Y
GY
SGND
Br
GB
FUEL+
GB
L
Y
OrW
Br
WB
P
BrW
FUEL -
14
BL
L
W

PASS ILLUMI
N W L
25
Y NR BL
12V21W/35W
Y
G R 18
OrW
G
B DIAG Lg
B L W
BL
Y
G
B
Ch
Dg
TURN
Dg
Ch
Y HI BEAM
Ch
Dg
Ch
Dg
L
Y
G
B
16 17 32 33
L L G
12V5W
- - Y B
B B
12V35W/35W
12V10W
12V10W
12V10W
12V10W
15
B
(BLACK) (BLACK)
B
B
B
B
CHARGING SYSTEM
CHARGING SYSTEM
1. AC magneto
3. R/R unit
4. Main fuse
5. Battery
21. +Ve lead wire
7-12
CHARGING SYSTEM
TROUBLESHOOTING
The battery is not being charged.
NOTE:
1. Seat
2. Left side panel/Side Cover.

on page 7-34.
OK ↓
page 7-34.
OK ↓
3. Check the stator coil. NG →
Replace the crankshaft position sen-
Refer to “CHECKING THE STATOR
sor/stator assembly.
COIL” on page 7-41.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR ” on page 7-41.
OK ↓
5. Check the entire charging system NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 7-11.
OK ↓
The charging system circuit is OK.
7-13
Sb
LY
G BL
B Br R
W W W - W2 (BLACK)
1 W2 W2 R
3 LY Or Or
B Br CRK+ IG 8
B
W W
Sb2
Sb
R
LY G 37
7
W W2 BL LY BL
Sb2
26 30 31
2 4 VCC 19 BL L Y
CIRCUIT DIAGRAM
OFF OFF OFF Y

MAIN SIG
15A
START RUN PO BL
ON SGND
R2
ON
Y
L
OFF Br RW
YW
LWWB TC
Lg
LIGHTING SYSTEM
B L DIAG
21 LW
R2
(BLACK) GND VB
LB
LW
WB
B
Br
Rw
L
RwBr
Br
B
RW
LW
RW
Sb
LW (BLACK) RW
22 27
RB LB
RW LB LB Sb RW
(Black)
13 NEUTRAL
B
RB
Br Sb
B
Br
Br
24
RB
Br
Br 11 B RB
9 (BLACK) 28
- -
B1 B
P 10 GY GY
12 - - Br W
SPEED
7-14
Br Br YW
ILLMI TC
B
L
(RED) (RED) VCC
BrW
BrW BL
Y
GY
SGND
Br
GB
FUEL+
GB
L
Y
OrW
Br
WB
P
BrW
FUEL -
14
BL
L
W
Dg Br Br Dg 34 HORN 35 FLASHER 36 29
PASS DIMMER ILLUMI
N W L
25
Y NR BL
12V21W/35W
Y
G R 18
OrW
G
B DIAG Lg
B L W
BL
Y
G
B
Ch
Dg
TURN
Dg
Ch
Y HI BEAM
Ch
Dg
Ch
Dg
L
Y
G
B
16 17 32 33
L L G
12V5W
- - Y B
B B
12V35W/35W
12V10W
12V10W
12V10W
12V10W
15
B
(BLACK) (BLACK)
B
B
B
B
LIGHTING SYSTEM
LIGHTING SYSTEM
4. Main fuse
5. Battery
6. Main switch
13. Meter
15. Head light
18. Tail light
21. +Ve lead wire
31 Light switch
34. Dimmer Switch
7-15
LIGHTING SYSTEM
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light.
NOTE:
1. Seat
2. Side cover 1 & side cover 2
3. Headlight
4. Fuel tank
1. Check the each bulbs and bulb NG →

sockets condition.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
7-33.
OK ↓
on page 7-34.
OK ↓
page 7-34.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
left handlebar switch.
OK ↓
6. Check the pass switch. NG →
The pass switch is faulty. Replace the left
handlebar switch.
OK ↓
7. Check the entire lighting system NG →
wiring. Properly connect or repair the lighting sys-
page 7-14.
OK ↓
This circuit is OK.
7-16
Sb
LY
G BL
B Br R
W W W - W (BLACK)
1 W W R
3 LY Or Or
B Br CRK+ IG 8
B
W W
Sb
Sb
R
LY G 20
7
W W BL LY BL
Sb
26 30 31
6 START STOP LIGHT L
CIRCUIT DIAGRAM
Sb VCC
2 4 19 BL L Y
OFF OFF OFF Y
MAIN SIG
15A
START RUN PO BL
ON SGND
R
Y
L
ON
OFF Br RW
YW
LWWB TC
Lg
B L DIAG
21 LW
R
(BLACK) GND VB
SIGNALING SYSTEM
LB
LW
WB
B
Br
Rw
L
RwBr
Br
B
RW
LW
RW
Sb
LW (BLACK) RW
22 27
RB LB
RW LB LB Sb RW
(Black)
13 NEUTRAL
B
RB
Br Sb
B
Br
Br
24
RB
Br
Br 11 B RB
9 (BLACK) 28
- -
B1 B
P 10 GY GY
12 - - Br2 W
SPEED
7-17
Br Br YW
ILLMI TC
B
L
(RED) (RED) VCC
BrW
BrW BL
Y
GY
SGND
Br
GB
FUEL+
GB
L
Y
OrW
Br
WB
P
BrW
FUEL -
14
BL
L
W

PASS ILLUMI
N W L
25
Y NR BL
12V21W/35W
Y
G R 18
OrW
G
B DIAG Lg
B L W
BL
Y
G
B
Dg
Ch
TURN
Dg
Ch
Y HI BEAM
Ch
Dg
Ch
Dg
L
Y
G
B
16 17 32 33
L L G
12V5W
- - Y B
B1 B1
12V35W/35W
12V10W
12V10W
12V10W
12V10W
15
B
(BLACK) (BLACK)
B
B
B
B
SIGNALING SYSTEM
SIGNALING SYSTEM
2. Neutral switch
4. Main fuse
5. Battery
6. Main switch
7. CDI
9. Horn
10. Turn signal relay
11. Front brake switch
12. Rear brake switch
13. Meter
16. Front turn signal light (LH)
17. Front turn signal light (RH)
21. +Ve lead wire
25. Speed sensor
29. Fuel sender
32. Rear turn signal light (LH)
33. Rear turn signal light (RH)
35. Horn switch
36. Turn signal switch
7-18
SIGNALING SYSTEM
TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake light or indicator lights.
• The horn fails to sound.
• The fuel gauge fails to operate.
NOTE:
1. Seat
2. Fuel tank
3. Headlight
4. LCD Meter

on page 7-34.
OK ↓
page 7-34.
OK ↓
OK ↓
4. Check the entire signaling system NG →
wiring. Properly connect or repair the signaling
page 7-17.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
Check the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
The horn switch is faulty. Replace the left
handlebar switch.
OK ↓
2. Check the horn. NG →
Refer to “CHECKING THE HORN” Replace the horn.
on page 7-42.
OK ↓
7-19
SIGNALING SYSTEM

page 7-17.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.

1. Check the tail/brake light bulb and NG →
socket.
Replace the tail/brake light bulb, socket or
Refer to “CHECKING THE BULBS
both.
7-33.
OK ↓
2. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
3. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
page 7-17.
OK ↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal light bulb and NG →
socket.
Replace the turn signal light bulb, socket or
both.
7-33.
OK ↓
2. Check the turn signal indicator light NG →
bulb and socket.
Replace the turn signal indicator light bulb,
socket or both.
7-33.
OK ↓
7-20
SIGNALING SYSTEM
3. Check the turn signal switch. NG →

The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
4. Check the turn signal relay. NG →
Refer to “CHECKING THE TURN Replace the turn signal relay.
SIGNAL RELAY ” on page 7-38.
OK ↓
page 7-17.
OK ↓
Replace the meter assembly.
The neutral indicator light fails to come on.

1. Check the neutral indicator light NG →
bulb and socket.
Replace the neutral indicator light bulb,
socket or both.
7-33.
OK ↓
2. Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
page 7-17.
OK ↓
The fuel gauge fails to operate.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 7-43.
OK ↓
7-21
SIGNALING SYSTEM

page 7-17.
OK ↓
7-22
SELF-DIAGNOSTIC FUNCTION
The vehicle is equipped with a self-diagnostic function. If this function detects a malfunction in the
system, it immediately operates the engine under substitute characteristics and illuminates the engine
trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunc-
tion has been detected, a fault code is stored in the memory of CDI.
• If a malfunction is detected in the system by the self-diagnostic function, alerts the rider of the detected
malfunction by illuminating the engine trouble warning light.
• After the engine has been stopped, the fault code number appears on the engine trouble warning
light. It remains stored in the memory of the system until it is deleted.
1. Engine trouble warning light
Engine trouble warning light fault code indication

Digit of 10: Cycles of 1 sec. ON and 1.5 sec. OFF.
Digit of 1: Cycles of 0.5 sec. ON and 0.5 sec. OFF.
Example: Fault code No. 15
ON b
a
OFF c d e e f
c. 1 sec d. 1.5 sec e. 0.5 sec f. 3.0 sec
a. Light ON
b. Light OFF
c. 1
d. 1.5
e. 0.5
f. 3
7-23
FAULT CODE TABLE

Fault Able/ Able/
Code Item Symptom unable to unable to
No. start drive
15 Throttle position sensor Throttle position sensor : Able Able

(open or short circuit) open or short circuit detected.
16 Throttle position sensor Throttle position sensor is stuck Able Able

(stuck)
Checking the engine trouble warning light bulb

The engine trouble warning light comes on for 3 seconds after the main switch has been turned to“ON”.
“ ”.
If the warning light does not come on under these conditions, the communication wire disconnection or
the warning light LEDs may be defective.
a b
c d c
a. Main switch “OFF” d. Engine trouble warning light on for 3 seconds

b. Main switch “ON”
c. Engine trouble warning light off
TROUBLESHOOTING METHOD
The engine operation is not normal and the

Fault code No. No fault code No.
engine trouble warning light comes on.
1. Check: Check and repair. Check and repair.
• Fault code number Refer to “TROUBLE- Refer to “Self-Diag-
ssssssssssssssssssssssssssss SHOOTING DE- nostic Function ta-
a. Check the fault code displayed onthe Meter TAILS” ble”.
panel. Monitor the opera-
b. Identify the faulty system with the fault code. tion of the sensors
Refer to “Self-Diagnostic Function table”. and actuators in the
c. Identify the probable cause of the malfunc- diagnostic mode. Re-
fer to “Sensor opera-
tion. Refer to “Diagnostic code table”.
tion table” and
ssssssssssssssssssssssssssss “Actuator operation
2. Check and repair the probable cause of mal- table”.
function.
Turn the main switch to “OFF” and back to
“ON”, then check that no fault code number is
displayed.
7-24
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter pannel. Check and
service the items or components that are the probable cause of the malfunction.
Fault code No. 15 Symptom Throttle position sensor: open or short circuit detected.
Order Item/components and probable Check or maintenance job Reinstatement

cause method
1 Installed condition of throttle position • Check for looseness or pinch- Turning the
sensor. ing. main switch to
• Check that the sensor is in- “ON”.
stalled in the specified position.
2 Connections • Check the coupler for any pins
• Throttle position sensor coupler that may be pulled out.
• Main wire harness CDI coupler • Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler se-
curely.
3 Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between throttle position sen-
sor coupler and CDI coupler
(black/blue-black/blue)
(yellow-yellow)
(blue-blue)
4 Defective throttle position sensor. • Check for open circuit and repla-
ce the throttle position sensor.
Open circuit Output voltage
item
Ground wire 5V
open circuit
Output wire 0V
open circuit
Power Supply 0V
wire open circuit
5 Defective throttle position sensor. • Replace the carburetor, If
defective
THROTTLE POSITION SENSOR
ASSEMBLY” on page 8-72.
CAUTION:
Do not remove the throttle
position sensor assembly from
the carburetor.
7-25
Fault code No. 16 Symptom Throttle position sensor is stuck.

Component : Throttle position sensor
cause method
1 Installed condition of throttle position • Check for looseness or pinch- Starting the eng-
sensor. ing. ine and operat-
• Check that the sensor is in- ing it at idle, and
stalled in the specified position. then by racing it.
2 Defective throttle position sensor. • Replace the carburetor if de-
fective.
THROTTLE POSITION SENSOR
ASSEMBLY” on page 7-43.
Symptom : Primary lead of the ignition coil: open circuit detected.

Component : Ignition coil
cause method
1 Connections • Check the connector and cou- Starting the en-
• Ignition coil connector (primary coil pler for any pins that may be gine.
side) pulled out.
• Main wire harness CDI coupler • Check the locking condition of
the connector and coupler.
and connect the coupler se-
curely.
2 Open or short circuit in wire harness. • Repair or replace if there is an
• Between ignition coil connector
and ECU coupler/main wire
harness.
& ground
(orange–orange)
3 Defective ignition coil. • Test the primary and secondary
coils for continuity.
• Replace if defective.
Refer to “IGNITION SYSTEM”
on page 7-1.
Symptom : Faulty CDI.

Component : CDI
cause method
1 Malfunction in CDI. Replace the CDI. Turning the
NOTE: main switch to
Do not perform this procedure “ON”.
with the main switch turned to
“ON”.
7-26
Symptom : No normal signals are received from the speed sensor.
Component : Vehicle speed sensor

cause method
1 Installed state of speed sensor. Check for looseness or pinching. Starting the
engine, and
2 Connections • Check the couplers for any pins activating the
• Speed sensor coupler that may be pulled out. speed sensor
• Main wire harness coupler. • Check the locking condition of by operating the
the couplers. vehicle.
and connect the coupler
securely.
3 Open or short circuit in lead. • Repair or replace if there is an
• Between speed sensor coupler
and wire harness coupler.
4 Defective speed sensor. • Replace if defective.

SPEED SENSOR” on page 7-43
7-27
ELECTRICAL COMPONENTS
1 2
3
4
5 10
11
12
14
13
7-28
1. Front brake switch

2. Fuel sender assy.
3. Starting circuit cut. off relay
4. CDI assy.
5. Main switch
6. Horn
7. Starter relay
8. Neutral switch
9. Rear brake switch
10. Battery
11. R R unit
12. Fuse
13. Spark plug cap
14. Ignition coil
7-29
CHECKING THE SWITCHES

1 2 3 4
R Br
B Br
OFF
R/B ON
B GY
(BLACK) R Br BR Br Y
B Y
(RED)
5
Sb
12 11 10 9 8 7 6 Br Dg
L/W B Br R/W
OFF Br Y W/B Y G Br P Ch Br/W Dg W/B Br/W Y
PO PASS P Ch
ON Br R/W
Y
L/W W/B
G
B L B
7-30
1. Clutch switch
2. Main switch
3. Front brake light switch
4. Rear brake light switch
5. Neutral switch
7. Horn switch
8. Dimmer switch
9. Pass switch
10. Engine stop switch
11. Start switch
12. Light switch
7-31
Check each switch for continuity with the multimeter. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
CAUTION:
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Multimeter
NOTE:
l Before checking for continuity, set the multimeter to continuity mode.
l When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red, and brown/blue when the switch is set to “ON”.
b
R Br
a ON
OFF
R
Br
7-32
CHECKING THE BULBS AND BULB WARNING

SOCKETS Since headlight bulb get extremely hot, keep
Check each bulb and bulb socket for damage or flammable products and your hands away
wear, proper connections, and also for continuity from them until they have cooled down.
between the terminals.
Damage/wear → Repair or replace the bulb, CAUTION:
bulb socket or both.
Improperly connected → Properly connect. • Be sure to hold the socket firmly when re-
No continuity → Repair or replace the bulb, bulb moving the bulb. Never pull the lead, other-
socket or both. wise it may be pulled out of the terminal in
the coupler.
Types of bulbs • Avoid touching the glass part of a headlight
The bulbs used on this vehicle are shown in the bulb to keep it free from oil, otherwise the
illustration on the left. transparency of the glass, the life of the
• Bulbs “a” and “b” are used for the headlights bulb, and the luminous flux will be adverse-
and usually use a bulb holder that must be de- ly affected. If the headlight bulb gets soiled,
tached before removing the bulb. The majority thoroughly clean it with a cloth moistened
of these types of bulbs can be removed from with alcohol or lacquer thinner.
their respective socket by turning them coun- 2. Check:
terclockwise. • Bulb (for continuity)
• Bulbs “c” is used for turn signal and tail/brake (with the multimeter)
lights and can be removed from the socket by No continuity → Replace.
pushing and turning the bulb counterclockwise.
Multimeter
NOTE:
Before checking for continuity, set the multi
meter to continuity mode.
ssssssssssssssssssssssssssss
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
Checking the condition of the bulbs

bulbs.
1. Remove:
• Bulb
7-33
Checking the condition of the bulb sockets
The following procedure applies to all of the bulb a. Set the main switch to “OFF”.
sockets. b. Install a new fuse of the correct amperage
1. Check: rating.
• Bulb socket (for continuity) c. Set on the switches to verify if the electrical
(with the multimeter) circuit is operational.
No continuity → Replace. d. If the fuse immediately blows again, check
the electrical circuit.
Multimeter Amperage
Item Q’ty
rating
NOTE: Fuse 15 A 1
Check each bulb socket for continuity in the
same manner as described in the bulb section; WARNING
however, note the following. Never use a fuse with an amperage rating
ssssssssssssssssssssssssssss other than that specified. Improvising or us-
a. Install a good bulb into the bulb socket. ing a fuse with the wrong amperage rating
b. Connect the multimeter probes to the re- may cause extensive damage to the electri-
spective leads of the bulb socket. cal system, cause the lighting and ignition
c. Check the bulb socket for continuity. If any of systems to malfunction and could possibly
the readings indicate no continuity, replace cause a fire.
the bulb socket. ssssssssssssssssssssssssssss
ssssssssssssssssssssssssssss 4. Install:
• Seat and right cover
CHECKING THE FUSE
Refer to “GENERAL CHASSIS” on page 4-1
CAUTION:
To avoid a short circuit, always turn the main CHECKING AND CHARGING THE BATTERY
switch to “OFF” when checking or replacing
a fuse. WARNING
Batteries generate explosive hydrogen gas
1. Remove:
and contain electrolyte which is made of poi-
• Seat and right side cover
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
2. Check:
measures:
• Fuse
ssssssssssssssssssssssssssss Wear protective eye gear when handling or
a. Connect the multimeter to the fuse and working near batteries.
check the continuity. Charge batteries in a well-ventilated area.
NOTE:
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
Set the multimeter selector to “Ω × 1”.
lighted cigarettes).
DO NOT SMOKE when charging or han-
Multimeter dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
b. If the multimeter indicates “∞ ”, replace the
Avoid bodily contact with electrolyte as it
fuse.
can cause severe burns or permanent eye
injury.
3. Replace: FIRST AID IN CASE OF BODILY CONTACT:
• Blown fuse EXTERNAL
Skin — Wash with water.
Eyes — Flush with water for 15 minutes and
get immediate medical attention.
7-34
INTERNAL
• Drink large quantities of water or milk fol- Example
lowed with milk of magnesia, beaten egg or Open-circuit voltage = 12.0 V
vegetable oil. Get immediate medical atten- Charging time = 5-10 hours
tion. Charge of the battery = 20–30%
1. Remove:
• Seat and right side cover
2. Disconnect:
• Battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
A. Open-circuit voltage (V)
B. Charging time (hours)
C. Relationship between the open-circuit voltage
2 and the charging time at 20 °C (68 °F)
D. These values vary with the temperature, the
1 condition of the battery plates, and the
1 electrolyte level.
3. Remove:
• Battery
4. Check:
• Battery voltage
• Electrolyte level in the battery cell
• Battery charging
a. Connect a multimeter to the battery termi- B. Charging condition of the battery (%)
nals. C. Ambient temperature 20 °C (68 °F)
• Positive tester probe → ssssssssssssssssssssssssssss
positive battery terminal
• Negative tester probe → 5. Charge:
negative battery terminal • Battery
(refer to the appropriate charging method il-
lustration)
NOTE:
The charge state of battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery ter-
minal is disconnected).
No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in

the charts and the following example.
7-35
WARNING
Do not quick charge a battery. ssssssssssssssssssssssssssss
CAUTION: Charging method using a variable-current

(voltage) charger
• Do not use a high-rate battery charger a. Measure the open-circuit voltage prior to
since it forces a high-amperage current charging.
into the battery quickly and can cause bat-
NOTE:
tery overheating and battery plate damage.
• If it is impossible to regulate the charging Voltage should be measured 30 minutes after
current on the battery charger, be careful the machine is stopped.
not to overcharge the battery. b. Connect a charger and ammeter to the bat-
• When charging a battery, be sure to remove tery and start charging.
it from the vehicle. (If charging has to be
done with the battery mounted on the vehi- c. Make sure that the current is higher than the
cle, disconnect the negative battery lead standard charging current written on the bat-
from the battery terminal.) tery.
• To reduce the chance of sparks, do not NOTE:
plug in the battery charger until the battery If the current is lower than the standard charging
charger leads are connected to the battery. current written on the battery, set the charging
• Before removing the battery charger lead voltage adjust dial at 20–24 V and monitor the
clips from the battery terminals, be sure to amperage for 3–5 minutes to check the battery.
turn off the battery charger.
• Make sure the battery charger lead clips are
• Standard charging current is reached
in full contact with the battery terminal and Battery is good.
that they are not shorted. A corroded bat- • Standard charging current is not reached
tery charger lead clip may generate heat in Replace the battery.
the contact area and a weak clip spring may
cause sparks. d. Adjust the voltage so that the current is at the
standard charging level.
• If the battery becomes hot to the touch at e. Set the time according to the charging time
any time during the charging process, dis- suitable for the open-circuit voltage.
connect the battery charger and let the bat- f. If charging requires more than 5 hours, it is
tery cool before reconnecting it. Hot advisable to check the charging current after
batteries can explode! a lapse of 5 hours. If there is any change in
the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.

B. Time (minutes)
C. Charging
D. Ambient temperature 20 °C (68 °F)
E. Check the open-circuit voltage.
7-36
8. Check:
Charging method using a constant volt- • Battery terminals
age charger Sulphation → Clean with hot water.
a. Measure the open-circuit voltage prior to Loose connection → Connect properly.
charging. 9. Lubricate:
NOTE: • Battery terminals
Voltage should be measured 30 minutes after Recommended lubricant
the engine is stopped. Dielectric grease
b. Connect a charger and ammeter to the bat-
tery and start charging. 10.Install:
c. Make sure that the current is higher than the • Seat and right side cover
standard charging current written on the bat- Refer to “GENERAL CHASSIS” on page 4-1.
tery.
NOTE: CHECKING THE RELAYS
If the current is lower than the standard charging Check each switch for continuity with the pocket
current written on the battery, this type of battery tester. If the continuity reading is incorrect, re-
charger cannot charge the MF battery. A vari- place the relay.
able voltage charger is recommended. Multimeter
d. Charge the battery until the battery’s charg-
ing voltage is 15 V.
NOTE: 1. Disconnect the relay from the wire harness.
Set the charging time at 20 hours (maximum). 2. Connect the multimeter (Ω ×1) and battery
(12 V) to the relay terminal as shown.
e. Measure the battery open-circuit voltage after Check the relay operation.
leaving the battery unused for more than 30 Out of specification → Replace.
minutes.
Starter relay
12.8 V or more --- Charging is complete. 1 2
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
6. Install: 3 4
• Battery R B
7. Connect: LW R/W
• Battery leads
(to the battery terminals)
CAUTION: 1. Positive battery terminal
2. Negative battery terminal
First, connect the positive battery lead “1”,
3. Positive tester probe
and then the negative battery lead “2”.
4. Negative tester probe
Result
2 Continuity
(between “3” to “4”)
1
1
7-37
Starting circuit cut-off relay b. Turn the main switch to “ON”.

c. Measure the turn signal relay input voltage.
1
Turn signal relay output voltage
DC 12 V
2 3
2. Check:
RB LB • Turn signal relay output voltage
Sb RW Out of specification → Replace.
a. Connect the multimeter to the
1. Positive battery terminal turn signal relay terminal as shown.
2. Negative battery terminal
3. Positive tester probe Multimeter
4. Negative tester probe
Result • Positive tester probe →

Continuity brown/white “1”
(between “1” to “3”) • Negative tester probe →
ground
CHECKING THE TURN SIGNAL RELAY

1. Check:
• Turn signal relay input voltage
Out of specification → The wiring circuit from 1
the main switch to the turn signal relay cou- Br/W
pler is faulty and must be repaired.
Br
Turn signal relay input voltage
DC 12 V
a. Connect the multimeter to the turn signal b. Turn the main switch to “ON”.
relay terminal as shown. c. Measure the turn signal relay output voltage.
Multimeter
• Positive tester probe →

brown “1”
• Negative tester probe →
ground
Br/W
Br
1
7-38
CHECKING THE SPARK PLUG CAP
1. Check: a. Disconnect the ignition coil connectors from
• Spark plug cap resistance the ignition coil terminals.
Out of specification → Replace. b. Connect the multimeter ( Ω × 1) to the igni-
tion coil as shown.
Spark plug cap resistance
5.0 k Ω at 20 °C (68 °F) Multimeter
a. Remove the spark plug cap from the spark
plug lead. • Positive tester probe →
b. Connect the multimeter ( Ω × 1k) to the orange “1”
spark plug cap as shown.
ground “2”
Multimeter
1
c. Measure the primary coil resistance.
c. Measure the spark plug cap resistance. ssssssssssssssssssssssssssss
ssssssssssssssssssssssssssss 2. Check:
• Secondary coil resistance
CHECKING THE IGNITION COIL Out of specification → Replace.
1. Check:
• Primary coil resistance
Out of specification → Replace. Secondary coil resistance
5.68–8.52 k Ω at 20 °C (68 °F)
Primary coil resistance ssssssssssssssssssssssssssss
0.32–0.48 Ω at 20 °C (68 °F)
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the multimeter ( Ω × 1k) to the ig-
nition coil as shown.
Multimeter
7-39
• Positive tester probe → CHECKING THE CRANKSHAFT POSITION

HT lead SENSOR
• Negative tester probe → 1. Disconnect:
ground • Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
1 Out of specification → Replace the crank-
shaft position sensor/stator assembly.
Crankshaft position sensor resis-

tance
192–288 Ω at 20 °C (68 °F)
2
c. Measure the secondary coil resistance.
a. Connect the multimeter to the crankshaft
position sensor coupler as shown.
CHECKING THE IGNITION SPARK GAP
1. Check: Multimeter
• Ignition spark gap
Out of specification → Perform the ignition
system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page • Positive tester probe →
blue/yellow “1”
7-3.
Minimum ignition spark gap green “2”
0.8 - 0.9 mm
NOTE:
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
a. Disconnect the spark plug cap from the spark
plug. LY G
b. Connect the ignition checker “1” as shown.
1 2
Ignition checker
b. Measure the crankshaft position sensor re-
sistance.
CHECKING THE STARTER MOTOR

OPERATION
1. Check:
• Starter motor operation
Does not operate → Perform the electric
1. Ignition checker starting system troubleshooting, starting with
2. Spark plug cap
step 4.
c. Turn the main switch to “ON” and engine stop Refer to “TROUBLESHOOTING” on page
switch to “ ”. 7-9.
d. Measure the ignition spark gap “a”. ssssssssssssssssssssssssssss
e. Crank the engine by pushing the start switch
“ ”
7-40
a. Connect the positive battery terminal “1” and

starter motor lead “2” with a jumper lead “3”.
WARNING
• A wire that is used as a jumper lead must 2
1
have at least the same capacity of the bat- W W
tery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks,
therefore, make sure no flammable gas or b. Measure the stator coil resistance.
fluid is in the vicinity. ssssssssssssssssssssssssssss
CHECKING THE RECTIFIER/REGULATOR

1. Check:
• Charging voltage
Out of specification → Replace the rectifi-
er/regulator.
Charging voltage
13.7-14.7 V at 5000 r/min
b. Check the starter motor operation. a. Set the engine tachometer to the spark plug
lead.
ssssssssssssssssssssssssssss b. Connect the multimeter to the rectifier/
regulator coupler as shown.
CHECKING THE STATOR COIL
1. Disconnect:
• Stator coil coupler Multimeter
(from the wire harness)
2. Check:
• Stator coil resistance • Positive tester probe →
Out of specification → Replace the crank- red “1”
shaft position sensor/stator assembly. • Negative tester probe →
black “2”
Stator coil resistance
0.464–0.696 Ω at 20 °C (68 °F)
a. Connect the multimeter Ω ×1) to the stator

coil coupler as shown.
B Br R
2 W W 1
Multimeter
• Positive tester probe → c. Start the engine and let it run at approximate-
white “1” ly 5000 r/min.
• Negative tester probe → d. Measure the charging voltage.
white “2”
7-41
ssssssssssssssssssssssssssss CHECKING THE FUEL SENDER

CHECKING THE HORN 1. Remove:
1. Check: • Fuel tank
• Horn resistance 2. Remove:
Out of specification → Replace. • Fuel sender assy.
(from the fuel tank)
Coil resistance 3. Check:
1.95–2.25 Ω at 20 °C • Fuel sender resistance
ssssssssssssssssssssssssssss Out of specification → Replace the fuel seder
a. Disconnect the horn connectors from the assembly.
horn terminals.
Fuel sender
b. Connect the multimeter ( Ω × 1) to the horn
Sender unit resistance (full)
terminals. 18.5 –21.5 Ω at 20 °C (68 °F)
Sender unit resistance (empty)
Multimeter 137-143 Ω at 20 °C (68 °F)
a. Connect the multimeter ( Ω × 100) to the

fuel sender coupler as shown.
horn terminal “1” Multimeter
horn terminal “2”

1 orange/white “1”
green/black “2”
c. Measure the horn resistance. 2 1

2. Check:
• Horn sound OrW GB
Faulty sound → Adjust or replace.

a. Connect a battery (12 V) to the horn.
b. Turn the adjusting screw in direction “a” or “b”
until the specified horn sound is obtained.
b. Move the fuel sender float to minimum
and maximum level position.
c. Measure the fuel sender resistance.
a b
7-42
CHECKING THE THROTTLE POSITION SENSOR CHECKING THE SPEED SENSOR

1. Check: 1. Check:
• Throttle position sensor • Speed sensor output voltage
Out of specification → Replace.
a. Connect the digital circuit tester to the termi-
nals of the throttle body sensor assembly Output voltage reading cycle
coupler as shown. 0 V to 5.0 V to 0 V to 5.0 V

blue terminal “1” a. Connect the multimeter to the speed sensor
• Negative tester probe → coupler (wire harness end) as shown.
black/blue terminal “2”
b. Measure the throttle position sensor input Multimeter

voltage.
Out of specification → Replace or repair the
wire harness. • Positive tester probe
Connect the multimeter to theterminals of the white “1”
throttle body sensor assem bly coupler as • Negative tester probe
shown. blue/black “2”
blue“1” 1
W L
black/blue terminal “2”
BL
Throttle position sensor input 2

voltage L W
5V BL
(blue–black/blue)
d. While slowly opening the throttle, check that b. Set the main switch to “ON”.
the throttle position sensor output voltage is c. Elevate the front wheel and slowly rotate it.
increased. d. Measure the voltage of white and blue/black.
Voltage does not change or it changes With each full rotation of the front wheel, the
abruptly → Replace the throttle body. voltage reading should cycle from 0 V to 5.0
Out of specification (closed position) → Re- V to 0 V to 5.0 V.
place the carburetor.
Throttle position sensor output

voltage (closed position)
0.65–0.75 V
(yellow –black/blue)
BL L Y
2
1 3
7-43
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................8-1
GENERAL INFORMATION ..................................................................8-1
STARTING FAILURES.........................................................................8-1
INCORRECT ENGINE IDLING SPEED ................................................8-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE......................8-2
FAULTY GEAR SHIFTING...................................................................8-2
SHIFT PEDAL DOES NOT MOVE.........................................................8-2
JUMPS OUT OF GEAR...................................................................8-2
FAULTY CLUTCH ..........................................................................8-2
OVERHEATING ...............................................................................8-2
OVERCOOLING................................................................................8-3
POOR BRAKING PERFORMANCE..................................................8-3
FAULTY FRONT FORK LEGS.........................................................8-3
UNSTABLE HANDLING...................................................................8-3
FAULTY LIGHTING OR SIGNALING SYSTEM ...............................8-4
WIRING DIAGRAM ....................................................................8-5
TROUBLESHOOTING
Electrical system
TROUBLESHOOTING 1. Battery
• Discharged battery
GENERAL INFORMATION • Faulty battery
NOTE: 2. Fuse
• Blown, damaged or incorrect fuse
The following guide for troubleshooting does not
• Improperly installed fuse
cover all the possible causes of trouble. It should
3. Spark plug
be helpful, however, as a guide to basic trouble-
• Incorrect spark plug gap
shooting. Refer to the relative procedure in this
• Incorrect spark plug heat range
manual for checks, adjustments, and replace-
• Fouled spark plug
ment of parts.
• Worn or damaged electrode
• Worn or damaged insulator
STARTING FAILURES • Faulty spark plug cap
4. Ignition coil
Engine • Cracked or broken ignition coil body
1. Cylinder and cylinder head • Broken or shorted primary or secondary coils
• Loose spark plug • Faulty spark plug lead
• Loose cylinder head or cylinder 5. Ignition system
• Damaged cylinder head gasket • Faulty CDI
• Damaged cylinder gasket • Faulty crankshaft position sensor
• Worn or damaged cylinder • Broken magneto rotor woodruff key
• Incorrect valve clearance 6. Switches and wiring
• Improperly sealed valve • Faulty main switch
• Incorrect valve-to-valve-seat contact • Faulty engine stop switch
• Incorrect valve timing • Broken or shorted wiring
• Faulty valve spring • Faulty neutral switch
• Seized valve • Faulty start switch
2. Piston and piston ring(s) • Faulty clutch switch
• Improperly installed piston ring • Improperly grounded circuit
• Damaged, worn or fatigued piston ring • Loose connections
• Seized piston ring 7. Starting system
• Seized or damaged piston • Faulty starter motor
3. Air filter • Faulty starter relay
• Improperly installed air filter • Faulty starting circuit cut-off relay
• Clogged air filter element • Faulty starter clutch
4. Crankcase and crankshaft
• Improperly assembled crankcase INCORRECT ENGINE IDLING SPEED
• Seized crankshaft
Engine
Fuel system 1. Cylinder and cylinder head
1. Fuel tank • Incorrect valve clearance
• Empty fuel tank • Damaged valve train components
• Clogged fuel filter 2. Air filter
• Deteriorated or contaminated fuel • Clogged air filter element
2. Carburetor
• Deteriorated or contaminated fuel Fuel system
• Clogged fuel jet 1. Carburetor
• Carburetor maladjustment • Damage or loose carburetor joint
• Improper throttle cable free play
• Flooded carburetor
• Faulty air induction system
8.1
TROUBLESHOOTING
Electrical system
JUMPS OUT OF GEAR
1. Battery
• Discharged battery
Shift shaft
• Faulty battery
• Incorrect shift pedal position
2. Spark plug
• Improperly returned stopper lever
• Incorrect spark plug gap
• Incorrect spark plug heat range Shift forks
• Fouled spark plug • Worn shift fork
• Worn or damaged electrode
• Worn or damaged insulator Shift drum
• Faulty spark plug cap • Incorrect axial play
3. Ignition coil • Worn shift drum groove
• Broken or shorted primary or secondary coils
• Faulty spark plug lead Transmission
• Cracked or broken ignition coil • Worn gear dog
4. Ignition system
• Faulty CDI
FAULTY CLUTCH
• Faulty crankshaft position sensor
• Broken magneto rotor woodruff key
Clutch slips
1. Clutch
POOR MEDIUM-AND-HIGH-SPEED • Improperly assembled clutch
PERFORMANCE • Improperly adjusted clutch cable
Refer to “STARTING FAILURES ” on page 8-1. • Loose or fatigued clutch spring
• Worn friction plate
Engine • Worn clutch plate
1. Air filter 2. Engine oil
• Clogged air filter element • Incorrect oil level
• Incorrect oil viscosity (low)
Fuel system • Deteriorated oil
1. Carburetor
• Faulty carburetor Clutch drags
1. Clutch
FAULTY GEAR SHIFTING • Unevenly tensioned clutch springs
• Warped pressure plate
Shifting is difficult • Bent clutch plate
Refer to “Clutch drags”. • Swollen friction plate
• Bent clutch push rod
SHIFT PEDAL DOES NOT MOVE • Broken clutch boss
• Burnt primary driven gear bushing
Shift shaft 2. Engine oil
• Bent shift shaft • Incorrect oil level
• Incorrect oil viscosity (high)
Shift drum and shift forks • Deteriorated oil
• Foreign object in a shift drum groove
• Seized shift fork OVERHEATING
• Bent shift fork guide bar
Ignition system
Transmission • Improper spark plug gap
• Seized transmission gear • Improper spark plug heat range
• Foreign object between transmission gears • Faculty CDI unit
• Improperly assembled transmission
8.2
TROUBLESHOOTING
Fuel system • Oil or grease on the brake disc

• Improper carburetor setting • Oil or grease on the brake pad
• Improper fuel level adjustment • Incorrect brake fluid level
• Clogged air filter element
FAULTY FRONT FORK LEGS
Compression system
• More carbon deposition Leaking oil
• Improperly adjusted valve timing • Bent, damaged or rusty inner tube
• Improperly adjusted valve clearance • Cracked or damaged outer tube
• Improperly installed oil seal
Engine oil • Damaged oil seal lip
• Incorrect engine oil level • Incorrect oil level (high)
• Improper engine oil quality • Loose damper rod bolt
• Low engine oil quality • Damaged damper rod bolt copper washer
• Cracked or damaged cap bolt O-ring
Fuel system
1. Throttle body Malfunction
• Damaged or loose throttle body joint • Bent or damaged inner tube
2. Air filter • Bent or damaged outer tube
• Clogged air filter element • Damaged fork spring
• Bent or damaged damper rod
Chassis • Incorrect oil viscosity
1. Brake(s) • Incorrect oil level
• Dragging brake
Electrical system UNSTABLE HANDLING

1. Spark plug 1. Handlebar
• Incorrect spark plug gap • Bent or improperly installed handlebar
• Incorrect spark plug heat range 2. Steering head components
2. Ignition system • Improperly installed upper bracket
• Faulty ECU • Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
OVERCOOLING • Damaged ball bearing or bearing race
3. Front fork leg(s)
Cooling system
• Uneven oil levels (both front fork legs)
1. Thermostat
• Unevenly tensioned fork spring (both front
• Thermostat stays open
fork legs)
• Broken fork spring
POOR BRAKING PERFORMANCE • Bent or damaged inner tube
1. Disc brake • Bent or damaged outer tube
• Worn brake pad 4. Swingarm
• Worn brake disc • Worn bearing
• Air in hydraulic brake system • Bent or damaged swingarm
• Leaking brake fluid
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
8.3
TROUBLESHOOTING
5. Rear shock absorber assembly • Burnt-out turn signal bulb

• Faulty rear shock absorber spring • Incorrect connection
• Leaking oil • Damaged or faulty wire harness
6. Tyre(s) • Improperly grounded circuit
• Uneven tyre pressures (front and rear) • Faulty battery
• Incorrect tyre pressure • Blown, damaged or incorrect fuse
• Uneven tyre wear
7. Wheel(s) Turn signal blinks slowly
• Incorrect wheel balance • Faulty turn signal relay
• Deformed cast wheel • Faulty main switch
• Damaged wheel bearing • Faulty turn signal switch
• Bent or loose wheel axle • Incorrect turn signal bulb
• Excessive wheel runout
8. Frame Turn signal remains lit
• Bent frame • Faulty turn signal relay
• Damaged steering head pipe • Burnt-out turn signal bulb
• Improperly installed bearing race
Turn signal blinks quickly
• Incorrect turn signal bulb
FAULTY LIGHTING OR SIGNALING SYSTEM
• Faulty turn signal relay
• Burnt-out turn signal bulb
Headlight does not come on
• Wrong headlight bulb
Horn does not sound
• Too many electrical accessories
• Improperly adjusted horn
• Hard charging
• Damaged or faulty horn
• Incorrect connection
• Faulty main switch
• Improperly grounded circuit
• Faulty horn switch
• Poor contacts (main or light switch)
• Faulty battery
• Burnt-out headlight bulb
• Blown, damaged or incorrect fuse
• Faulty wire harness
Headlight bulb burnt out
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Faulty light switch
• Headlight bulb life expired
Tail/brake light does not come on

• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
Tail/brake light bulb burnt out

• Wrong tail/brake light bulb
• Faulty battery
• Incorrectly adjusted rear brake light switch
• Tail/brake light bulb life expired
Turn signal does not come on

• Faulty turn signal switch
• Faulty turn signal relay
8.4
Sb
LY
G BL
B Br R
W W W - W (BLACK)
1 W W R
3 LY Or Or
B Br CRK+ IG 8
B
W W
Sb
Sb
R
LY G 20
7
W W BL LY BL
Sb
26 30 31
2 4 VCC 19 BL L Y
OFF OFF OFF Y
MAIN SIG
15A
START RUN PO BL
ON SGND
R
ON
Y
L
OFF Br RW
YW
LWWB TC
Lg
B L DIAG
21 LW
R
(BLACK) GND VB
LB
LW
WB
B
Br
Rw
L
RwBr
Br
B
RW
LW
RW
Sb
LW (BLACK) RW
22 27
RB LB
RW LB LB Sb RW
(Black)
13 NEUTRAL
B
RB
Br Sb
B
Br
Br
24
RB
Br
Br 11 B RB
9 (BLACK) 28
- -
B1 B
P 10 GY GY
8.5
12 - - Br2 W
SPEED
BR BR YW
ILLMI TC
B
L
(RED) (RED) VCC
BrW
BrW BL
Y
GY
SGND
Br
GB
FUEL+
GB
L
Y
OrW
Br
WB
P
BrW
FUEL -
14
BL
L
W

PASS ILLUMI
BrW WB WB BrW L
OFF HI OFF GB
N W L
25
Y NR BL
12V21W/35W
Y
G R 18
OrW
G
B DIAG Lg
B L W
BL
Y
G
B
Ch
Dg
TURN
Dg
Ch
Y HI BEAM
Ch
Dg
Ch
Dg
L
Y
G
B
16 17 32 33
L L G
12V5W
- - Y B
B1 B1
12V35W/35W
12V10W
12V10W
12V10W
12V10W
15
B
(BLACK) (BLACK)
B
B
B
B
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
FZ-16 COLOR CODE
1. AC magneto B Black
2. Neutral switch Br Brown
Ch Chocolate
3. R/R unit
Dg Dark green
4. Main fuse G Green
5. Battery Gy Gray
6. Main switch L Blue
7. CDI unit Lg Light green
8. Ignition coil O Orange
P Pink
9. Horn
R Red
10. Turn signal relay Sb Sky blue
11. Front brake switch W White
12. Rear brake switch Y Yellow
13. Meter B/L Black/Blue
14. Pass switch Br/L Brown/Blue
Br/W Brown/White
15. Head light G/R Green/Red
16. Front turn signal light (L/H) G/W Green/White
17. Front turn signal light (R/H) G/Y Green/Yellow
18. Tail light L/B Blue/Black
19. TPS L/W Blue/White
20. Spark plug O/B Orange/Black
P/W Pink/White
21. +ve lead wire R/B Red/Black
22. -ve lead wire R/L Red/Blue
23. Starter relay R/W Red/White
24. Starting motor W/Y White/Yellow
25. Speed sensor Y/G Yellow/Green
Y/L Yellow/Blue
26. Start switch
Y/R Yellow/Red
27. Starting circuit cut off relay
28. Clutch switch
29. Fuel sender
30. Engine stop switch
31. Light switch
32. Rear turn signal (L/H)
33. Rear turn signal (R/H)
34. Dimmer Switch
35. Horn switch
8.6

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Manual Servicio FZ-16 PDF

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SERVICE MANUAL

IMPORTANT MANUAL INFORMATION

NOTE : A NOTE provides key information to make procedures easier or clearer.

3 Clutch Hub Holder

IMPORTANT INFORMATION ..........................................................................1-3

CHECKING THE CONNECTIONS ..................................................................1-5

SPECIAL TOOLS ............................................................................................1-6

VEHICLE IDENTIFICATION NUMBER (FRAME

ENGINE SERIAL NUMBER

The LCD Meter is equipped

ODOMETER & TRIP METER MODE

The fuel meter indicates the amount of fuel in the

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

Tool name/Tool No. Illustration

Tappet screw holder

This tool is used to adjust the valve clearance by tappet

Tappet adjusting socket

This tool is used to loosen and tighten tappet adjusting nut.

This tool is used to adjust the valve clearance

Rear shock absorber adjuster

This tool is used to measure the preload of rear shock

This tool is used to hold the magneto when removing

This tool is used to remove the magneto with the help of

Tool name/Tool No. Illustration

Crank Shaft Installing Tool with Spacer

These tools are used for installation of Crank Shaft.

Crankshaft removing tool

This tool is used to remove the Crank Shaft from

Clutch hub holder

This tool is used to hold the Clutch Hub while

This instrument is used to check the ignition timing.

This instrument is used to measure the engine

This tool is used for scraping the sealent from

Valve spring compressor

This tool is used to remove and install Valve & Spring

Tool name/Tool No. Illustration

Valve spring compressor attachment

This tool is used to remove and install Valve & Spring

Vacuum/pressure pump gauge set

This instrument is used to offer the vacuum to air

Steering nut socket

This tool is used to loosen and tighten the steering

This tool is used to hold the TFF plunger for loosening

TFF Oil Seal Installation Tool

This tool assists to install the TFF Oil Seal.

This instrument is used to check the effficiency of

Tool name/Tool No. Illustration

This instrument is used to check the electrical circuits

Yamaha bond No. 1215

This adhesive is used on mating surfaces while assem-

This adhesive is used to offer extra strength to torx screw

This tool is needed to support the piston while installing

Center plug spanner

This tool is used to remove/install the Center plug from

GENERAL SPECIFICATIONS ..........................................................................2-1

ENGINE SPECIFICATIONS .............................................................................2-2

ELECTRICAL SPECIFICATIONS ..................................................................2-12

TIGHTENING TORQUES ...............................................................................2-14

LUBRICATION POINTS AND LUBRICANT TYPES .......................................2-21

LUBRICATION SYSTEM CHART AND DIAGRAMS.......................................2-24

CABLE ROUTING ..........................................................................................2-27

Spark plug (s)